Danfoss OPTBL VACON NXP Air Cooled Installation Guide
- June 16, 2024
- Danfoss
Table of Contents
- OPTBL VACON NXP Air Cooled
- Produt Information
- Specifications
- Product Overview
- Safety
- Installation
- VACON Safe Tool
- Safety Functions
- Safe Fieldbuses
- Parameter List
- Product Usage Instructions
- Installation
- VACON Safe Tool
- Safety Functions
- Safe Fieldbuses
- Parameter List
- FAQ
- Q: How can I ensure the safety of the OPTBL, OPTBM, and OPTBN
- Q: Can I use the drives with other systems?
OPTBL VACON NXP Air Cooled
Produt Information
Specifications
- Product Name: OPTBL, OPTBM, OPTBN
- Website: drives.danfoss.com
Product Overview
The OPTBL, OPTBM, and OPTBN drives are advanced safety options
designed for integration into various systems. These options allow
for the achievement of a high level of safety in drive
applications. The drives come with a range of safety functions and
fieldbus compatibility.
Safety
The OPTBL, OPTBM, and OPTBN drives prioritize safety and include
various safety functions to ensure the protection of users and
equipment. The drives are equipped with safety symbols and warning
signs to alert users to potential dangers. Grounding is also an
important safety measure to prevent electrical hazards.
Installation
Before installing the option board, it is crucial to follow the
installation safety guidelines provided in the manual. Proper
installation ensures the correct functioning of the drives and
enhances safety.
VACON Safe Tool
The VACON Safe Tool is a software tool that allows users to
manage the parameters and settings of the OPTBL, OPTBM, and OPTBN
drives. It provides functions for setting parameters, saving
parameter files, and online monitoring. User levels and password
management ensure secure access to the tool.
Safety Functions
The OPTBL, OPTBM, and OPTBN drives offer a range of safety
functions to meet specific application requirements. These
functions include safe stopping functions like Safe Torque Off
(STO) and Safe Brake Control (SBC), as well as speed monitoring
functions like Safe Speed Monitor (SSM).
Safe Fieldbuses
The drives support safe fieldbuses, allowing for reliable
communication between the drives and other systems. This enables
seamless integration and enhances the overall safety of the
system.
Parameter List
The parameter list provides a comprehensive overview of the
different parameters available for customization. These parameters
cover general settings, safety function parameters, speed
measurement parameters, ramp parameters, and more.
Product Usage Instructions
Installation
To install the option board on the OPTBL, OPTBM, or OPTBN drive,
follow these steps:
-
Ensure that the drive is turned off and disconnected from the
power source. -
Locate the option board slot on the drive.
-
Carefully insert the option board into the slot, ensuring
proper alignment. -
Firmly push the option board until it is securely seated in the
slot. -
Reconnect the drive to the power source and turn it on.
VACON Safe Tool
The VACON Safe Tool provides a user-friendly interface for
managing the parameters and settings of the drives. To use the
tool, follow these steps:
-
Launch the VACON Safe Tool software on your computer.
-
Connect the computer to the OPTBL, OPTBM, or OPTBN drive using
a compatible interface cable. -
Select the desired drive from the software interface.
-
Access the parameter settings to customize the drive’s behavior
based on your application requirements. -
Save the parameter file to the option board for later use or
online monitoring.
Safety Functions
The OPTBL, OPTBM, and OPTBN drives offer various safety
functions that can be configured to meet specific safety
requirements. Follow these instructions to utilize the safety
functions:
-
Refer to the manual for detailed information on each safety
function and its purpose. -
Access the drive’s control panel or the VACON Safe Tool
software to configure the safety functions. -
Set the desired parameters for each safety function to achieve
the desired level of safety. -
Regularly monitor the status and performance of the safety
functions to ensure their proper functioning.
Safe Fieldbuses
To use the safe fieldbus feature of the drives, follow these
steps:
-
Ensure that the drives and other systems are compatible with
the selected safe fieldbus. -
Configure the communication settings of the drives and other
systems to establish a reliable connection. -
Test the communication between the drives and other systems to
verify proper integration. -
Monitor the communication status and address any issues
promptly to maintain system safety.
Parameter List
The parameter list provides access to a wide range of
customization options for the drives. Follow these steps to modify
parameters:
-
Refer to the parameter list in the manual for a comprehensive
overview of available parameters. -
Access the parameter settings through the VACON Safe Tool
software or the drive’s control panel. -
Review each parameter and its description to understand its
purpose and potential impact. -
Modify the parameter values as needed to align with your
specific application requirements. -
Save the parameter settings to apply the changes to the
drives.
FAQ
Q: How can I ensure the safety of the OPTBL, OPTBM, and OPTBN
drives?
A: To ensure the safety of the drives, follow the safety
guidelines provided in the manual. Use the safety functions,
properly install the option board, and regularly monitor the
drives’ performance.
Q: Can I use the drives with other systems?
A: Yes, the drives can be integrated into other systems. Refer
to the manual for information on integration and interfaces to
ensure compatibility.
Operating Guide
VACON® NXP Advanced Safety Options
OPTBL, OPTBM, OPTBN
drives.danfoss.com
VACON® NXP Advanced Safety Options
Operating Guide
Contents
1 Introduction
1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Manual and Software
Version 1.4 Approvals and Certificates 1.5 Product Overview 1.6 Terms and
Abbreviations
2 Safety
2.1 Safety Symbols 2.2 Danger and Warnings 2.3 Cautions and Notices 2.4
Grounding
3 Overview of the System
3.1 Using the Advanced Safety Options 3.2 The Safe State 3.3 Integration and
Interfaces to Other Systems 3.4 Determining the Achieved Safety Level 3.5
Advanced Safety Option Variants
3.5.1 General Information 3.5.2 Input Configuration 3.5.3 Output Configuration
3.5.4 Option Board OPTBL 3.5.5 Option Board OPTBM 3.5.6 Option Board OPTBN
3.5.7 Closed-loop Control with OPTBM 3.5.8 Closed-loop Control with OPTBN 3.6
Speed Measurement 3.6.1 Safety Speed Sensors 3.6.2 Standard Speed Sensors and
Combinations 3.6.3 Speed Discrepancy with Multiple Speed Sources 3.6.4
Encoders 3.6.5 Proximity sensors 3.6.6 Encoder Signal Verification 3.6.7 Usage
of Only One Speed Sensor 3.6.8 Estimated Speed
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3.6.9 Estimated Speed and Gear Systems 3.6.10 Estimated Speed and External
Accelerative Forces 3.7 Storage of Parameters 3.7.1 Storing a Parameter File
Backup 3.7.2 Restoring a Parameter File from Backup 3.8 Advanced Safety
Options with the NXP Drive 3.8.1 Requirements 3.8.2 Compatibility with Drive
Applications 3.8.3 Option Board Menu on the Control Panel 3.8.4 Fault Types
4 Installation
4.1 Installation Safety 4.2 Installing the Option Board
5 VACON Safe Tool
5.1 Functions of the VACON Safe Tool 5.2 The Parameter File 5.3 User Levels
and Password Management 5.4 Setting the Parameters 5.5 Saving a Verified
Parameter File to the Option Board 5.6 Online Monitoring
5.6.1 Viewing the State of the Option Board 5.6.2 Activity Log
6 Safety Functions
6.1 General Information 6.1.1 The Different Safety Functions 6.1.2 Safety
Function States 6.1.3 Activation of a Safety Function 6.1.4 Violation of a
Safety Function 6.1.5 Acknowledgment of a Safety Function 6.1.5.1
Acknowledgment of a Safety Function 6.1.5.2 Start-up Acknowledgment 6.1.6
Reset of a Safety Function 6.1.7 Ramps
6.2 Safe Stopping Functions 6.2.1 Introduction to the Safe Stopping Functions
6.2.2 STO – Safe Torque Off and SBC – Safe Brake Control
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6.2.2.1 Introduction to the STO and SBC Functions 6.2.2.2 The STO Function
Used without the SBC Function 6.2.2.3 The STO Function Used with the SBC
Function 6.2.2.4 The STO and SBC Signals 6.2.3 SS1 – Safe Stop 1 6.2.3.1
Introduction to the SS1 Function 6.2.3.2 Time Monitoring 6.2.3.3 Zero Speed
Monitoring 6.2.3.4 Ramp Monitoring 6.2.3.5 The SS1 Signals 6.2.4 SS2 – Safe
Stop 2 and SOS – Safe Operating Stop 6.2.4.1 Introduction to the SS2 and SOS
Functions 6.2.4.2 Time Monitoring 6.2.4.3 Zero Speed Monitoring 6.2.4.4 Ramp
Monitoring 6.2.4.5 The SOS Safety Function 6.2.4.6 The SS2 and SOS Signals
6.2.5 SQS – Safe Quick Stop 6.2.5.1 Introduction to the SQS Function 6.2.5.2
The SQS Modes 6.2.5.3 The SQS Signals 6.3 Safe Monitoring Functions 6.3.1
Introduction to the Safe Monitoring Functions 6.3.2 SLS – Safe Limited Speed
6.3.2.1 Introduction to the SLS Function 6.3.2.2 Time Monitoring 6.3.2.3 Ramp
Monitoring 6.3.2.4 The Speed Limit Selection of the SLS Function 6.3.2.5 The
SLS Signals 6.3.3 SMS – Safe Maximum Speed 6.3.3.1 Introduction to the SMS
Function 6.3.3.2 The Maximum Speed Monitoring 6.3.3.3 The SMS Signals 6.3.4
SSR – Safe Speed Range 6.3.4.1 Introduction to the SSR Function 6.3.4.2 Time
Monitoring 6.3.4.3 Ramp Monitoring 6.3.4.4 The SSR Signals
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VACON® NXP Advanced Safety Options
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6.3.5 SSM – Safe Speed Monitor 6.3.5.1 Introduction to the SSM Function
6.3.5.2 Speed Monitoring 6.3.5.3 The SSM Safe Output 6.3.5.4 The SSM Signals
6.4 Combinations of Safety Functions
7 Safe Fieldbuses
7.1 PROFIsafe 7.1.1 Introduction to PROFIsafe 7.1.2 The Requirements and
Restrictions 7.1.3 Overview of the PROFIsafe System 7.1.4 The PROFIsafe Frame
7.1.5 Parameterization for PROFIsafe 7.1.5.1 General Information on
Parameterization 7.1.5.2 PROFIsafe Watchdog Time 7.1.5.3 The PROFIsafe Safety
Function Response Time (SFRT) 7.1.6 PROFIdrive on PROFIsafe 7.1.6.1 General
Information on PROFIdrive on PROFIsafe 7.1.6.2 PROFIsafe over PROFIBUS 7.1.6.3
PROFIsafe over PROFINET 7.1.6.4 Data Mapping for PROFIdrive on PROFIsafe
7.1.6.5 Safety Control Word 1 (S_STW1) 7.1.6.6 Safety Status Word 1 (S_ZSW1)
7.1.6.7 Safety Control Word 2 (S_STW2) 7.1.6.8 Safety Status Word 2 (S_ZSW2)
7.1.6.9 VACON Safety Control Word (VS_CW) 7.1.6.10 VACON Safety Status Word
(VS_SW)
8 Parameter List
8.1 General Parameters 8.1.1 Parameter File Parameters 8.1.2 Common Safety
Function Parameters 8.1.3 Speed Measurement Parameters 8.1.4 Ramp Parameters
8.1.5 Estimated Speed Parameters
8.2 Safe I/O Parameters 8.2.1 Digital Input/Output Parameters
8.3 Safe Fieldbus Parameters
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8.3.1 PROFIsafe Parameters 8.4 STO and SBC Parameters 8.5 SS1 Parameters 8.6
SS2 and SOS Parameters 8.7 SQS Parameters 8.8 SLS Parameters 8.9 SMS
Parameters 8.10 SSR Parameters 8.11 SSM Parameters 8.12 Validation Parameters
9 Commissioning and Validation
9.1 Preparing for Commissioning 9.1.1 Preparing for Commissioning 9.1.2
Procedures Before the First Start-up of the System with the Option
9.2 Doing the First Start-up After the Installation of the Option Board 9.3
Validating the Parameter File 9.4 Checklist before Taking the System into Use
9.5 Bypassing Safety Features
10 Operation and Maintenance
10.3 Resetting the Password 10.4 Factory Reset
10.5.1 Updating the Firmware 10.6 Replacing the Option Board 10.7 Replacement
of Other Components of the Safety System 10.8 Disposal
11 Technical Data
11.1 Safety Data 11.2 Safe Input/Output Data 11.3 Speed Measurement Data 11.4
Safe Fieldbus Data 11.5 Environmental Data
12 Fault Tracing
12.1 Presentation of Faults on the Control Board 12.2 Fault Codes 12.3 OPTAF
STO and ATEX Option Board Fault Information
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13 Configuration Examples
13.1 General Information 13.2 Emergency Stop Using the STO Function 13.3 SS1
Used with STO(+SBC) 13.4 SS1 Without a Direct Support of the Drive Application
13.5 Light Curtain Control of SLS 13.6 SLS without a Direct Support of the
Drive Application 13.7 Using an Output of the Option Board to Control the
Access to an Area 13.8 PROFIdrive over PROFIsafe Using the PROFIBUS or
PROFINET Option Board 13.9 A Proximity Sensor for Speed Measurement
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
1 Introduction
1.1 Purpose of the Manual
This manual describes the VACON® Advanced Safety Options (OPTBL, OPTBM, or
OPTBN). The VACON® Advanced Safety Options can be used with the VACON® NXP AC
drive. The operating guide is intended for use by qualified personnel, who are
familiar with the VACON® drives and functional safety. To use the product
safely, read and follow the operating instructions.
1.2 Additional Resources
Resources Available for the Drive and Optional Equipment · VACON® NX OPTAF STO
Board Manual · VACON® NX All in One Application Guide – information on working
with parameters and many application examples · VACON® OPTE3/E5 PROFIBUS DP
User Guide · VACON® NX I/O Boards User Manual · VACON® OPTEA/OPTE9 Ethernet
Board User Guide · VACON® Ethernet Option Boards Installation Guide · VACON®
RS485 and CAN Bus Option Boards Installation Guide · VACON® NXP Advanced
Safety Options Quick Guide · The Operating Guide of the AC drive provides the
necessary information to get the drive up and running. Supplementary
publications and manuals are available from drives.danfoss.com/knowledge-
center/technical-documentation/. Standards, specifications, and official
recommendations · EN IEC-62061 Safety of machinery Functional safety of
safety-related electrical, electronic and programmable electronic con-
trol systems, 2005 · IEC 61784-3 Industrial communication networks
Profiles Part 3: Functional safety fieldbuses – General rules and profile
defi-
nitions, 2010 · EN ISO 13849-1 Safety of machinery Safety-related parts of
control systems Part 1: General principles for design, 2015 · EN IEC 60204-1
Safety of machinery Electrical equipment of machines Part 1: General
requirements, 2006 · EN IEC 61800-5-2 Adjustable speed electrical power
drive systems Part 5-2: Safety requirements Functional, 2007 · IEC 61508
Functional safety of electrical/electronic/programmable electronic safety
related systems, 2010 · EN ISO 12100 Safety of machinery — General
principles for design — Risk assessment and risk reduction, 2010 · ISO 14121-1
Safety of machinery — Risk assessment — Part 1: Principles, 2007 · Amendment
PROFIdrive on PROFIsafe Interface for functional safety; Technical
Specification for PROFIBUS and PROFINET rela-
ted to PROFIdrive Profile Drive Technology V4.1, Version 3.00.4, April 2011,
Order No.: 3.272 · PROFIsafe Profile for Safety Technology on PROFIBUS DP
and PROFINET IO, Version 2.4, March 2007, Order No: 3.192b · Recommendation of
Use CNB/M/11.050, rev 05; European co-ordination of Notified Bodies for
Machinery, 2013 · BGIA Report 2/2008e Functional safety of machine controls
Application of EN ISO 13849 , 2009 Software and Configurations Files · The
firmware for the Advanced Safety Option, https://www.danfoss.com/en/service-
and-support/downloads/dds/fieldbus-firm-
ware/. · VACON® Safe, https://www.danfoss.com/en/service-and-
support/downloads/dds/vacon-safe/. · The GSD/GSDML file,
https://www.danfoss.com/en/service-and-support/downloads/dds/fieldbus-
configuration-files/. For US and Canadian markets:
NOTE! Download the English and French product guides with applicable safety,
warning and caution information from https:// www.danfoss.com/en/service-and-
support/.
REMARQUE Vous pouvez télécharger les versions anglaise et française des guides
produit contenant l’ensemble des informations de sécurité, avertissements et
mises en garde applicables sur le site https://www.danfoss.com/en/service-and-
support/.
Danfoss A/S © 2021.06
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
1.3 Manual and Software Version
This manual is regularly reviewed and updated. All suggestions for improvement
are welcome. The original language of this manual is English. Always make sure
that you use the latest or correct revision of the manual when assessing the
behavior of the Advanced safety option board.
Table 1: Manual and Software Version
Manual ver- New features sion
Firmware ver- Hardware ver-
sion
sion
DPD01798B The first published version of this manual.
DPD01798C · PROFIsafe over PROFINET information added. Chapter Safe fieldbuses
and throughout the manual.
· Version history table added.
· Table linking option board names to option board codes. Chapter 3.5.1
General Information.
· Images edited. Chapters VACON Advanced Safety Option variants and
Configuration examples.
· Warning added. Chapter 6.1.4 Violation of a Safety Function.
· Fault settings table added. Chapter 3.8.3 Option Board Menu on the Control
Panel.
· Safety bypass procedure updated. Chapter 9.5 Bypassing Safety Features.
· Fault codes edited. Chapter Fault codes.
· New configuration example on SLS without drive application support added.
Chapter 13.6 SLS without a Direct Support of the Drive Application.
· Configuration examples numbered. Chapter Configuration examples.
· Other minor updates. Throughout the manual.
DPD01798D · Safety function acknowledgment and reset descriptions updated to match new behavior. Chapters 6.1.5.1 Acknowledgment of a Safety Function and 6.1.6 Reset of a Safety Function.
FW0281V001 or later
· Example of system level calculations updated. Chapter 3.4 Determining the Achieved Safety Level.
· Encoder terminals updated. Chapters 3.5.5 Option Board OPTBM and 3.5.6 Option Board OPTBN.
· Option board installation instructions updated. Chapter 4.2 Installing the Option Board.
· Extended slot support and example configuration updated. Chapter 3.1 Using the Advanced Safety Options.
· Comment on closed-loop control added. Chapter 3.6.7 Usage of Only One Speed Sensor.
· Old parameters edited and new added. Chapter 3.8.3 Option Board Menu on the Control Panel.
· Watchdog times updated. Chapter 7.1.5.2 PROFIsafe Watchdog Time.
· Technical details updated. Chapter 11.1 Safety Data.
· Fault codes updated. Chapter Fault codes.
· Images edited. Chapters 3.1 Using the Advanced Safety Options, 3.6.8 Estimated Speed, 6.2.3.5 The SS1 Signals, 6.3.4.2 Time Monitoring, 6.3.4.3 Ramp Monitoring, 13.3 SS1 Used with STO(+SBC), 13.5 Light Cur-
70CVB01938 F (141X4588) or later, 70CVB01957 F (141X4608) or later, 70CVB01958 E (141X4610) or later
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
Manual version
New features
tain Control of SLS, and 13.6 SLS without a Direct Support of the Drive
Application. · Other minor updates. Throughout the manual.
Firmware ver- Hardware ver-
sion
sion
DPD01798E
·
New chapter added, 3.6.3 Speed Discrepancy with Multiple Speed Sources.
FW0281V001 or later
· Information on internal variables added. Chapter 10.1 Gathering Diagnostic Data.
· Some fault numbers for fault code 20 Safety system updated. Chapter Fault codes.
· OPTAF option board fault information added. Chapter 12.3 OPTAF STO and ATEX Option Board Fault Information.
· Other minor updates. Throughout the manual.
70CVB01938 F (141X4588) or later, 70CVB01957 F (141X4608) or later, 70CVB01958 E (141X4610) or later
DPD01798F · PROFINET IO/PROFIsafe Certificate updated. 1.4 Approvals and
Certificates.
· Changes in layout and structure.
FW0281V001 or later
70CVB01938 F (141X4588) or later, 70CVB01957 F (141X4608) or later, 70CVB01958 E (141X4610) or later
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VACON® NXP Advanced Safety Options Operating Guide
1.4 Approvals and Certificates
Introduction
e30bi948.10
Illustration 1: TÜV Certificate 12 | Danfoss A/S © 2021.06
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
e30bi950.10
Certificate
PROFIBUS Nutzerorganisation e.V. grants to Vacon Ltd Runsorintie 7, 65380 VAASA, FINLAND
the Certificate No: Z20212 for the PROFIsafe Device:
Model Name: Vacon OPTEA, OPTBL, OPTBM, OPTBN Advanced Safety Option
Order-Number: OPTBL, OPTBM, OPTBN
Revision:
SW/FW: V4.0.0; HW: 6
Application CRC: Channel A: 0x84C3
Channel B: 0xCB77
This certificate confi rms that the product has successfully passed the
certfii cation tests with the following PROFIsafe scope:
PROFIsafe_V2 functionality on PROFINET IO
Test Report Number: Authorized Test Laboratory:
PS127-2 SIEMENS AG, Fürth, Germany
The tests were executed in accordance with the following documents: “PROFIsafe
– Test Specification for F-Slaves, F-Devices, and F-Hosts, Version 2.1, March
2007”.
This certificate is granted according to the document: “Framework for testing
and certification of PROFIBUS and PROFINET products”.
For all products that are placed in circulation by March 19, 2023 the
certificate is valid for life.
Karlsruhe, May 14, 2020
Board of PROFIBUS Nutzerorganisation e. V.
(Official in Charge)
(Karsten Schneider)
(Dr. Jörg Hähniche)
Illustration 2: PROFINET IO/PROFIsafe Certificate
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
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Illustration 3: EC Declaration of Conformity 14 | Danfoss A/S © 2021.06
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
1.5 Product Overview
The Advanced safety option board is intended to be used for implementing
safety functions according to application needs. The option board is intended
to be used with the OPTAF STO option board to implement the safety functions
and features in VACON® NX drives. The safety functions available with the
Advanced safety option board (according to EN IEC 61800-5-2) · Safe Torque Off
(STO) · Safe Stop 1 (SS1) · Safe Stop 2 (SS2) · Safe Operating Stop (SOS) ·
Safe Brake Control (SBC) · Safe Limited Speed (SLS) · Safe Speed Range (SSR) ·
Safe Speed Monitor (SSM) The manufacturer-specific safety functions · Safe
Maximum Speed (SMS) · Safe Quick Stop (SQS) For more information on the safety
functions, see chapter Safety functions. The safe fieldbuses supported by the
option board · PROFIsafe communication over PROFIBUS · PROFIsafe communication
over PROFINET Communication over PROFIsafe is implemented according to the
PROFIdrive on PROFIsafe amendment.
WARNING
DESIGNING OF SAFETY SYSTEMS Designing a safety-related system incorrectly
could result in death or serious injury.
– The designing of safety-related systems requires special knowledge and
skills. – Only qualified persons are permitted to install and set up the
product.
WARNING
RISK ASSESSMENT OF A SAFETY SYSTEM The use of safety functions provided by the
Advanced Safety Option does not in itself ensure safety.
– To make sure that the commissioned system is safe, you must make an overall
risk assessment. – Safety devices like the Advanced safety option board must
be correctly incorporated into the entire system. – The entire system must be
designed in compliance with all relevant standards within the field of
industry. Standards such as
EN 12100 Part 1, Part 2, and ISO 14121-1 provide methods for designing safe
machinery and for making a risk assessment.
CAUTION
PROTECTION AGAINST CONTAMINATION For the product to work properly, it must be
protected against conductive dust and contaminants.
– For example, install the Advanced Safety Option board in at least an IP54
enclosure.
NOTICE
This guide provides information on the use of the safety functions that the
Advanced Safety Option provides. This information is in compliance with
accepted practice and regulations at the time of writing. However, the
product/system designer is responsible for making sure that the system is safe
and in compliance with relevant regulations.
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VACON® NXP Advanced Safety Options Operating Guide
Introduction
1.6 Terms and Abbreviations
Table 2: Symbols and Abbreviations
Abbreviation
Definition
Admin
The highest user level for accessing the Advanced safety option board functions. Identified via a password.
Acknowledgment
A signal that indicates that a safety function can be deactivated. Valid for safety functions that use manual acknowledgment.
ASM
An asynchronous motor
Continuous mode Safety function is active as a part of normal operation.
CRC
Cyclic Redundancy Check
CW
Control word
DAT
Device Acknowledgment Time
Diagnostic Coverage The coverage of dangerous failures by run-time diagnostics. (DC)
EMC
Electromagnetic compatibility
Encoder interface board
An option board that has an encoder interface.
F-Device
A communication peer that can perform the PROFIsafe protocol.
F-Host
A data processing unit that can perform the PROFIsafe protocol and service the “black channel”.
FMEA
Failure Mode and Effects Analysis
Critical fault
A fault that causes the option board to enter into a fault state and requires a reboot to be reset.
GSD
Generic Station Description (used with PROFIBUS).
GSDML
General Station Description Markup Language (used with PROFINET).
Hardware Fault Tol- The number of hardware failures that the safety system can tolerate without the loss of the safety func-
erance (HFT)
tion.
HAT
Host Acknowledgment Time.
High demand mode Safety functions are performed on demand. The frequency of demand is more than once a year.
HTL
High Threshold Logic. A voltage level definition.
I/O
Input/Output
Low demand mode Safety functions are performed on demand. The frequency of demand is less than once a year.
MTTF
Mean Time To Failure
OPTAF
An option board that handles the activation of the STO function for the AC drive.
OPTBL, OPTBM, OPTBN
The variants of the Advanced safety option. OPTBL: no encoder interface. OPTBM: with digital pulse type encoder interface board. OPTBN: with Sin/Cos type encoder interface board.
OPTE3/5
Option board that handles the PROFIBUS DP interface.
OPTEA
Option board that handles the PROFINET IO interface.
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Introduction
Abbreviation
Definition
Parameter file
A configuration file that contains the parameters for an Advanced safety option board.
Unverified parame- A parameter file that contains parameters that have not been verified by an Advanced safety option
ter file
board.
Verified parameter file
A parameter file that contains parameters that have been verified and can be used in an Advanced safety option board.
Validated parameter A verified parameter file that contains parameters that have been tested and approved in the system. file
PFH
Probability of failure per hour. Valid for systems that operate in a high demand mode or continuous
mode.
PFHd
Probability of dangerous failure per hour.
PFD
Probability of failure on demand. The probability that the safety function does not work when requested.
Valid for systems that operate in a low demand mode.
PL
Performance Level
PLC
Programmable Logic Controller
PMSM
A permanent magnet synchronous motor
PROFIBUS
Standardized fieldbus protocol for RS-485 communication.
PROFIdrive
A specification for implementing AC drive related behavior over PROFIBUS/ PROFINET.
PROFINET
Standardized fieldbus protocol for Ethernet communication.
PROFIsafe
A safe fieldbus layer that operates over PROFIBUS/PROFINET.
Reached
A safety function that is reached has stopped the drive (safe stopping functions), or reached a safe area for the measured value and monitoring for leaving the area has been activated (safe monitoring functions).
Resettable fault
An error in that can be reset with a reset signal.
Reset (signal)
A signal used to reset the current violations and faults in the drive and/or the Advanced safety option board and to deactivate the STO function after a violation or fault.
SFF
Safe Failure Fraction
Safe monitoring function
A safety function that monitors a specific value, usually speed.
Safe stopping func- A safety function intended to stop the motor. tion
Safe range
A range where the monitored value can be. Exceeding the limits of a safe range will cause a violation of the safety function.
Safe state
A state of a device or process that should be maintained to avoid dangerous incidents. For the AC drive system, the safe state is defined as activated STO function.
Service
A user level for accessing the Advanced safety option board functions. Identified via a password. In this user level, it is not possible to verify a parameter file or change passwords.
SFRT
Safety Function Response Time
SRP/CS
Safety-Related Part of a Control System
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Introduction
Abbreviation STO SS1 SS2 SQS
SQS-STO, SQS-SS1, SQS-SS2 SLS SSR SSM SMS SBC SOS SIL SW TTL Violation
Violation response
WCDT WDTime
Definition Safe Torque Off. A safety function according to EN IEC 61800-5-2.
Safe Stop 1. A safety function according to EN IEC 61800-5-2. Safe Stop 2. A
safety function according to EN IEC 61800-5-2. Safe Quick Stop. A
manufacturer-specific safety function. Used as a violation response for safe
monitoring functions. Parameterizable to behave as the STO, SS1 or SS2
function. Used to indicate the STO, SS1 or SS2 function as the selected
behavior of the SQS function.
Safe Limited Speed. A safety function according to EN IEC 61800-5-2. Safe
Speed Range. A safety function according to EN IEC 61800-5-2. Safe Speed
Monitor. A safety function according to EN IEC 61800-5-2. Safe Maximum Speed.
A manufacturer-specific safety function. Safe Brake Control. A safety function
according to EN IEC 61800-5-2. Safe Operating Stop. A safety function
according to EN IEC 61800-5-2. Safety Integrity Level Status word Transistor-
Transistor Logic. A voltage level definition. A fault caused by a safety
function detecting a violation of the monitored value(s). The value monitored
by a safety function has exceeded the set limit for that value. A reaction to
a violation. It is the STO function for the safe stopping functions, and the
SQS function for the safe monitoring functions. Worst Case Delay Time Watchdog
Time
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Safety
2 Safety
2.1 Safety Symbols
The following symbols are used in this manual:
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury.
NOTICE
Indicates information considered important, but not hazard-related (for
example, messages relating to property damage).
2.2 Danger and Warnings
DANGER
SHOCK HAZARD FROM POWER UNIT COMPONENTS The power unit components are live
when the drive is connected to mains. A contact with this voltage can lead to
death or serious injury.
– Do not touch the components of the power unit when the drive is connected to
mains. Before connecting the drive to mains,
make sure that the covers of the drive are closed.
DANGER
SHOCK HAZARD FROM TERMINALS The motor terminals U, V, W, the brake resistor
terminals, or the DC terminals are live when the drive is connected to mains,
also when the motor does not operate. A contact with this voltage can lead to
death or serious injury.
– Do not touch the motor terminals U, V, W, the brake resistor terminals, or
the DC terminals when the drive is connected to
mains. Before connecting the drive to mains, make sure that the covers of the
drive are closed.
DANGER
SHOCK HAZARD FROM DC LINK OR EXTERNAL SOURCE The terminal connections and the
components of the drive can be live 5 minutes after the drive is disconnected
from the mains and the motor has stopped. Also the load side of the drive can
generate voltage. A contact with this voltage can lead to death or serious
injury.
– Before doing electrical work on the drive:
Disconnect the drive from the mains and make sure that the motor has stopped.
Lock out and tag out the power source to the drive. Make sure that no external
source generates unintended voltage during work. Wait 5 minutes before opening
the cabinet door or the cover of the AC drive. Use a measuring device to make
sure that there is no voltage.
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Safety
WARNING
SHOCK HAZARD FROM CONTROL TERMINALS The control terminals can have a dangerous
voltage also when the drive is disconnected from mains. A contact with this
voltage can lead to injury.
– Make sure that there is no voltage in the control terminals before touching
the control terminals.
WARNING
ACCIDENTAL MOTOR START When there is a power-up, a power break, or a fault
reset, the motor starts immediately if the start signal is active, unless the
pulse control for Start/Stop logic is selected. If the parameters, the
applications or the software change, the I/O functions (including the start
inputs) can change. If you activate the auto reset function, the motor starts
automatically after an automatic fault reset. See the Application Guide.
Failure to ensure that the motor, system, and any attached equipment are ready
for start can result in personal injury or equipment damage.
– Disconnect the motor from the drive if an accidental start can be dangerous.
Make sure that the equipment is safe to operate
under any condition.
WARNING
LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
– Ensure the correct grounding of the equipment by a certified electrical
installer.
WARNING
SHOCK HAZARD FROM PE CONDUCTOR The drive can cause a DC current in the PE
conductor. Failure to use a residual current-operated protective (RCD) device
Type B or a residual current-operated monitoring (RCM) device can lead to the
RCD not providing the intended protection and therefore can result in death or
serious injury.
– Use a type B RCD or RCM device on the mains side of the drive.
2.3 Cautions and Notices
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT MEASUREMENTS Doing measurements on the
AC drive when it is connected to mains can damage the drive.
– Do not do measurements when the AC drive is connected to mains.
CAUTION
DAMAGE TO THE AC DRIVE FROM INCORRECT SPARE PARTS Using spare parts that are
not from the manufacturer can damage the drive.
– Do not use spare parts that are not from the manufacturer.
CAUTION
DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING Not using a grounding
conductor can damage the drive.
– Make sure that the AC drive is always grounded with a grounding conductor
that is connected to the grounding terminal
that is identified with the PE symbol.
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Safety
CAUTION
CUT HAZARD FROM SHARP EDGES There can be sharp edges in the AC drive that can
cause cuts.
– Wear protective gloves when mounting, cabling, or doing maintenance
operations.
CAUTION
BURN HAZARD FROM HOT SURFACES Touching surfaces, which are marked with the
‘hot surface’ sticker, can result in injury.
– Do not touch surfaces which are marked with the ‘hot surface’ sticker.
NOTICE
DAMAGE TO THE AC DRIVE FROM STATIC VOLTAGE Some of the electronic components
inside the AC drive are sensitive to ESD. Static voltage can damage the
components.
– Remember to use ESD protection always when working with electronic
components of the AC drive. Do not touch the com-
ponents on the circuit boards without proper ESD protection.
NOTICE
DAMAGE TO THE AC DRIVE FROM MOVEMENT Movement after installation can damage
the drive.
– Do not move the AC drive during operation. Use a fixed installation to
prevent damage to the drive.
NOTICE
DAMAGE TO THE AC DRIVE FROM INCORRECT EMC LEVEL The EMC level requirements for
the AC drive depend on the installation environment. An incorrect EMC level
can damage the drive.
– Before connecting the AC drive to the mains, make sure that the EMC level of
the AC drive is correct for the mains.
NOTICE
RADIO INTERFERENCE In a residential environment, this product can cause radio
interference.
– Take supplementary mitigation measures.
NOTICE
MAINS DISCONNECTION DEVICE If the AC drive is used as a part of a machine, the
machine manufacturer must supply a mains disconnection device (refer to EN
60204-1).
NOTICE
MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES Because there are high
capacitive currents in the AC drive, it is possible that the fault current
protective switches do not operate correctly.
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Safety
NOTICE
VOLTAGE WITHSTAND TESTS Doing voltage withstand tests can damage the drive.
– Do not do voltage withstand tests on the AC drive. The manufacturer has
already done the tests.
2.4 Grounding
Ground the AC drive in accordance with applicable standards and directives.
CAUTION
DAMAGE TO THE AC DRIVE FROM INSUFFICIENT GROUNDING Not using a grounding
conductor can damage the drive.
– Make sure that the AC drive is always grounded with a grounding conductor
that is connected to the grounding terminal
that is identified with the PE symbol.
WARNING
LEAKAGE CURRENT HAZARD Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
– Ensure the correct grounding of the equipment by a certified electrical
installer.
The standard EN 61800-5-1 tells that 1 or more of these conditions for the
protective circuit must be true. The connection must be fixed. · The
protective earthing conductor must have a cross-sectional area of minimum 10
mm2 Cu or 16 mm2 Al. OR · There must be an automatic disconnection of the
mains, if the protective earthing conductor breaks. OR · There must be a
terminal for a second protective earthing conductor in the same cross-
sectional area as the first protective
earthing conductor.
Cross-sectional area of the phase conductors (S) [mm2] The minimum cross-
sectional area of the protective earthing conductor in question [mm2]
S 16
S
16 < S 35
16
35 < S
S/2
The values of the table are valid only if the protective earthing conductor is
made of the same metal as the phase conductors. If this is not so, the cross-
sectional area of the protective earthing conductor must be determined in a
manner that produces a conductance equivalent to that which results from the
application of this table. The cross-sectional area of each protective
earthing conductor that is not a part of the mains cable or the cable
enclosure, must be a minimum of: · 2.5 mm2 if there is mechanical protection,
and · 4 mm2 if there is not mechanical protection. With cord-connected
equipment, make sure that the protective earthing conductor
in the cord is the last conductor to be interrupted, if the strain-relief
mechanism breaks.
Obey the local regulations on the minimum size of the protective earthing
conductor.
NOTICE
MALFUNCTION OF FAULT CURRENT PROTECTIVE SWITCHES Because there are high
capacitive currents in the AC drive, it is possible that the fault current
protective switches do not operate correctly.
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Safety
NOTICE
VOLTAGE WITHSTAND TESTS Doing voltage withstand tests can damage the drive.
– Do not do voltage withstand tests on the AC drive. The manufacturer has
already done the tests.
WARNING
SHOCK HAZARD FROM PE CONDUCTOR The drive can cause a DC current in the PE
conductor. Failure to use a residual current-operated protective (RCD) device
Type B or a residual current-operated monitoring (RCM) device can lead to the
RCD not providing the intended protection and therefore can result in death or
serious injury.
– Use a type B RCD or RCM device on the mains side of the drive.
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VACON® NXP Advanced Safety Options Operating Guide
Overview of the System
3 Overview of the System
3.1 Using the Advanced Safety Options
The Advanced safety option board is used to implement safety functions in
accordance with the standard EN IEC 61800-5-2. The option board handles the
safe I/O and the monitoring of active safety functions. The option board does
not handle the control of the AC drive. The AC drive can be controlled, for
example, with the drive application, or the external process control system
can give the speed reference to the AC drive. The Advanced safety option board
must be used with a subsystem that provides the STO function, it is not
possible to use the Advanced safety option board alone. The STO function is
provided, for example, by the OPTAF STO option board. To use the safety
functions that do speed monitoring, an external speed sensor is necessary. The
sensor can be a digital or an analog encoder or a digital proximity sensor.
See chapter Speed Measurement. The Advanced safety option board can be used
with the digital I/O and over safe fieldbus. Using a safe fieldbus allows you
to control more safety functions than is possible with the limited number of
inputs and outputs that the Advanced safety option board has. When using a
safe fieldbus, install an option board that supports the fieldbus. See 7.1.1
Introduction to PROFIsafe. The Illustration 4 shows the configuration of the
AC drive with the Advanced safety option board in slot C. The safe fieldbus
and the closed-loop control are optional. The possible configuration and
available features can depend on other option boards and their installation
slots. For use cases with other encoder board installed in slot C, see 3.6.4
Encoders.
PC
NCDrive
VACON® Loader VACON® Safe
e30bi367.10
Power Unit
Control Board
Drive
SLOT A Basic I/O
SLOT B SLOT C SLOT D
STO option board
Advanced safety option board
SLOT E
Fieldbus board
Motor
Encoder
STO
Encoder signals
Digital I/O
Safe fieldbus
Safety PLC or other safety systems
Illustration 4: An example configuration of the VACON® NXP drive with the
Advanced safety option board. The subsystems that handle safety actions are
marked in gray.
The parameterization of the option board is done by selecting and editing the
safety functions and features with the VACON® Safe tool. See 5.4 Setting the
Parameters and chapter Parameter List.
3.2 The Safe State
There must be a safe state to which the system can be set when necessary.
Usually the safe state is reached when the AC drive does not generate torque
to the motor shaft. In the Advanced safety option board, this is realized by
the Safe Torque Off (STO) safety function. In some systems, the active STO
function in the AC drive does not create a safe state. It means that external
forces can generate torque to the motor shaft and cause it to rotate. To
achieve the safe state in these systems, additional means are necessary. For
example, it is possible to use the STO function and a mechanical brake. The
brake can be used with the Safe Brake Control (SBC) safety function of the
Advanced option board, or with another safe control system for the brake.
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The Advanced safety option board forces the AC drive to the safe state, for
example, if there is an error detected in the safety system. Other situations
when the safe state is enforced are, for example, the parameterization phase
and during the start-up of the drive.
3.3 Integration and Interfaces to Other Systems
When the Advanced safety option board is integrated to a safety system, the
system designer and/or the operator is responsible for these things: · Making
an initial system-level risk assessment and reassessing the system any time a
change is made. · The setup and suitability of parameters, sensors, and
actuators used in the system. · Validation of the system to the correct safety
level. · Maintenance and periodic testing. · Controlling the access to the
system, including password handling. External systems can collect information
from the Advanced safety option board in a few different ways. The option
board related fault and violation information is available in the fault log of
the AC drive like other faults. This data must be interpreted differently to
the fault data of the AC drive. See chapter Fault tracing. The option board
has configurable outputs where desired information can be set to be sent to
external systems. The status data can be received over a safe fieldbus.
3.4 Determining the Achieved Safety Level
WARNING
SAFETY AWARENESS IN DESIGN This chapter is an example and contains
simplifications. Using only this data in designing the system can damage the
equipment.
– Do not use this chapter as a template for designing your system. – Perform
the design work carefully.
The achieved safety level depends on the whole safety chain. The AC drive with
integrated safety functions is only one component in the safety chain. The
things related to the AC drive that affect the achieved safety level: · The
used speed measurement combination. · The implementation of the violation
response and of the fault response. In most cases it is realized via the STO
option board
(the OPTAF option board for the VACON® NX products). The components of the
safety chain that affect the achieved safety level: · The controllers (for
example, the safety PLC) that control the safety functions · The stop switches
· The wiring EXAMPLE Implementation of the STO safety function, consisting of
these subsystems. · Emergency stop switch: Pilz PIT es Set/1-family using two
N/C contacts. B10d = 104 000 (EN ISO 13849-1) and d/ = 0.20 (EN IEC
62061) for one channel. · The OPTAF option board, version VB00328H (141L7786).
A two-channel STO option board for the NX family. · The Advanced safety option
board OPTBL.
NOTICE
Check the corresponding product guides for the safety values and usage
instructions.
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e30bi368.10
Channel 1
Emergency stop switch
(SIL3, PLe)
OPTBL (SIL3, PLe,
Cat 4)
Stop (STO) request
STO
OPTAF & AC drive (SIL3, PLe,
Cat 3)
Channel 2
Stop (STO) request
STO
Illustration 5: A Logical Presentation of the STO Safety Function
In this example case, the STO function has one activation per day, and a lifetime of 20 years. For the emergency stop switch, = 10% is used as the susceptibility to common cause failure between the channels. No proof test is executed during the lifetime. The example system is limited to Category 3 because the Category 3 element OPTAF option board is used as a single final element.
Table 3: An Example of System Level Calculations for the STO Safety Function
Subsystem
SIL, PL
PFHd
Emergency stop switch
SIL3, PLe
4.2 x 10-9(1)
PFDavg 3.7 x 10-4(2)
DCavg [%] 90(3)
MTTFd [a] 2849.3 (4)(4)
OPTBL
SIL3, PLe
6.45 x 10-11
5.61 x 10-6
99
373
OPTAF
SIL3, PLe
2.7 x 10-9
1.3 x 10-4
60(5)
1918
Overall safety system (for STO)
SIL3, PLe
6.94 x 10-9(6)
5.06 x 10-4(7)
74(8)
281(9)
1 This value is calculated directly from the values provided by the manufacturer. The diagnostic capabilities of OPTBL have not been taken into account. The calculation formula: PFHd = (1- )2 x ch1 x ch2 x T1 + x (ch1 + ch2)/2, where ch = (0.1 x cycles per hour) / B10d). 2 The calculation formula: PFDavg = (PFHd x TM)/2. 3 The OPTBL executes “Cross monitoring of inputs without dynamic test”, DC: 0%…99%, depending on how often a signal change is done by the application. A DC of 90% is assumed with the once a day activation. 4 The calculation formula: MTTFd = B10d / (0.1 x cycles per year). 5 OPTAF manual: DCavg = low, using the lower end of the possible range (60%…90%) 6 Sum of the individual PFHd values. 7 Sum of the individual PFHavg values. 8 The calculation formula:
DCavg STO =
DCSwitch MTTFd Switch
1 MTTFd Switch
+ +
DCOPTBL MTTFd OPTBL
1 MTTFd OPTBL
DCOPTAF MTTFd OPTAF
1 MTTFd OPTAF
9 According to EN ISO 13849-1, the MTTFd must be limited to a maximum limit of 100 years per channel. The calculation formula:
MTTFd STO =
1 MTTFd Switch
1 1 MTTFd OPTBL
1 MTTFd OPTAF
NOTICE
When designing systems according to IEC-61508, the requirement for the value
of the Safe Failure Fraction (SFF) is considered on subsystem level, not on
system level.
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3.5 Advanced Safety Option Variants
3.5.1 General Information
Newer versions of the Advanced Safety Option have extended slot compatibility.
The table Table 4 describes the supported slots for different revisions of the
option board. The compatibility is determined by the revision of the board
70CVB01938 (141X4588). See Illustration 6 for the location of the revision
information.
Table 4: Supported Slots of the Revisions of the Option Board Option board revision (70CVB01938, 141X4588)
Slot C
Slot D
Slot E
C, E
–
Yes
–
F
Yes
Yes
Yes
e30bi413.10
Illustration 6: The Board Identification Sticker on the Advanced Safety Option
Board
The Advanced safety option board contains a safe digital I/O for the control
and status word signals. The available connectors of the Advanced safety
option board · 4 two-terminal digital inputs · 2 two-terminal digital outputs
· 2 STO outputs · +24 V supply · GND It is possible to use the digital inputs
for selecting ramps and for activating, acknowledging, and resetting safety
functions. The twoterminal digital outputs can be used as output signals of
the SBC or the SSM function, or configured by combining various signals of the
option board. If a connected device is powered by an external power supply,
make sure that there is common ground between the device and the Advanced
safety option board.
NOTICE
The digital outputs use internal diagnostic test pulses to make sure that the
output logic operates correctly. These test pulses are visible to external
systems. See 11.2 Safe Input/Output Data.
3.5.2 Input Configuration
The 4 two-terminal digital inputs operate in a two-terminal equivalent mode:
the state of both terminals must match each other within a discrepancy time
(see 11.2 Safe Input/Output Data).
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Table 5: The Input States Input terminal A Input terminal B State
Active
Active
The assigned safety function is not requested.
Active
Inactive
The assigned safety state is requested. If longer than 500 ms: the option board detects a fault.
Inactive
Active
The assigned safety state is requested. If longer than 500 ms: the option board detects a fault.
Inactive
Inactive
The assigned safety function is requested.
It is possible to assign these tasks to each of the digital inputs: · the
request of a safety function · the acknowledgment signal · the reset signal ·
the proximity sensor It is possible to assign 1 task per digital input. The
exceptions are the acknowledgment signal and the reset signal which can be
assigned to the same input.
NOTICE
If proximity sensors are used, it is not possible to assign safety function
features to the corresponding inputs. See 3.6.5 Proximity sensors.
3.5.3 Output Configuration
The 2 two-terminal digital outputs operate in a two-terminal equivalent mode:
the state of both terminals must match each other within a discrepancy time
(see 11.2 Safe Input/Output Data). The external system or systems should make
sure that the two terminals are in the same state. The tasks that can be
assigned to each of the digital outputs:
· the SSM function output
· the SBC function output
· simple custom logic
For more information on the SSM and the SBC function outputs, see 6.2.2.3 The
STO Function Used with the SBC Function and 6.3.5.3 The SSM Safe Output. To
configure the simple custom logic for an output, select a logical function and
desired signals from a configuration group. The option board uses the selected
signals and applies the selected logical function to determine the state of
the output. 1. Select the group that contains the desired signal or signals.
2. Select the logical function to combine the selected signals. 3. Select the
signal or signals. If only 1 signal is selected: AND or OR (regardless of
which): output = signal. NAND or NOR (regardless of which): output = negative
signal. See the examples below for signal and output correspondence. The
available logical functions:
· AND
· OR
· NAND
· NOR
Only 1 logical function per output can be selected.
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Table 6: The Available Signals in Configuration Groups Group 1 and Group 5 Group 2 and Group 6
STO Reached SS1 Reached SS2 Reached SQS Reached SOS Reached SBC Reached STO and SBC Reached
SLS 1 Reached SLS 2 Reached SLS 3 Reached SSR Reached SMS Reached SSM Reached SSM Above Max Limit SSM Below Min Limit
Group 3 and Group 7
STO Active SS1 Active SS2 Active SQS Active SLS 1 Active SLS 2 Active SLS 3
Active SSR Active SMS Active SSM Active
Group 4 and Group 8
Warning in any safety function Limit violation fault in any safety function
During operation, the option board uses the selected signals and applies the
selected logical function to determine the state of the output. If the result
of the logical function on the actual state of the selected signals is “true”,
the output is active. If the result is “false”, the output is inactive.
EXAMPLE 1 (USING GROUP 2):
Selected signals: SLS 1 Reached, SSM Below Min Limit
Logical function: OR
Table 7: Example 1 State of the signals
Result of the logical function
State of the output
SLS 1 Reached = 0 SSM Below Min Limit = 0
0 OR 0 -> false
Inactive
SLS 1 Reached = 0 SSM Below Min Limit = 1 or SLS 1 Reached = 1 SSM Below Min Limit = 0
0 OR 1 -> true
Active
SLS 1 Reached = 1 SSM Below Min Limit = 1
1 OR 1 -> true
Active
EXAMPLE 2 (USING GROUP 2): Selected signals: SLS 1 Reached Logical function:
NOR Table 8: Example 2
State of the signals
SLS 1 Reached = 0
SLS 1 Reached = 1
Result of the logical function 0 NOR 0 -> true 1 NOR 1 -> false
EXAMPLE 3 (USING GROUP 2): Selected signals: SLS 1 Reached, SSM Below Min Limit Logical function: AND
State of the output Active Inactive
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Table 9: Example 3 State of the signals
SLS 1 Reached = 0 SSM Below Min Limit = 0
SLS 1 Reached = 0 SSM Below Min Limit = 1 or SLS 1 Reached = 1 SSM Below Min
Limit = 0
SLS 1 Reached = 1 SSM Below Min Limit = 1
Result of the logical function 0 AND 0 -> false 0 AND 1 -> false
1 AND 1 -> true
EXAMPLE 4 (USING GROUP 2): Selected signals: SLS 1 Reached, SSM Below Min Limit Logical function: NAND
Table 10: Example 4 State of the signals
Result of the logical function
SLS 1 Reached = 0 SSM Below Min Limit = 0
0 NAND 0 -> true
SLS 1 Reached = 0 SSM Below Min Limit = 1 or SLS 1 Reached = 1 SSM Below Min Limit = 0
0 NAND 1 -> true
SLS 1 Reached = 1 SSM Below Min Limit = 1
1 NAND 1 -> false
State of the output Inactive Inactive
Active
State of the output Active Active
Inactive
3.5.4 Option Board OPTBL
Use the Advanced safety option board OPTBL when no encoder is used to measure
the speed of the motor shaft.
X3 Dout1 Dout2
X4 Din1 Din2 Din3 Din4
e30bi410.10
13
5
7
9
2
4
6
8 10
Illustration 7: The Terminals X3 and X4 of the OPTBL Option Board
11 13 15 17 12 14 16 18
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Overview of the System
1
STO 1. STO terminal 1 +24 V, to be connected to OP- 10
GND.
TAF terminal SD1+.
11
Din 1A. Terminal A of digital input 1.
2
STO 2. STO terminal 2 +24 V, to be connected to OP-
TAF terminal SD2+.
12
Din 1B. Terminal B of digital input 1.
3
GND.
13
Din 2A. Terminal A of digital input 2.
4
GND.
14
Din 2B. Terminal B of digital input 2.
5
Dout 1A. Terminal A of digital output 1.
15
Din 3A. Terminal A of digital input 3.
6
Dout 1B. Terminal B of digital output 1.
16
Din 3B. Terminal B of digital input 3.
7
Dout 2A. Terminal A of digital output 2.
17
Din 4A. Terminal A of digital input 4.
8
Dout 2B. Terminal B of digital output 2.
18
Din 4B. Terminal B of digital input 4.
9
+24 V. +24 V supply for external logic.
3.5.5 Option Board OPTBM
The OPTBM option board is similar to the OPTBL option board, but in addition,
the OPTBM option board has a digital pulse TTL/HTL type encoder interface
board attached to it.
The digital pulse type encoder interface board is used to connect encoders
with digital signals to the OPTBM option board. The option board supports
encoders with Transistor-Transistor Logic (TTL) and High Threshold Logic (HTL)
type signals. Make sure that the used type is correctly set during
parameterization.
The digital pulse type encoder interface board is designed for HTL encoders
with a voltage output type of push-pull.
From revision F onwards, the OPTBM (70CVB01957, 141X4608) board enables the
use of closed-loop control. To use closed-loop control, the OPTBM board must
be installed in slot C. For further information, see 3.5.7 Closed-loop Control
with OPTBM.
X5
X6
12345678
9 10 11 12 13 14
e30bi411.10
V GND + – + – + X3
+ – + -+ X4
Illustration 8: The Terminals X5 and X6 of the Digital Pulse Type Encoder Interface Board
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VACON® NXP Advanced Safety Options Operating Guide
Overview of the System
1
Configurable encoder voltage.
2
GND.
3
A+. Terminal A of digital pulse signal.
4
A-. Terminal A of digital pulse signal.
5
B+. Terminal B of digital pulse signal.
6
B-. Terminal B of digital pulse signal.
7
Z+. Reference signal, optional.
8
Z-. Reference signal, optional.
9
A+. Unmodified encoder signal loopback.
10
A-. Unmodified encoder signal loopback.
11
B+. Unmodified encoder signal loopback.
12
B-. Unmodified encoder signal loopback.
13
Z+. Unmodified encoder signal loopback.
14
Z-. Unmodified encoder signal loopback.
3.5.6 Option Board OPTBN
The OPTBN option board is similar to the OPTBL option board, but in addition,
the OPTBN option board has a Sin/Cos type encoder interface board attached to
it.
The Sin/Cos type encoder interface board is used to connect an encoder with
analog sinus and cosine signal to the OPTBN option board.
From revision E onwards, the OPTBN (70CVB01958, 141X4610) board enables the
use of closed-loop control. To use closed-loop control, the OPTBN board must
be installed in slot C. For further information, see 3.5.8 Closed-loop Control
with OPTBN.
X7
X8
12345678
9 10 11 12 13 14
e30bi958.10
V GND + – + – + X3
+ – + -+ X4
Illustration 9: The Terminals X7 and X8 of the Sin/Cos Type Encoder Interface Board
1
Encoder voltage. Selectable encoder voltage.
2
GND.
3
Sin+. Sinus terminal of analog pulse signal.
4
Sin-. Sinus terminal of analog pulse signal.
5
Cos+. Cosine terminal of analog pulse signal.
6
Cos-. Cosine terminal of analog pulse signal.
7
Z+. Reference signal, optional.
8
Z-. Reference signal, optional.
9
Sin+. Unmodified encoder signal loopback.
10
Sin-. Unmodified encoder signal loopback.
11
Cos+. Unmodified encoder signal loopback.
12
Cos-. Unmodified encoder signal loopback.
13
Z+. Unmodified encoder signal loopback.
14
Z-. Unmodified encoder signal loopback.
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3.5.7 Closed-loop Control with OPTBM
The OPTBM board can be used to realize closed-loop control. To use closed-loop
control with OPTBM, check that the OPTBM revision supports closed-loop
control, and that the OPTBM board is installed in slot C. When using closed-
loop control with OPTBM, consider the following features or differences
compared to the other encoder boards used for closed-loop control. · The value
of Pulse/revolution (normally shown as P7.3.1.1) used for closed-loop control
is copied from the parameterization of
the Advanced Safety Option. It cannot be edited independently. · The parameter
Reading Rate (shown as P7.3.1.3.1) can be edited normally. · Parameter Invert
Direction (normally shown as P7.3.1.2) is not supported or shown. Value “0 =
No” is always used. · Parameter Encoder Type (normally shown as P7.3.1.4) is
not supported or shown. Value “1 = A, B = speed” is always used. · The
qualifier input ENC1Q is not included in OPTBM. · The fast digital input DIC4
is not included in OPTBM. · The encoder must use differential signals. Single-
ended encoders are not supported.
3.5.8 Closed-loop Control with OPTBN
The OPTBN board can be used to realize closed-loop control. To use closed-loop
control with OPTBN, check that the OPTBN revision supports closed-loop
control, and that the OPTBN board is installed in slot C. When using closed-
loop control with OPTBN, consider the following features or differences
compared to the other encoder boards used for closed-loop control. · The value
of Pulse/revolution (normally shown as P7.3.1.1) used for closed-loop control
is copied from the parameterization of
the Advanced Safety Option. It cannot be edited independently. · The parameter
Reading Rate (shown as P7.3.1.3.1) can be edited normally. · Parameter Invert
Direction (normally shown as P7.3.1.2) is not supported or shown. Value “0 =
No” is always used. · The parameter Interpolation (normally shown as P7.3.1.4)
is not supported. Value “0 = No” is always used.
3.6 Speed Measurement
3.6.1 Safety Speed Sensors
The speed measurement methods supported by the Advanced safety option board: ·
Sin/Cos encoder · Digital pulse encoder (TTL or HTL) · Proximity sensor For
parametric information, see 8.1.3 Speed Measurement Parameters. When certified
speed sensors are used, the sensors can be used to implement safety functions
up to the safety level stated in the certificate. To use these speed sensors,
make sure that the sensor monitoring executed by the option board fulfills the
requirements that the sensor has for the speed monitoring device. For the
monitoring executed by the Advanced safety option board, see 3.6.6 Encoder
Signal Verification.
3.6.2 Standard Speed Sensors and Combinations
The speed measurement methods supported by the Advanced safety option board: ·
Sin/Cos encoder · Digital pulse encoder (TTL or HTL) · Proximity sensor For
parametric information, see 8.1.3 Speed Measurement Parameters. The option
board can be used with standard speed sensors. The table below shows the
maximum achievable safety levels for combinations of different speed sensors
without certificate. In addition to speed sensors, it is possible use
estimated speed from the control board of the AC drive as a second channel for
speed measurement diagnostics. Calculate and take into account the relevant
safety values for the encoder when assessing the fulfillment of the
requirements for the targeted safety level(s). The relevant safety values
include these values:
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VACON® NXP Advanced Safety Options Operating Guide
Overview of the System
· PFH · Category · Performance level For the diagnostic coverage for the encoder, see 3.6.6 Encoder Signal Verification.
Table 11: Achievable Safety Levels when Using Speed Sensors without Certificate
Safety
Sin/Cos
function
Digital Pulse + 2 x Proximity
estimated
sensor
speed
Proximity sensor + estimated speed
Sin/Cos + proximity sensor
Digital Pulse + proximity sensor
Any other combination
STO (+SBC)
SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SS1
SIL 3, PLe, SIL 3, PLe, Cat4 SIL 3, PLe,
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe,
Cat4
Cat4
Cat4
SS2, SOS SIL 2, PLd, Cat3
–
–
SIL 2, PLd, Cat3 –
–
SQS-STO SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SQS-SS1
SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4
SQS-SS2 SIL 2, PLd, Cat3
–
–
SIL 2, PLd, Cat3 –
–
SLS
SIL 2, PLd, SIL 2, PLd, Cat2 SIL 3, PLe,
SIL 2, PLd, Cat2 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 –
Cat3
Cat4
SMS
SIL 2, PLd, SIL 2, PLd,
SIL 3, PLe,
SIL 2, PLd,
SIL 3, PLe,
SIL 3, PLe,
–
Cat3
Cat2(1)
Cat4(2)
Cat2(1)
Cat4(2)
Cat4(2)
SSM
SIL 2, PLd, SIL 2, PLd, Cat2 SIL 3, PLe,
SIL 2, PLd, Cat2 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 –
Cat3
Cat4
SSR
SIL 2, PLd, SIL 2, PLd, Cat2 SIL 3, PLe,
SIL 2, PLd, Cat2 SIL 3, PLe, Cat4 SIL 3, PLe, Cat4 –
Cat3
Cat4
1 Only if the monitored limits to both directions are set to the same value or
both values are greater than the value of Allowed Deviation of Speed Sources.
2 Only if the monitored limits to both directions are set to the same value.
Table Table 11 gives the maximum SIL, PL, and Cat levels that can be achieved
with a combination. Other factors than speed measurement can be the limiting
factor on system level. For example, either SIL 2 or SIL 3 can be achieved
with the OPTAF STO option board as a single final element. See the VACON® NX
OPTAF STO Board Manual for further information.
NOTICE
For non-safe Sin/Cos encoders, it is required in the table Table 11 that the
encoder is implemented in analog design. The fault model “Exchange of Sin and
Cos signal inside the encoder” must be excluded.
Combinations that are not listed in the table Table 11 are not tested or
supported, and offer no increase to the claimed safety levels. It can still be
possible to use unlisted combinations. Regardless of the used speed
measurement combination, it is the responsibility of the system designer to
make sure that the used combination is adequate and sufficient.
NOTICE
When multiple speed sources are used, the monitored limit of a safety function
must not be set below the value of Allowed Deviation of Speed Sources.
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3.6.3 Speed Discrepancy with Multiple Speed Sources
When you use multiple speed sources, for example, a Sin/Cos encoder and a
proximity sensor, or estimated speed and a speed sensor, the speed values
measured by these sensors must be within the allowed deviation of each other.
There is new behavior in the software version FW0281 V004: the reaction to
exceeding the deviation depends on the request for safety functions. If a
safety function is requested, the reaction is a fault and STO will be
activated. If no safety function is requested, the reaction is a warning and
STO will not be activated. This enables continuing the process and stopping at
an acceptable and safe position. It is also possible to start a single drive
in already running process where there is a difference in estimated speed and
encoder speed before the drive enters run mode, that is, a “flying start”
situation.
CAUTION
INSUFFICIENT SPEED MEASUREMENT CAPACITY When the warning for speed difference
is active, the safety system cannot guarantee that the speed measuring
capability is sufficient.
– Running in this mode should be kept to minimal, for example to only start
the motor in “flying start” situation or to continue
to a safe position.
If running the motor in this situation cannot be accepted, a possible solution
is to use the Safe Speed Monitor (SSM) safety function. It can be set to
“Always active” mode. So, the safety function is always requested and the
reaction to speed discrepancy is always fault and STO. This is the same as the
behavior in the previous software version (FW0281 V003 and older). The value
for the allowed deviation between the speeds can be set during
parameterization. A formula for a recommended value with a speed sensor and
estimated speed can be found in chapter Estimated speed.
3.6.4 Encoders
The encoder interface boards of the Advanced safety option board have two
connector sets. The cables from an encoder are connected to one connector set.
The other connector set provides the encoder signals as output that can be
connected to other devices that use the encoder data. Such device can be, for
example the standard encoder board that is used to realize the closed-loop
control. The Advanced safety option board transmits the signals from the
encoder to the other connector set without any modification.
NOTICE
When you use speed sensors for the safety functions, it is possible that the
AC drive operates in open loop or closed-loop control. When closed-loop
control is used, a closed-loop enabling option board must be used in slot C.
This can be either a separate encoder board or the Advanced Safety Option.
NOTICE
When you use speed sensors without SIL claims, estimated speed from the AC
drive can be used as a second independent channel to fulfill the requirements
of safety standards. See chapter Standard Speed Sensors and Combinations.
NOTICE
The encoder signals consist of two separate channels (for example, sinus and
cosine). Do not change the order or modify the channels before connecting them
to the Advanced safety option.
When the Advanced Safety Option is used for closed-loop control, it must be
installed in slot C. Connect the encoder cables to the board normally. When
closed-loop control is used with a separate encoder board, connect the
SinCos/Digital pulse signal cables of the encoder to the encoder interface
board of the Advanced safety option board. Connect also the encoder interface
board to the encoder board in slot C. The encoder board implements the closed-
loop control by using the encoder interface board to receive feedback. See the
figure below.
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VACON® NXP Advanced Safety Options Operating Guide
Control Board
Overview of the System Drive
e30bi369.10
Encoder
SLOT C
Encoder Board
SLOT D
Advanced safety option board
SinCos / Digital pulse
SinCos / Digital pulse signals
Illustration 10: Encoder Signals in Closed-loop Control
When an absolute encoder is used, the cables for the absolute data are
connected directly to the encoder board id slot C. The SinCos/Digital pulse
signal cables are connected to the Advanced safety option board and from there
to the option board in slot C.
e30bi370.10
Control Board
Drive
SLOT C
Absolute Encoder
Board
SLOT D
Advanced safety option board
Absolute
SinCos / Digital pulse
Absolute Data
Encoder
SinCos / Digital pulse signals
Illustration 11: Absolute Encoder Signals in Closed-loop Control
This configuration enables the use of absolute encoder with position data for
control. The safety functions are implemented without the absolute data, and
the safety functions with position monitoring are monitoring the relative
position based on the incremental signals from the encoder.
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Control Board
Overview of the System Drive
e30bi371.10
SLOT C
No Encoder
Board
SLOT D
Advanced safety option board
Encoder
SinCos / Digital pulse signals
Illustration 12: Open Loop Control without an Encoder Board in Slot C
Because of EMC reasons, the last component that handles the encoder signals
should have a termination resistor when Sin/Cos or TTL type encoders are used.
The termination resistor enhances the quality of the signals. If there are no
components on the encoder signal chain after the Advanced safety option board,
the termination must be on the Advanced safety option board. If the Advanced
safety option board transmits the encoder signals to the encoder board in slot
C, use termination on the encoder board and not on the Advanced safety option
board. This applies to the cases in Illustration 10 and Illustration 11. It
also applies to other possible components that handle the encoder signals. Do
not use multiple termination resistors. Configure the termination resistor
during the parameterization of the Advanced safety option board.
Subsequent logic
1
e30bi372.10
Encoder
TTL: A+, B+, Z+ Sin/Cos: Sin+, Cos+, Ref+
TTL: A-, B-, ZSin/Cos: Sin-, Cos-, Ref-
Advanced safety option board
2 150
Illustration 13: Using Termination Resistors, Resistor 1 or Resistor 2 The use of resistor on the Advanced safety option board is selected during parameterization.
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Table 12: Termination Resistor Usage Encoder type Encoder signal loop-back used
TTL or Sin/Cos No
TTL or Sin/Cos Yes
HTL
Any
Termination resistor on the Advanced safety option board used Yes No Use of a termination resistor is not required
3.6.5 Proximity sensors
It is possible to connect two proximity sensors to the safe I/O of the
Advanced safety option board. The option board supports only the 4-wire PNP
type proximity sensors. A proximity sensor must supply two signals, a normal
and an inverted signal, to the Advanced safety option board.
When one proximity sensor is used, connect it to the digital input 1 of the
safe I/O. If a second proximity sensor is added, connect it to the digital
input 2. The two proximity sensors must be installed so that they have the
same number of pulses per rotation.
For a proximity sensor connection example, see 13.9 A Proximity Sensor for
Speed Measurement.
e30bi409.10
X3
X4
1 Din1 Din2 2
Illustration 14: Connecting Proximity Sensors to the Connectors of the Option Board
1
Terminals for the first proximity sensor
2
Terminals for the second proximity sensor
The duty cycle (that is, the active-inactive signal ratio) of the proximity sensors is set during the parameterization. Setting the duty cycle to a value other than 50% (1:1 signal ratio) decreases the supported maximum frequency of the proximity sensor signals. The Advanced safety option board does not monitor that the actual duty cycle corresponds to the parametrized value. The duty cycle must be set to an approximately correct value so that the Advanced safety option board can correctly detect when the speed exceeds the supported maximum frequency and trigger a fault. Otherwise the short pulses at high speed may not be detected and the speed measurement may indicate too low a speed.
NOTICE
Use of ramp monitoring is not recommended when only proximity sensors are used
as speed sensor.
Due to the way the speed is calculated, it is not recommended to set the safety function speed limits below a certain value. This value depends on the pulses per revolution of the proximity sensor signal. A formula for calculation of the rpm value is 15000/ppr.
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Table 13: Recommended Minimum Limits
Sensor ppr
Minimum recommended speed limits (rpm)
1
15000
4
3750
8
1875
32
469
3.6.6 Encoder Signal Verification
The Advanced safety option board verifies the correctness of the encoder
signals. During the operation of the option board, the encoders are
supervised. Supervision of all encoder types · When two speed sources are
used, they are cross-checked against each other. Supervision of Sin/Cos type
encoders · The amplitude of the encoder signals is monitored to keep it within
acceptable limits. · Making sure that the encoder signals are in valid
differential state (for example, Sin+ to Sin-). · Making sure that the sinus
and cosine signals are in phase shift between the different channels. · The
tests of the Sin/Cos encoder are equivalent to Sin2 (x) + Cos2 (x) = 1.
Supervision of Digital pulse type encoders · Making sure that the encoder
signals are in valid differential state (for example, A+ to A-). · Making sure
that the signals are in phase shift between the different channels.
Supervision of proximity sensors · Making sure that the proximity sensor
signals are in valid differential state (for example, A+, A-). Diagnostic
coverage for the encoder · Sin/Cos 99% · Digital pulse 90% · Proximity sensor
90%
NOTICE
In addition to the two differential channels used for speed measurement, a
reference signal (also called Zero/Z-pulse) can be used for additional
supervision of the correctness of the encoder signals. If the reference signal
is parameterized to be used, the total absence of the reference signal will be
detected. The disconnection of one of the differential signals might not be
detected. In such cases, the additional supervision based on the reference
signal is not lost.
The tests are done automatically when the motor rotates. To make sure that the
correct operation continues, the motor cannot be kept at standstill for longer
than 30 days. In practice, the conditions that are listed below must be valid
for the standstill counter to reset. When estimated speed is used · Estimated
speed is valid (that is, the AC drive is rotating the motor). · Estimated
speed and the speed measured by the encoder are greater than the allowed
deviation of the speed sources. When estimated speed is not used · The motor
must be rotated for at least two revolutions with a speed above 120/k rpm,
where k is “encoder number of pulses” or
“proximity sensor number of pulses”, depending on the used speed sensor. If an
encoder and a proximity sensor are used, the calculation must be valid for
both.
3.6.7 Usage of Only One Speed Sensor
When a single speed sensor is used, take into account these fault models. To
prevent these faults, plan the design and installation of your system
carefully. For more information, see the standard.
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VACON® NXP Advanced Safety Options Operating Guide
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Table 14: Speed Sensor Fault Models and their Fault Exclusions
Fault model as stated in EN IEC 61800-5-2
Fault exclusion as stated in EN IEC 61800-5-2 (Annex D Table D.16)
A loss of an attachment during motion: · sensor housing from motor chassis · sensor shaft from motor shaft · mounting of the readhead
Prepare the Failure mode and effects analysis (FMEA) and prove: · permanent fastness for formlocked connections · fastness for force-locked connections
A loosening of an attachment during motion: · sensor housing from motor chassis · sensor shaft from motor shaft · mounting of the readhead
A loss of an attachment during standstill: · sensor housing from motor chassis · sensor shaft from motor shaft · mounting of the readhead
In practice, the solution is over dimensioning against the occurrence of the
fault model. The sufficient over dimensioning factor depends on the connection
type and the fault model. In case the drive operates in open loop and the
estimated speed is also used, cross-check with the estimated speed will detect
the fault in the encoder. In closed loop with no external accelerative forces,
it is likely that the fault will not be detected. In this case, after the loss
of the encoder, the drive will either trigger a fault or the speed of the
motor will not accelerate but will stabilize to a speed value that corresponds
to the nominal slip of the motor. See also the operating instructions of the
encoder.
3.6.8 Estimated Speed
It is recommended to use two standard speed sensors or a single certified
speed sensor. When it is not possible, a standard speed sensor can be used
with estimated speed measured by the AC drive. The estimated speed is used as
a second independent channel to compare against the value of the speed sensor.
Estimated speed is used for diagnostics only and it does not trigger safety
function limit violation on its own. Estimated speed can be used with a
digital pulse encoder or a proximity sensor. With a Sin/Cos type encoder, the
estimated speed offers no benefits because it is limited to SIL2 which an
analog Sin/Cos type encoder can fulfill alone. Estimated speed can be used
with these safety functions:
· The STO function
· The SS1 function
· The SQS function (in STO and SS1 mode)
· The SLS function
· The SSR function
· The SSM function
· The SMS function (when the SMS limits have the same value, or when the
values of SMS Limit Plus and SMS Limit Minus are greater than the value of
Allowed Deviation of Speed Sources)
Estimated speed cannot be used with these safety functions:
· The SS2 function
· The SQS function (in SS2 mode)
NOTICE
Estimated speed with a speed sensor fulfills the safety requirements, but it
is possible that estimated speed is less accurate than a sensor, especially
when sudden changes occur in the load or the speed.
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WARNING
EXTERNAL BRAKES NEEDED Estimated speed is calculated only when the drive is in
RUN state, that is, when the drive is operating.
– If external forces can cause acceleration to the motor when the drive is not
in RUN state, use, for example, external brakes to
stop the motor and to keep it in standstill.
WARNING
OPEN-LOOP CONTROL AND EXTERNAL FORCES If the drive operates in open-loop
control and there are external forces that can cause acceleration to the
motor, the drive can pull out (that is, the motor is not under control). This
situation can cause estimated speed to be invalid.
WARNING
USAGE OF ONLY ONE SPEED SENSOR If only one encoder is used for safety
monitoring and closed-loop control, the fault model detachment of the encoder
from the motor shaft must be analyzed.
– Make sure that the fault model detachment of the encoder from the motor
shaft is analyzed. – See 3.6.7 Usage of Only One Speed Sensor.
When estimated speed is used, the speed value from an external speed sensor is
compared against the calculated value from the AC drive. If the two values
differ from each other more than the value of Allowed Deviation of Speed
Sources, during a time set with Speed Deviation Timer, a reaction as described
in 3.6.3 Speed Discrepancy with Multiple Speed Sources is executed. See
Illustration 15.
Speed difference > Allowed deviation of speed sources
Speed difference > Allowed deviation of speed sources
e30bi373.10
Reaction
Speed deviation timer
Speed deviation timer
Illustration 15: The speed difference of estimated speed and the speed
measured by a sensor does not stay within the set limits and causes a
comparison fault
When the AC drive is not in RUN state, estimated speed is not calculated, and
the motor is assumed to be coasting to stop. During that time, the comparison
between estimated speed and the speed measured by a sensor is not made. The
comparison is activated again when the value of Coast Stop Time passes, or
once the speed of the encoder goes below the value of Allowed Deviation of
Speed Sources. If the speed sensor indicates rotation that is not permitted by
Allowed Deviation of Speed Sources, a fault appears. See Illustration 16.
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VACON® NXP Advanced Safety Options Operating Guide
Speed Coast Stop
Overview of the System
Encoder Speed Allowed Deviation of Speed Sources
e30bi374.10
Allowed error monitoring
Speed deviation timer Reaction
t
Coast Stop Time
Drive State
RUN Not RUN Not RUN
Illustration 16: Estimated speed monitoring when the AC drive is not operating. A state “Not RUN” can be caused, for example, by a fault or a stop command given to the AC drive.
To make sure that your system operates correctly and safely, set the value of
Allowed Deviation of Speed Sources separately for each application. Use this
formula as a starting point to find the optimal value for the parameter. It is
possible that the formula does not give correct values with motors that have a
large nominal slip, for example small motors or specially designed motors.
The Allowed Deviation of Speed Sources [rpm] =
max
5 100
× Synchronous
nominal
speed
rpm ,
2×Nominal slip
rpm
where
Nominal slip rpm = Synchronous nominal speed rpm – Nominal speed rpm
Synchronous nominal speed rpm
=
Nominal frequency Hz × 60 s pole pair number
To make sure that the system is safe, parameters Allowed Deviation of Speed Sources and Speed Deviation Timer should be set to the smallest possible values with which the process can operate without the comparison fault appearing too often. Setting parameter Speed Deviation Timer to a greater value can give additional process availability but decrease the response time of the safety system in fault situations.
3.6.9 Estimated Speed and Gear Systems
Set the ratio between the speed measured by a sensor and estimated speed
during parameterization of the option board. Estimated speed is calculated for
the motor shaft. If the speed sensor is not on the motor shaft and thus
measures a different speed, the ratio between the speeds must be set with
parameters Gear Ratio Divider and Gear Ratio Multiplier. The safety functions
operate in the external speed sensor speed level. In practice, the estimated
speed calculated for the motor shaft is scaled to match to the external sensor
speed level.
Estimated speed (Actual) rpm
=
Estimated speed (Motor shaft) rpm Gear Ratio Multiplier / Gear Ratio Divider
The relation between the estimated speed and external speed sensor speed can be expressed by this formula:
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Estimated speed rpm
=
Gear Ratio Multiplier Gear Ratio Divider
× external sensor speed
rpm
See the parameters related to estimated speed in 8.1.3 Speed Measurement Parameters.
3.6.10 Estimated Speed and External Accelerative Forces
If estimated speed is used in systems where the safe state is not the STO
function alone, analyze the consequences on system level. As estimated speed
is not calculated when the AC drive is not in RUN state, the safety system
depends on the external speed sensor. During a standstill, only a single
channel speed estimation is available. When external forces can cause
acceleration and torque to the motor and make the motor rotate, a mechanical
brake must keep the motor shaft stationary.
3.7 Storage of Parameters
It is possible to store the parameters of the Advanced safety option board as
a backup in other locations. The different backup locations are handled in the
control board of the AC drive. Use the control panel of the AC drive to
control the parameter backup.
Table 15: Parameter Storing Locations Location Description
Checks and restrictions
OPTBL OPTBM OPTBN
The currently used parameter file is always saved on the option board.
In the start-up of the option board, the option board checks the parameter file to make sure that it is compatible. The option board always checks a new parameter file.
Control board of the AC drive
The currently used parameter file is uploaded to the control board during start-up and after each change in the parameter file. The parameter file is not stored permanently. To store the parameter file permanently in the control board as a backup, use the control panel.
The control board checks the CRC of the uploaded or stored parameter file to make sure that it is correct, but does not check the compatibility of the parameter values.
PC
The parameter files should be stored on the PC and in VACON® Safe creates unverified parameter files and
the version control or another system that is used to
stores verified parameter files “as is” without modifica-
handle the configurations used on the field.
tions to the safety critical and CRC protected area.
For more information on the PC tool VACON® Safe or the parameter file, see 5.2
The Parameter File.
The handling of the parameter file backup on the control board is not a safety
critical feature, and it is the responsibility of the operator to use the
correct parameters for the Advanced safety option board. A verified parameter
file that is read from a backup to the option board will be accepted and taken
into use. If the parameter file does not correspond to the actual
configuration, for example, if it has a different encoder parameterized than
what is supported by the used encoder interface board, the option board does
not allow the STO function to be deactivated.
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Control Board
Location select Save/Restore
Control panel
Advanced safety option
board
Parameter file
Control board back-up
PC tool
PC
Illustration 17: The Backup Locations of the Parameter File and their Control
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NOTICE
Only compatible parameter files are taken into use on the option board. If the
data in the backup location is faulty and sent to the option board, the option
board detects the faultiness. The STO function stays active until a valid
parameter file is provided.
3.7.1 Storing a Parameter File Backup
Use these instructions to store a parameter file backup from the Advanced
Safety Option. Procedure
1. Find parameter P7.4.1.1.3 Save Backup To under the menu group G7.4.1.1
Config Settings. 2. Select a backup location with parameter P7.4.1.1.3. 3.
Make sure that the parameter file backup was stored successfully.
a. Make sure that the parameter file is also stored on the PC. b. Do factory
reset for the Advanced safety option board. c. Do a parameter restore from the
backup location.
3.7.2 Restoring a Parameter File from Backup
Use these instructions to restore a parameter file from a backup into Advanced
Safety Option.
NOTICE
When the parameter file is restored from backup, the passwords are reset to
the default.
Procedure 1. Find parameter P7.4.1.1.4 Load Backup From under the menu group
G7.4.1.1 Config Settings. 2. Select a backup location with parameter
P7.4.1.1.4. 3. Make sure that the restored parameter file is accepted by the
Advanced safety option board. 4. Make sure that the restored parameter file is
the correct file. a. Load and view the parameter file on VACON® Safe. b. Check
the parameter file CRC on the control panel. c. Check the used safety
functions on the control panel. d. Check the parameter file creator and date
on the control panel. 5. Set the passwords to the intended values if
necessary.
3.8 Advanced Safety Options with the NXP Drive
3.8.1 Requirements
To use the Advanced safety option board with the VACON® NXP AC drive, obey
these requirements.
Table 16: Required Drive Component Versions Component
Version
Comment
The control board of VACON® NXP AC drive Hardware: VB00761 B (141L8026) or newer Software: NXP00002V198 or newer
The STO and ATEX option board (OPTAF)
Hardware: VB00328 E (141L7786) or newer Check the safety levels of STO in the product manual.
When a safe fieldbus is used, see also 7.1.1 Introduction to PROFIsafe for the fieldbus related requirements.
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Table 17: The PC Tools that Can Be Used with the Option Board
PC tool
Version
Comment
NCDrive
2.0.29 or newer Older versions than this can be used, but they do not show correctly the details of safety related faults.
VACON® Loader 1.1.12.0 or newer The tool is used to update the option board firmware.
VACON® Safe
1.0.2.0 or newer The tool is used to parameterize and monitor the option board. See 5.1 Functions of the VACON Safe Tool.
3.8.2 Compatibility with Drive Applications
The safety monitoring in the Advanced safety option board is independent of
the drive application and of the methods used to control the AC drive to
fulfill the monitored limits. The monitoring is always executed the same way.
Violations of safety limits result in the set responses in the option board.
The option board can be used with any drive application. Older drive
applications do not monitor or react to the safety system data. When a such
drive application is used, the AC drive must be monitored and controlled by
external systems for the AC drive to operate within the limits set by the
safety functions. For example, the drive application can ramp down and limit
the speed to a safe value when the Safe Limited Speed (SLS) function is
activated. Refer to the VACON® NX All-in-One Application Manual for more
information.
NOTICE
It is possible to use any drive application with the Advanced safety option
board, but some applications cannot operate correctly with the option board
added to the system. In such cases, update the application.
The drive applications that are aware of the Advanced safety option board and
able to use the related data can be used. A such drive application can keep
the AC drive within the limits set by the safety functions.
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Drive application
– Execution of ramp stops – Realisation of speed limit – Process-specific
actions
Control board firmware
– Communication with the option board – Basic handling of faults and warnings
Advanced safety option board
– Handling of safe I/O and safe fieldbus – Monitoring of safety functions
Illustration 18: Basic Tasks of the Option Board and the Control Board
Firmware, and the Optional Tasks of the Drive Application
3.8.3 Option Board Menu on the Control Panel
When the Advanced safety option is used, use menu M7 Expander boards on the
control panel of the drive to control the option board and to read status
data. It is possible to reset the option board passwords, do a factory reset,
and control of the parameter file backup. The status data includes the
identification data for the parameter file, certain parameter values of the
parameter file, and the run-time monitoring data. The option board menu
structure can be seen in Illustration 19, and all the values are described in
the tables below. The figure and tables are for installation in slot D.For
other slots the indexes are different. For example, G7.4.1 Parameters is
G7.3.1 Parameters in slot C.
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M7 Expander boards G7.4 OPTBL/OPTBM/OPTBN G7.4.1 Parameters G7.4.1.1 Config
Settings
G7.4.1.2 Fault Settings
G7.4.1.3 Encoder
G7.4.2 Monitor G7.4.2.1 Safety Functions G7.4.2.2 Digital I/O G7.4.2.3 Encoder G7.4.2.4 PROFIsafe
G7.4.2.5 File Info
G7.4.2.6 Diagnostics
Illustration 19: The Menu Structure of the Menus Related to the Advanced Safety Option Board
Table 18: Config Settings Group (G7.4.1.1)
Index
Parameter
Min
Max
Unit
Default
P7.4.1.1.1
Password Reset
0
1
0
P7.4.1.1.2
Factory Reset
0
1
0
P7.4.1.1.3
Save Backup To
0
1
0
P7.4.1.1.4
Load Backup From
0
1
0
ID Description
0 = No action
1 = Reset
0 = No action
1 = Reset
0 = No action
1 = Control unit
2 = Keypad
(1)
0 = No action
1 = Control unit
2 = Keypad
(1)
1 Back-up to keypad requires a newer keypad unit with extended storage capability.
Table 19: Fault Settings (G7.4.1.2)
Index
Parame- Min Max Unit De-
ter
fault
ID Description
P7.4.1.2.1 SafetySys- 0 2 0 tem flt
Selects the control board firmware response for fault code 20.
0 = “Default”, F20 activated as fault or warning depending on the case
(application may decrease the reporting level, e.g. fault -> warning)
1 = “Warning”, F20 activated as alarm
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Index
Parameter
Min Max Unit Default
ID Description 2 = “No Action”, F20 not activated
P7.4.1.2.2 SafeF indi- 0 2 0 cation
Selects the control board firmware response to safety function status
changes.
0 = “Default”, F46/F47/F48 activated as alarm (application may decrease the
reporting level, e.g. warning -> no action)
1 = “Violat only”, F48 activated as alarm, F46/F47 not activated
2 = “No Action”, F46/F47/F48 not activated
Table 20: Encoder (G7.4.1.3)
Index
Parameter
Min Max Unit Default ID Description
P7.4.1.3.1(1) Reading Rate 0 4
1
Time used to calculate actual speed value. Note: Use value 1 in closed loop mode. 0 = No 1 = 1 ms 2 = 5 ms 3 = 10 ms 4 = 50 ms
1 The menu group is accessible only when the Advanced safety option board is installed in slot C.
Table 21: Safety Functions Group (G7.4.2.1)
Index
Pa- Min Max Unit De-
rame-
fault
ter
ID Description
V7.4.2.1.1 STO V7.4.2.1.2 SS1 V7.4.2.1.3 SS2 V7.4.2.1.4 SQS V7.4.2.1.5 SSR
Shows the status of the safety function. Not in use = The function is not
taken into use in the parameter file.
Inactive = The safety function is not requested. Requested = The safety
function is requested.
Active = The safety function is active. (The signal xxx Active is “1”.)
Reached = The safety function is reached. (The signal xxx Reached is “1”.)
V7.4.2.1.6 SLS 1
V7.4.2.1.7 SLS 2
V7.4.2.1.8 SLS 3
V7.4.2.1.11 SSM
V7.4.2.1.12 SMS
V7.4.2.1.14 SOS
V7.4.2.1.15 SBC
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Table 22: Digital I/O Group (G7.4.2.2)
Index
Parameter Min Max Unit Default
V7.4.2.2.1 DI1 DI2 DI3 DI4
V7.4.2.2.2 DO1 DO2
ID Description
Shows the logical value of the option board digital input. Updated only for
inputs that have safety functions assigned. 0 = The input is inactive 1 = The
input is active – = The input is not used
Shows the logical value of the option board digital output. 0 = The output
is inactive 1 = The output is active – = The output is not used
Table 23: Encoder Group (G7.4.2.3)
Index
Parameter Min Max Unit Default
V7.4.2.3.1 Encoder Type
ID Description
Shows the encoder type specified in the parameter file. Values: · None ·
Increm. TTL · Increm. HTL · SinCos
V7.4.2.3.2 Estimated Speed
Shows whether estimated speed is used in the parameter file. Values:
· Not in us
· In use
V7.4.2.3.3 Proximity Sensor
Shows the number of used proximity sensors in use. Values: · None ·1 ·2
V7.4.2.3.4 Encoder Speed
V7.4.2.3.5 Encoder Freq
rpm Hz
Shows the average speed measured by the option board (encoder and proximity
sensors)
Shows the speed of the motor based on the encoder data.
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Table 24: PROFIsafe Group (G7.4.2.4)
Index
Parameter
Min Max Unit Default ID Description
V7.4.2.4.1 Safety Telegram
Shows the number of the used telegram. Values: · ST 30 · ST 31 · ST 58000
V7.4.2.4.2 F-Par SRC Addr
V7.4.2.4.3 F-Par DEST Addr
V7.4.2.4.4 F-Par WD Time
Shows the value of F Source Address Shows the value of F Destination Address Shows the value of F WD Time
Table 25: File Info Group (G7.4.2.5)
Index
Parameter
Min Max Unit Default ID Description
V7.4.2.5.1 File Name
Shows the first 12 characters of parameter File name
V7.4.2.5.2 File Creator
Shows the first 12 characters of parameter File creator
V7.4.2.5.3 Company Name
Shows the first 12 characters of parameter Company (Parameter file)
V7.4.2.5.4 CRC
Shows the CRC of the used parameter file in hex format
V7.4.2.5.5 CRC integer
Shows the CRC of the used parameter file in decimal integer format
Table 26: Diagnostics Group (G7.4.2.6)
Index
Parameter
Min Max Unit Default ID Description
V7.4.2.6.1 Last Error Code
Shows the number of the last fault of the Advanced safety option board in hex format.
V7.4.2.6.2 SW Version
Shows the software version of the Advanced safety option board.
V7.4.2.6.3 HW Version
Shows the hardware version of the Advanced safety option board.
V7.4.2.6.4 FPGA Version
Shows the FPGA version of the encoder interface board on the Advanced safety option board.
3.8.4 Fault Types
The Advanced safety option board has different fault types: critical fault,
resettable fault, violation, and warning. The fault types of the Advanced
safety option board are not the same as the fault types of the AC drive. For
more details on faults, see 12.1 Presentation of Faults on the Control Board.
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Table 27: Fault types of the Advanced safety option board
Fault type of the option board
Possible cause
Correction
Fault type of the AC drive
Response of the option board
Critical Fault
Resettable Fault
Violation
Internal broken hardware, incorrect Attempt to fix the issue. Reboot configuration, temporary malfunc- of the AC drive. tion detected by the diagnostics.
Fault
The STO function becomes active, all outputs are inactive.
External broken hardware, incorrect Attempt to fix the issue. Cleared configuration, temporary malfunc- with the reset signal. See 6.1.6 tion detected by the diagnostics. Reset of a Safety Function.
Fault
The STO+SBC function becomes active, see 6.2.2.3 The STO Function Used with the SBC Function.
Violation of a monitoring limit in an active safety function.
Cleared with the reset signal. See chapters 6.1.4 Violation of a Safety Function and 6.1.6 Reset of a Safety Function.
Warning
Safe monitoring functions: the SQS function.
Safe stopping functions: the STO+SBC function.
Warning
An event that does not affect the operation, but is shown for information.
Does not require clearing. / Cleared with the reset signal.
Warning No response.
Failures that are detected by the internal diagnostics of the option board
trigger a fault. The faults can be resettable or critical. Resettable faults
are informed to the control board of the AC drive and reported on the fault
log of the AC drive. They can be cleared by a reset signal. See 6.1.6 Reset of
a Safety Function. Critical faults of the option board cause the option board
to deactivate its outputs and communication to other systems. This means that
both the channels of the two-channel outputs are in the deactivated state. The
safe fieldbus communication is also stopped. To other systems, the situation
looks as if the option board is not turned on or the cabling is faulty. Take
this into account when designing and implementing other systems. If the fault
that causes the critical fault does not have an effect on the communication
between the option board and the control board of the AC drive, this
communication stays active. The fault data can be read from the fault log of
the AC drive. If the fault is related to the communication or otherwise
prevents the option board from communicating with the control board, the
communication stops. In this case, the fault data cannot be read from the
fault log.
NOTICE
If the option board starts after a reboot of the AC drive, it may be possible
to read the fault data in the activity log of the Advanced safety option
board. See 5.6.2 Activity Log.
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Installation
4 Installation
4.1 Installation Safety
Read these warnings before starting the installation of the option board.
WARNING
SHOCK HAZARD FROM CONTROL TERMINALS The control terminals can have a dangerous
voltage also when the drive is disconnected from mains. A contact with this
voltage can lead to injury.
– Make sure that there is no voltage in the control terminals before touching
the control terminals.
CAUTION
DAMAGE TO OPTION BOARDS Do not install, remove, or replace option boards on
the drive when the power is on. Doing this can cause damage to the boards.
– Switch off the AC drive before installing, removing, or replacing option
boards on the drive.
NOTICE
Measure or do a check of the encoder supply voltage of the encoder interface
board before connecting a new encoder. It is possible that the encoder supply
voltage was set to a higher voltage than what is supported by the new encoder.
An incorrect encoder supply voltage can damage the equipment.
4.2 Installing the Option Board
This topic gives instructions for installing the option board in VACON® NXP,
FR4FR9. Procedure
1. In FR5FR9, open the cover of the AC drive. 2. In FR4, remove the cable
cover.
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3. Open the cover of the control unit.
Installation
e30bi037.10
4. Install the option board into the slot C, D, or E on the control board of
the AC drive. Make sure that the grounding plate fits tightly in the clamp.
The board revision can affect the applicable installation slot.
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5. In IP21, cut free the opening on the cover of the AC drive for the fieldbus cable. 6. Install the cables. 7. Close the cover of the control unit and attach the cable cover.
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VACON Safe Tool
5 VACON Safe Tool
5.1 Functions of the VACON Safe Tool
Use the VACON® Safe tool to parameterize the Advanced safety option board. The
functions of the VACON® Safe tool · Parameterization of the option board ·
Validation of the parameter file · Monitoring of the state of the option board
and the safety functions · Setting the passwords for the option board
NOTICE
VACON® Safe tool cannot be used for the general control and diagnostic of the
AC drive. For those purposes, use NCDrive. The option board firmware is
updated with VACON® Loader.
5.2 The Parameter File
The configuration of the Advanced safety option board and the selected safety
functions and their parameters are stored in a parameter file. The parameter
files are created, viewed, and transferred between a PC and the option board
with the VACON® Safe tool.
A newly created parameter file on the PC is in state unverified. This means
that the Advanced safety option board has not yet verified that the file is
valid and can be taken into use. Once the option board has done the
verification, the parameter file becomes verified. The verification is done
during the parameterization process.
If the verified parameter file is not modified, it can be saved to other
Advanced safety option boards. The other option boards check the parameter
file to make sure that the content is not corrupted and that it matches the
option board configuration, for example, the encoder type.
The verification of a parameter file means that it can be taken into use, but
the option board cannot determine if the parameter values are correct for the
process where the option board is used. After the verified parameter file is
saved to the option board, test the whole safety system to make sure that all
safety subsystems operate correctly together. Test also that the safety
functions of the Advanced safety option board are correctly set for the
process. After the testing, the parameter file can be updated to indicate that
it has been tested with the rest of the system.
After testing, the parameter file is validated. Validated parameter files can
be saved to other Advanced safety option boards, like verified parameter
files, but the validation is cleared in the process. The report from
commissioning should be included in the documentation and in the process of
certifying the whole system.
5.3 User Levels and Password Management
To protect the parameters of the option board from accidental modifications,
the option board has a two-level password system. The admin and service level
passwords have different rights for modifying the parameters of the option
board.
A password is required in actions that write data on the option board. Reading
actions are not password-protected. The PC tool asks for the password when you
try to start an action that requires a password. The default passwords are
listed in the table below.
Table 28: Default Passwords User level
Default password
Admin
admin
Service
service
Actions that are available with the service level password · Validation of the parameter file · Saving the verified parameter file to the option board Actions that are available with the admin level password
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· Validation of the parameter file · Saving the verified parameter file to the
option board · Saving a new, unverified parameter file to the option board ·
Changing the admin and service level passwords Actions that are available
without a password · Reading the verified parameter file from the option board
· Online monitoring of the option board
NOTICE
If the passwords are forgotten, they can be reset from the control panel menu
of the AC drive. This operation is not passwordprotected. The controlling of
password reset must be done with other means.
5.4 Setting the Parameters
The parameterization process of the Advanced safety option board has 4 steps.
Procedure
1. To select the desired safety functions and features, go to “Select
functions” in the PC tool. A short description is visible for every available
option. For information on the safety functions, see chapter Safety Functions.
2. Go to “Adjust parameters” in the PC tool. All selected safety functions
and features must be parameterized. See chapter Parameter List for information
on the parameters.
When all safety functions and features have been parameterized, it is possible
to save the parameter file to the option board. The option board checks the
compatibility of the parameter file. Only valid parameter files are accepted.
VACON® Safe also limits the parameterization, so that invalid combinations are
not sent to the option board.
NOTICE
It is possible to save the current parameterization as a draft on the PC.
NOTICE
Saving a new parameter file to the option board requires the admin level
password.
3. Verify the transfer of parameters to the option board. Go to “Verify and
Approve”. The verifying view offers automated checks.
Accepting the parameters takes them into use in the option board. The
parameter file is verified but not validated, that is, it is not tested with
the rest of the system.
The parameter file is marked as verified by the option board. A verified
parameter file can be loaded from the op-
tion board and stored on the PC.
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4. Validate the parameter file by going to “Validate”.
VACON Safe Tool
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Operator actions
Initial parameterization
– Parameterization of
speed measurement
PC
– Parameterization of
safe fieldbus
– Parameterization of
safety functions
Advanced safety option board actions
Send parameter file to drive
Advanced safety option board
Parameter file check – Compatibility check
of parameters
Verification of parameters
– Comparison of sent and
readback values
PC
– Approval of parameters
Parameter file readback for verification
Operator approval
Upload parameter file
Advanced Parameter file verification safety – Adding verification option confirmation board – Calculation of final CRC – Parameter file taken into use
Finalisation
– Storing of the final
parameter file
PC
– Documentation of
parameterization
Commissioning & testing of the safety system
Validation of parameters
– Adding validation
information
PC
Illustration 20: The Process of Creating a New Parameter File
Send validation information
Advanced safety option board
– Parameter file with validation information stored
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5.5 Saving a Verified Parameter File to the Option Board
A verified parameter file can be saved to the option board without executing
the whole parameterization process. Saving a verified parameter file can be
done with the service level password. Modifications to a verified parameter
file invalidate the verification and the verification must be done again.
Procedure
1. Open the verified parameter file. Make sure that also the PC tool confirms
that it is verified. 2. Check the parameters in the opened file. For example:
a. Make sure that the I/O assignments match the wiring. b. Make sure that the
correct safety functions are parameterized. c. Read the parameter file
comment. 3. Press “Save” to begin the saving process. 4. Select an AC drive
and connect to it. 5. Save the parameter file and start testing the system.
5.6 Online Monitoring
5.6.1 Viewing the State of the Option Board
In the online monitoring mode, VACON® Safe reads the states and values of
various signals of the Advanced safety option board from the AC drive. These
signals can be used to monitor the status and execution of the safety features
of the AC drive. The data available for monitoring: · States of the safety
functions · States of the digital I/O · Speed values (estimated speed, the
measured speed value of the external speed sensor) · Safe fieldbus status
NOTICE
Online monitoring values are periodically read from the AC drive and the
actual values can change between the readings.
5.6.2 Activity Log
The Advanced safety option board logs the events that occur during its
operation. This log can be read from the option board and viewed on the PC
tool. Some of the data included in the log is also available when the state of
the option board is viewed. The activity log can be used when it is necessary
to analyze the behavior of the option board during a time when the PC tool was
not connected to the option board. The log can be saved to the PC for further
use. The activity log contains · A timestamp that is synchronized to the AC
drive operating time · Request signals for safety functions · Active and
Reached signals for safety functions · Acknowledgment and Reset signals and
their source · Information on the faults that occurred in the option board The
activity log logs the states of the signals when a change occurs in them. The
length of the activity log is limited. Depending on the used safety functions
and the frequency of changes in the safety functions, the log may show only a
short time. When there is a situation that requires analysis, read the log as
soon as possible to prevent new events from overwriting the critical parts.
The log is not lost when you do power-down to the AC drive.
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Safety Functions
6 Safety Functions
6.1 General Information
6.1.1 The Different Safety Functions
The safety functions of the Advanced safety option board fulfill the
corresponding requirements of the standard EN IEC 61800-5-2. The standard EN
IEC 61800-5-2 does not define the SQS safety function, but the function can be
parameterized to behave like STO(+SBC), SS1 or SS2. These functions fulfill
the requirements of the standard. The safety functions are divided into two
categories: the safe stopping functions and the safe monitoring functions. The
safe stopping functions start and monitor the stopping of the motor, the safe
monitoring functions monitor the speed, the position, or the acceleration of
the motor. The safe stopping functions
· the STO function
· the SBC function
· the SS1 function
· the SS2 function
· the SOS function
· the SQS function
The safe monitoring functions
· the SLS function
· the SMS function
· the SSR function
· the SSM function
The SQS function can be used in STO, SS1 or SS2 modes. In this manual, these
modes are referred to as SQS-STO, SQS-SS1, and SQSSS2.
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Safe monitoring functions
Safety function request
Acknowledgement
SLS SSR
Safety function request
Acknowledgement
Safe stopping functions
Limit violation
SS1
STO
SS2
SMS
Limit violation
SQS
SSM
SOS
SBC
Active, Reached
Illustration 21: The Simplified Relations Between the Safety Functions
Active, Reached
Reset
6.1.2 Safety Function States
The safety functions can be in three different states: inactive, active, and
reached. The safety functions that are not requested or have been acknowledged
after their execution are inactive. Inactive safety functions are not executed
and they do not do any monitoring. The states active and reached are shown
with signals.
An inactive safety function becomes active when it receives a request. An
active safe stopping function becomes reached when the function is completed.
An active safe monitoring function becomes reached when the monitored values
are within the monitoring limits.
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Active and reached functions can have their monitoring limits violated. When
the STO function is active in the option board, for example because of a
violation or a fault, all active safety functions stop the monitoring of their
limits. The functions stay active until they are acknowledged. The SSM
function is an exception. It continues to monitor even during standstill of
the motor and violations of other safety functions.
6.1.3 Activation of a Safety Function
Most safety functions can be activated with an external request from a safe
digital input or a safe fieldbus. Both methods can be used at the same time.
When the two methods are used, a request from one source is sufficient to
activate the safety function. When a safety function becomes active, it gives
an Active signal. Many functions can be active at the same time, but this does
not apply to all functions. Any combination of safe monitoring functions can
be active at the same time, but for the safe stopping functions there are
limitations because of their set priorities. These safety functions can be
activated with an external request from a digital input or a safe fieldbus:
STO(+SBC), SS1, SS2, SQS, SSR, SLS, SSM, and SMS. The safety functions that
cannot be activated with an external request are SBC and SOS. They are always
activated by other safety functions. The safety function STO activates SBC.
The safety functions SS2 and SQS-SS2 activate SOS. Some safety functions can
also become active without an external request. The SQS function can become
active as a violation response, the SSM function when always active, and the
STO function as a violation response of safe stopping functions. In some
special conditions, a function cannot become active even if there is a
request. These conditions include a request for a lower priority function, an
active violation or fault in the Advanced safety option board, and the active
STO safety function. When the Advanced safety option board is in the STO
state, for example, because of a STO request, it is not necessary to activate
safety functions.
NOTICE
Most safety functions do not become active or start operating if the drive is
in the STO state. If there is a request, they become active when the drive
leaves the STO state.
In this manual, the external request signal has the format “[Safety Function
Name] Request”, for example “SMS Request”.
6.1.4 Violation of a Safety Function
It is possible that violations occur in the monitoring. Causes for violations
are, for example, the speed exceeding the monitored speed limit, the speed not
following the monitored ramp, or an operation exceeding the set time limit.
There are two different violation responses:
· the STO (+SBC) function
· the SQS function
NOTICE
NO AUTOMATIC RAMP WITH SQS FUNCTION When the SQS safety function is used, the
Advanced safety option board does not execute any ramps on its own. Make sure
that the system reacts to violation situations in an acceptable way.
– Execute a ramp stop by a drive application with safety support. See 13.3 SS1
Used with STO(+SBC). – Execute a ramp stop by a drive application without
safety support by triggering a stop command externally. – Execute a ramp stop
by a process control system. See 13.4 SS1 Without a Direct Support of the
Drive Application and 13.6
SLS without a Direct Support of the Drive Application.
For safe stopping functions, the response to a violation is the STO (+SBC)
function. For safe monitoring functions excluding SSM, the response to a
violation is the SQS function. With the SSM function, there is no response to
a violation. Instead, external systems are notified of the violation by a
digital output or a fieldbus. To make a safety function recover from a
violation, use a reset signal. See 6.1.6 Reset of a Safety Function.
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6.1.5 Acknowledgment of a Safety Function
6.1.5.1 Acknowledgment of a Safety Function
The acknowledgment signal is used to deactivate a safety function that has
been set to require a manual acknowledgment after the safety function request
has ended. The acknowledgment mode can be set as automatic or manual. In the
automatic mode, the acknowledgment is tied to the deactivation of the safety
function request. In the manual mode, a separate acknowledgment signal from a
digital input, the drive control board, or a fieldbus is necessary. The
selection between automatic and manual acknowledgment is made with a parameter
and separately for each function. It is possible to use functions with
different acknowledgment settings at the same time. A function can be
acknowledged when these conditions apply: · There is no request signal. When
executed as a violation response, the SQS safety function may not be
acknowledged separately. It is acknowledged as a part of the safety function
reset. See 6.1.6 Reset of a Safety Function. If a function is set to have
automatic acknowledgment, the function is deactivated when its request is
deactivated.
NOTICE
A higher priority safe stopping function can interrupt a lower priority safe
stopping function before it is reached.
The manual acknowledgment signal has three allowed sources: · A safe digital
input · A safe fieldbus · A not safe control board of the AC drive The sources
of the acknowledgment signal are equal. A manual acknowledgment signal from
any of them is permitted to stop a safety function. The acknowledgment signal
from the control board of the drive is sent when a fault reset command (drive
input, fieldbus, drive application, or drive control panel) is sent to the
drive. You can disable the acknowledgment signal from the control board during
parameterization.
NOTICE
When a safety function is requested by both a digital input and a fieldbus,
both of them must deactivate the request before the function can be
acknowledged. When the last request is deactivated, the automatic
acknowledgment signal becomes active, and the manual acknowledgment signal
becomes acceptable.
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Logical level
SS2 Request
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Safety Functions t
SS2 Active
t
SOS Reached
t
SS2 Reached
t
Acknowledgement A
t B
Illustration 22: The Deactivation of the SS2 Request Before the Function is Reached. Acknowledgment: Manual.
A
The manual acknowledgment is rejected because the safe stopping function is requested
B
After the safety functions are not requested, the manual acknowledgment is accepted.
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SS2 Request
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Safety Functions t
SS2 Active
t
SOS Reached
t
SS2 Reached
t
Acknowledgement
t
A
Illustration 23: The Deactivation of the SS2 Request Before the Function is Reached. Acknowledgment: Automatic.
A
The automatic acknowledgment occurs when the SS2 request ends.
When there are safety functions that can be acknowledged by manual acknowledgment and safety functions that cannot (if, for example, they are requested), a manual acknowledgment signal deactivates the functions that can be acknowledged. Functions that could not be acknowledged continue their execution normally.
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SSR Request
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Safety Functions t
SSR Active
t
SSR Reached
t
SLS Request
t
SLS Active
t
SLS Reached
t
Acknowledgement
t
Illustration 24: Acknowledging a safety function separately. The SLS function is acknowledged. The SSR function is not acknowledged because it stays requested. SLS: manual acknowledgment, SSR: manual acknowledgment.
NOTICE
After safe stopping functions are acknowledged and the STO function is
deactivated, the drive can start if it has an active run request.
The acknowledgment signal can also be used to control accidental starts of the
drive. If the deactivation of the request of a safe stopping function should
not be able to allow the drive to start, use the manual acknowledgment. The
drive can then start only after a separate acknowledgment signal.
If a safe stopping function is used as an emergency stop according to the
standard IEC-60204-1, the acknowledgment signal can be used as the reset
signal required by the standard. The reset signal of the Advanced safety
option board does not correspond to the emergency stop reset signal described
in the standard.
In digital inputs, the acknowledgment signal is edge sensitive. The
acknowledgment is done with inactive -> active transition (logical level). In
safe fieldbuses, the acknowledgment signal is also edge sensitive, and it is
done with a 0 -> 1 transition of the related telegram bit.
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NOTICE
Acknowledgment and Reset can be assigned to the same digital input of the
Advanced safety option board. Consider the behavior of the safety functions
and the safety system carefully, if you decide to do that.
6.1.5.2 Start-up Acknowledgment
In addition to acknowledging safety functions, the acknowledgment signal can
also be used to permit the Advanced safety option board to release STO(+SBC)
after start-up. This acknowledgment signal can be automatic or manual. If
automatic acknowledgment is used, STO(+SBC) is released after the Advanced
safety option board has done the start-up and established communication to the
drive control board and over safe fieldbus (when used). If manual start-up
acknowledgment is used, the STO(+SBC) is kept active until the acknowledgment
signal is received.
6.1.6 Reset of a Safety Function
Violations of safety functions or faults of the Advanced safety option board
cause the STO(+SBC) function to be activated. Use a reset signal to deactivate
the STO(+SBC) function, reset faults and return the system to normal
operation. For the Advanced safety option board, the reset signal is always an
explicit signal from another system.
NOTICE
If the SQS-SS2 function is used, a violation of a safe monitoring function can
activate the SOS function. You can reset the SOS function in the same way as
the STO function.
The reset signal has three allowed sources: · A safe digital input · A safe
fieldbus · A not safe control board of the AC drive The sources of the reset
signal are equal. A reset signal from any of them is permitted to reset
violations of safety functions and faults in the Advanced safety option board.
The reset signal from the control board of the drive is sent when a fault
reset command (drive input, fieldbus, drive application, or drive control
panel) is sent to the drive. If a safe reset signal is required, disable the
reset signal from the control board of the AC drive in parameterization.
Different conditions apply for resetting the violations of safety functions
and the faults of the Advanced safety option board. To reset violations of
safety functions or faults of the Advanced safety option board, these
conditions apply: · STO(+SBC) or SOS is active (SOS in case of SQS-SS2) · The
speed is below the monitoring limit of all requested safety functions In
digital inputs, the reset signal is edge sensitive. The reset is done with
inactive -> active transition (logical level). A reset over a safe fieldbus
depends on the selected fieldbus. See 7.1.1 Introduction to PROFIsafe for
information on the differences of the fieldbuses.
NOTICE
After a violation or a fault, the reset signal behaves as an implicit
acknowledgment signal for safety functions for which acknowledgment conditions
apply when a reset signal is sent.
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Logical level SSR Request
SSR Active SSR Reached
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Safety Functions
t t t
SLS Request
t
SLS Active
t
SLS Reached
t
SQS Active
t
SQS Reached
t
Reset A
t B
Illustration 25: Resetting a Safety Function Separately. SLS: Manual Acknowledgment.
A
A violation in the SLS function.
B
A reset signal resets the violation. The operation of the SSR and SLS functions continues.
NOTICE
Acknowledgment and Reset can be assigned to the same digital input of the
Advanced safety option board. Consider the behavior of the safety functions
and the safety system carefully, if you decide to do that.
NOTICE
Some faults of the Advanced safety option board can only be reset with a
reboot of the drive. See chapter Fault Tracing for more information.
There can be a delay between the reset signal and the removal of faults and
warnings from the AC drive.
6.1.7 Ramps
The safety functions SS1, SS2, SQS, SSR, and SLS can monitor the ramping of
the motor speed. The ramps are optional, and all safety functions that provide
ramp monitoring can be parameterized to not monitor them.
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The monitored ramps are defined with two shared ramp definitions that the
other safety functions than the SQS function can use to calculate the actual
ramps. The SQS function has its own ramp values. The ramp definition has a
maximum and a minimum time that is permitted for the ramping.
NOTICE
When a safety function uses a ramp, the related ramp must be defined. It is
not necessary to parameterize both minimum and maximum ramps if they are not
necessary for the application.
Deceleration ramps are defined by a nominal speed value and two time values that represent the maximum and minimum time that the ramping from the nominal speed is permitted to take. The actual monitored ramps are calculated when ramp monitoring starts. The ramps are defined as slopes between the request moment and the parameterized times (SS1 used as an example).
SS1_Dec_Max
s
=
Speed
rpm × Rampx_Dec_Time_max Rampx_speed rpm
s
SS1_Dec_Min
s
=
Speed
rpm
× (Rampx_Dec_Time_min Rampx_speed rpm
s
– SS1_td1
s)
where Speed[rpm] is the speed at the time of the calculation. SS1_Dec_Max and SS1_Dec_Min are the time from ramp start (points A and B) to where speed should be zero (points C and D). Rampx_speed is the nominal speed for the used ramp set. See the figure below. At any given point during the ramp monitoring, the actual value of monitoring is calculated from the slope connecting the respective points. The area outside the permitted speed range during ramp monitoring is shaded.
NOTICE
Use of ramp monitoring is not recommended when only proximity sensors are used
as speed sensor.
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Speed Rampx Speed
Rampx Dec Time Max Rampx Dec Time Min
Speed
AB
Zero Speed
C
D
t
SS1 td1
SS1 Dec Min
SS1 Dec Max
Nominal deceleration ramp Scaled deceleration ramp
Illustration 26: Deceleration Ramp, the SS1 Function as an Example
A
Start of the minimum deceleration ramp
B
Start of the maximum deceleration ramp
C
End of the minimum deceleration ramp
D
End of the maximum deceleration ramp
Ramp monitoring does not continue in the safe speed range of the safe monitoring function. For example, for the SLS function, the maximum ramp value is limited to the selected SLS limit. This can be noted, for example, with long SLS td2 delays. The minimum ramp monitoring stops when the monitoring value would be below the selected SLS limit.
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The acceleration ramps are valid only for the SSR function. The acceleration ramps are defined in the same way as deceleration ramps. A nominal speed value (shared with the deceleration ramp) and two time values that represent the maximum and minimum time that the ramping is permitted to take. The actual monitored ramps are calculated when ramp monitoring starts.
SSR_Acc_max
s
=
(SSR_Min_Limit
rpm – Speed rpm ) × Ramp_Acc_Time_Min Rampx_speed rpm
s
SSR_Acc_min
s
=
(SSR_Min_Limit
rpm
– Speed rpm ) × (Ramp_Acc_Time_Min Rampx_speed rpm
s
– SSR_td1
s
where Speed is the speed at the time of the calculation. SSR_Acc_Max and SSR_Acc_Min are the time from ramp start (A and B) where speed should be at the monitored minimum limit speed (C and D). Rampx_speed is the nominal speed for the ramp set. At any given point during the ramp monitoring the actual value of monitoring is calculated from the slope connecting the respective points.
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Speed Rampx Speed
Rampx Acc Time Min Rampx Acc Time Max
SSR Max Limit
SSR Min Limit
C D
A
Speed
t
SSR td1
B
SSR Acc Min
SSR Acc Max
Illustration 27: Acceleration Ramps, the SSR Function as an Example
Nominal Acceleration Ramp Scaled Acceleration Ramp
A
Start of the minimum acceleration ramp
B
Start of the maximum acceleration ramp
C
End of the minimum deceleration ramp
D
End of the maximum deceleration ramp
NOTICE
The response to a ramp violation is the STO(+SBC) function for safe stopping
functions, and the SQS function for safe monitoring functions.
6.2 Safe Stopping Functions
6.2.1 Introduction to the Safe Stopping Functions
The safe stopping functions are used to start and monitor the stopping of the
motor. The safe stopping functions do not take into account the rotation
direction of the motor when they are in the optional zero speed or th
References
- Global AC drive manufacturer - Danfoss Drives | Danfoss
- Global AC drive manufacturer - Danfoss Drives | Danfoss
- Global AC drive manufacturer - Danfoss Drives | Danfoss
- Search | Danfoss
- Engineering Tomorrow | Danfoss
- Service and support - need help? | Danfoss
- Service and support - need help? | Danfoss
- Fieldbus configuration files | Danfoss
- Option board and fieldbus firmware | Danfoss
- MyDrive® Suite
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