Danfoss VLT PTC Thermistor Card MCB 112 User manual

Operating Guide
VLT® PTC Thermistor Card MCB 112
VLT® HVAC Drive FC 102, VLT® AQUA Drive FC 202, VLT® Automation
Drive FC 302
vlt-drives.danfoss.com

1
1.1
1.2
1.3
1.4
1.5
1.5.1
1.5.1.1
1.5.2
1.5.3
1.5.4
1.5.5
1.5.6
1.5.7
1.5.8
1.6
1.6.1
1.6.2
1.6.3
1.7
1.7.1
1.7.2
2
2.1
2.2
2.3
2.4
2.5
3
3.1
3.2
3.3
3.4
3.5
3.6
Contents
Introduction 6
Purpose of this Operating Guide 6
Additional Resources 6
Version History 6
Products Covered 6
Functional Overview 6
Intended Use 6
Markings of the Drive 7
Foreseeable Misuse 7
Thermal Motor Protection 7
ATEX ETR Thermal Monitoring 7
Tripping Function 8
Safe Separation 8
Safe Disconnection Principle 8
Safe Disconnection Principle Diagram 8
Motor Requirements 9
Motor Limits and Rules 9
Additional Motor Requirements 9
Approvals and Certifications 9
Abbreviations and Conventions 9
Abbreviations 9
Conventions 10
Safety 11
Safety Symbols 11
Qualified Personnel 11
Responsibilities of Users of Safety-related Power Drive Systems PDS (SR) 11
Protective Measures 11
Safety Precautions 12
Installation 13
Safety Instructions 13
Installing the VLT® PTC Thermistor Card MCB 112 13
Sensor Circuit Wire Requirements 14
Connecting Sensor Circuit Wires 15
Maximum Current on MCB 112 16
Wiring of STO 16
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Contents
VLT® PTC Thermistor Card MCB 112
Operating Guide

3.7
4
4.1
4.2
4.2.1
4.2.2
4.2.3
4.3
4.3.1
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
5
5.1
5.2
6
6.1
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
6.2.8
6.2.9
7
7.1
Assembly 17
Commissioning 18
Commissioning the Drive 18
Operation and Maintenence 18
Testing 18
Monitoring Sensor Resistance 18
Thermal Limitation Curve (Ex eb and Ex ec Motors Only) 19
Parameter Set-up 20
Alarm Handling 20
Parameter Set-up for Ex eb and Ex ec Motors 20
Overview of Ex eb and Ex ec Specific Parameters 20
Activate the ATEX ETR Monitor Function 21
Maximum Current Limit 21
Minimum Motor Frequency 21
Maximum Motor Frequency 22
Minimum Switching Frequency 22
Disable Protection Mode 22
Safe Torque Off Functionality 22
Functions, Alarms, and Warnings 23
Application Examples 24
Setting up the Option for Standard Use 24
Combination with Other Components using STO 25
Maintenance and Troubleshooting 27
Maintenance 27
Troubleshooting 27
Test the Sensor Circuit and Relay Function 27
Alarm/Warning Code List 27
Description of Alarm Word, Warning Word, and Extended Status Word 27
Alarm 68, Safe Stop 27
Warning 68, Safe Stop 27
Alarm 71, PTC 1 Safe Stop 27
Warning 71, PTC 1 Safe Stop 28
Alarm 72, Dangerous Failure 28
Unexpected Combinations 28
Specifications 29
Mains Supply 29
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Contents
VLT® PTC Thermistor Card MCB 112
Operating Guide

7.2
7.2.1
7.2.2
7.2.3
7.3
7.3.1
7.3.2
7.4
7.5
Control Inputs and Outputs 29
PTC Thermistor Connection X44/1+X44/2 29
Safe Stop Terminal 37, X44/12 29
Logic out, X44/10 29
Ambient Conditions 29
Environment 29
Testing Conditions 29
Other Specifications 30
Safety Characteristics of the Built-in MCB 112 30
AQ267038105120en-000101/130R0104 | 5Danfoss A/S © 2022.08
Contents
VLT® PTC Thermistor Card MCB 112
Operating Guide

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1 Introduction
1.1 Purpose of this Operating Guide
This operating guide provides information for safe installation and commissioning of the VLT®PTC Thermistor Card MCB 112 used
with a Danfoss VLT®drive with Safe Torque Off (STO).
VLT®PTC Thermistor Card MCB 112 is also referred to as MS 220 DA.
This operating guide is intended for use by qualified personnel only. To use the drive safely and professionally, read and follow the
instructions, and pay particular attention to the safety instructions and general warnings. Keep this operating guide available with
the drive at all times.
VLT® is a registered trademark.
1.2 Additional Resources
This manual is targeted at users already familiar with the VLT®drives. It is intended as a supplement to the manuals and instructions
for download at http://drives.danfoss.com/downloads/portal/.
Read the instructions shipped with the drive and/or drive option before installing the unit, and observe the instructions for safe
installation.
1.3 Version History
This guide is regularly reviewed and updated. All suggestions for improvement are welcome.
The original language of this guide is English.
Table 1: Version History
Version
Remarks
MG33V302
Editorial changes. Now covering the complete system.
AQ267038105120, version 0101
Update for compliance to ATEX directive 2014/34/EU and actual standards.
1.4 Products Covered
The VLT®PTC Thermistor Card MCB 112 is available for the following drives:
VLT®HVAC Drive FC 102.
VLT®AQUA Drive FC 202.
VLT®AutomationDrive FC 302.
1.5 Functional Overview
1.5.1 Intended Use
The VLT®PTC Thermistor Card MCB 112 is intended to:
Protect electrical motors against inadmissible heating due to overload.
Protect explosion-protected motors in explosive atmospheres caused by:
gases, vapors, or mists, Zone 1 and Zone 2,
and/or in explosive atmospheres caused by dust, Zone 21 and Zone 22.
NOTICE
MARKINGS
Refer to marking G for Zone 1 and Zone 2. Refer to marking D for Zone 21 and Zone 22.
All functions in the MCB 112 serve to protect both non-explosive-protected motors and explosive-protected motors in regular oper-
ation and in case of failure.
The VLT®PTC Thermistor Card MCB 112 is designed in accordance with EN 60947-8 (VDE 0660 part 0302). Only connect PTC thermis-
tor sensors according to DIN VDE V 0898-1-401: 2020-03 (EN 60947-8).
AQ267038105120en-000101 / 130R01046 | Danfoss A/S © 2022.08
Introduction
VLT® PTC Thermistor Card MCB 112
Operating Guide

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NOTICE
BUILT-IN OPTION
The VLT®PTC Thermistor Card MCB 112 is only functional if it is built into the drive. The option cannot be used as a standalone.
1.5.1.1 Markings of the Drive
A sticker is delivered with the option as spare part or with the drive to signify ATEX certification. Apply this sticker to the front of the
drive in which the ATEX module is integrated. This sticker indicates that the drive is ATEX certified.
e30be103.12
Illustration 1: Label to Apply to Drive
1.5.2 Foreseeable Misuse
Any use not expressly approved by Danfoss constitues misuse. This also applies to failure to comply with the specified operating
conditions and applications.
Danfoss assumes no liability of any sort for damage attributable to improper use.
Only operate with explosion-protected 3-phase motors which are built, tested, and labeled separately for use with drives.
WARNING
EXPLOSION DANGER
Zone 0 and Zone 20 are not applicable to electrical motors. Using electrical motors in those zones can cause explosions.
Only use elecrical motors in:
Zone 1/21.
Zone 2/22.
1.5.3 Thermal Motor Protection
According to ATEX Directive 2014/34/EU and Standard EN 60079-14, motor overload protection is a requirement. The VLT®PTC
Thermistor Card MCB 112 monitors the temperature in the motor windings with an ATEX-approved motor overload protection de-
vice. If there is a critical temperature level or a malfunction, switch off the motor. If the drive is equipped with 3 or 6 PTC thermistors
in series according to DIN VDE V 0898-1-401: 2020-03, the MCB 112 offers ATEX-approved monitoring of the motor temperature.
Alternatively, an external ATEX-approved PTC protection device can be used.
1.5.4 ATEX ETR Thermal Monitoring
NOTICE
The ATEX ETR thermal monitoring function only applies to Ex eb and Ex ec motors. There is no need of ATEX ETR thermal moni-
toring for Ex db motors.
AQ267038105120en-000101 / 130R0104 | 7Danfoss A/S © 2022.08
Introduction
VLT® PTC Thermistor Card MCB 112
Operating Guide

FC 302 with firmware version V6.3x or higher, FC 102 with firmware version V4.40 or higher, and FC 202 with firmware version V2.63
or higher are equipped with an ATEX ETR thermal monitoring function for operation of Ex eb and Ex ec motors according to EN
60079-7. Combined with an ATEX-approved PTC monitoring device like the MCB 112, the installation does not need an individual
approval from an approbated organization, so there is no need for a specific matched-pairs approval.
The ETR Thermal Monitoring feature makes it easier to apply Ex eb and Ex ec motors instead of the more expensive, larger, and
heavier Ex db motors. The use of Ex eb and Ex ec motors is possible by ensuring that the drive limits the motor current to prevent
the motor from heating up.
1.5.5 Tripping Function
The VLT®PTC Thermistor Card MCB 112 includes a tripping stage for PTC thermistor sensors with safe potential separation of supply
voltage from ground. The tripping function switches off the +24 V DC directly at terminal 37 on the drive.
The PNP logic output terminal X44/10 signals the status in case of failure. The MCB 112 works according to the closed-circuit princi-
ple. The device trips in case of short circuit or line interruption.
1.5.6 Safe Separation
The PTC thermistor circuit (T1, T2) has a safe separation of low-voltage electric circuits (PELV, see 3.4 Connecting Sensor Circuit
Wires.
1.5.7 Safe Disconnection Principle
The Safe Torque Off function disables the control voltage of the power semicondictors or the drive output stage. Disabling the con-
trol voltage prevents the inverter from generating the voltage required to rotate the motor.
1.5.8 Safe Disconnection Principle Diagram
Drive
Logic
out
Control card
Potentially explosive
atmosphere
PTC-sensors
3~Ex-Motor
Safe channel
T37
Safe stop
T37
T1
TP TP
T2
+24 V
PTC Thermistor Card
MCB 112
Non-explosive hazard zone
91
92
93
96
97
98
Converter module
e30be102.11
DI
Illustration 2: Block Diagram of Safe Disconnect with MCB 112
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Introduction
VLT® PTC Thermistor Card MCB 112
Operating Guide

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1.6 Motor Requirements
1.6.1 Motor Limits and Rules
For every certified motor with increased safety, the manufacturer supplies a data list including limits and rules. During planning,
installation, commissioning, operation, and service, respect the limits for:
Minimum switching frequency.
Maximum current.
Minimum motor frequency.
Maximum motor frequency.
Furthermore, respect the following:
Do not exceed the maximum allowable ratio between drive size and motor size. The typical value is IVLT,n≤2 x Im,n.
Consider all voltage drops from the drive to the motor. If the motor is running with lower voltage than listed in the U/f charac-
teristics, current might increase and cause an alarm.
Multi-motor applications are not allowed. Only connect 1 motor to the drive.
1.6.2 Additional Motor Requirements
The Ex eb motor must be approved for operation in hazardous zones (ATEX Zone 1/21, ATEX Zone 2/22) in combination with drives.
The motor must be certified for the particular hazardous zone.
The Ex ec motor must be approved for operation in hazardous zones (ATEX Zone 2/22) in combination with drives. The motor must
be certified for the particular hazardous zone.
NOTICE
The motor can be placed in Zone 1/21 or 2/22 according to motor approval. The drive must always be installed outside of the
hazardous zone.
Only operate explosion-protected 3-phase motors with drives if the motors are built, tested, approved, and labeled separately
for this mode.
When the usage of the motor and its thermal protective device are approved for drive operation, use the VLT®PTC Thermistor
Card MCB 112 for each ignition protection system for all motor types. For motors of Ex eb and Ex ec ignition protection, which
are OEM-approved for drive operation in Ex-hazardous areas, consider and use the requested limitations in the drive's ATEX ETR
thermal monitoring settings.
The necessary parameters and conditions are on the nameplate and in the documentation of the motor. To prevent prohibited
temperatures, the motors are equipped as standard with thermal winding protection, which has to be evaluated by a suitable
device like MCB 112. The motors must not be operated as a group drive.
1.6.3 Approvals and Certifications
Certification number: PTB 14 ATEX 3009
Certificates and declarations of conformity are available. Contact a local Danfoss partner.
1.7 Abbreviations and Conventions
1.7.1 Abbreviations
Abbreviation
Description
ETR
Electronic thermal relay
LCP
Local control panel
AQ267038105120en-000101 / 130R0104 | 9Danfoss A/S © 2022.08
Introduction
VLT® PTC Thermistor Card MCB 112
Operating Guide

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Abbreviation
Description
NC
Not connected
PNP
Positive negative positive (transistor)
TNF
Nominal response temperature
Abbreviation
Reference
Description
ATEX
ATEX Directive 2014/34/EU
ATmosphere EXplosibles.
HFT
EN IEC 61508
Hardware fault tolerance: HFT=n means that n+1 faults could cause a loss of the
safety function.
PDS/SR
EN IEC 61800-5-2
Power drive system (safety-related).
PFD
EN IEC 61508
Average probability of failure on demand, value used for low-demand operation.
SFF
EN IEC 61508
Safe failure fraction [%]; percentage of safe failures and dangerous detected fail-
ures of a safety function or a subsystem related to all failures.
SIL
EN IEC 61508, EN IEC 62061
Safety integrity level.
STO
EN IEC 61800-5-2
Safe Torque Off
SRECS
EN IEC 62061
Safety-related electrical control system.
1.7.2 Conventions
Numbered lists indicate procedures.
Bulleted and dashed lists indicate listings of other information where the order of the information is not relevant.
Bolded text indicates highlighting and section headings.
Italicized text indicates the following:
Cross-reference.
Link.
Footnote.
Parameter name.
Parameter option.
Parameter group name.
All dimensions in drawings are in metric values (imperial values in brackets).
An asterisk (*) indicates the default setting of a parameter.
AQ267038105120en-000101 / 130R010410 | Danfoss A/S © 2022.08
Introduction
VLT® PTC Thermistor Card MCB 112
Operating Guide