Danfoss MCB 152 User manual

Installation Guide

VLT®Safety Option MCB 152

VLT® AutomationDrive FC 302 and VLT® Decen-

tral Drive FCD 302

Contents

1 Introduction 6

1.1 Purpose of this Installation Guide 6

1.2 Trademarks 6

1.3 Additional Resources 6

1.4 Document Version 6

1.5 Product Overview 6

1.5.1 Intended Use 6

1.5.2 Unit Features 7

1.5.3 Items Supplied 8

1.5.4 Compatible Drive Series 8

1.5.5 Front View 8

1.5.6 Hardware and Software Requirements 8

1.6 Compliance and Certifications 9

1.7 Disposal 9

2 Safety 10

2.1 Safety Symbols 10

2.2 Qualified Personnel 10

2.3 Responsibilities of Users of PDS(SR) 10

2.4 Protective Measures 11

2.5 Safety Precautions 11

2.6 Risk Assessment 13

2.6.1 Validation of Performance Level 13

3 Functions 14

3.1 Safety Functions 14

3.2 Safe Torque Off - STO 14

3.3 Specification of Safety functions 16

3.4 Activation of Safety functions 16

3.5 Activation of STO from Multiple Sources 16

3.6 Functional Proof Tests 16

3.7 PFD and PFH Definitions 16

3.8 Internal Faults 16

3.9 Inputs and Outputs 17

3.9.1 Allowed Sensor Types on Digital Inputs 17

3.9.2 Inputs 17

3.9.3 Safe Option Monitoring (SO Mon) 17

3.9.4 Output 17

3.9.5 Signal Filtering 17

3.9.6 Stable Signal Time from Safe Outputs 18

ContentsInstallation Guide | VLT®Safety Option MCB 152

4 Installation 20

4.1 Safety Instructions 20

4.2 Installation Overview 20

4.3 Installing the Option 21

4.4 Electrical Installation 22

4.4.1 Cabling Requirements 22

4.4.2 Connector Pin Assignment 23

4.4.3 Wiring Procedures 24

4.4.4 Installation Checklist 26

5 Commissioning 27

5.1 Before Commissioning 27

5.2 Commissioning Procedure 27

5.3 Power-up/Self-test 28

5.4 Commissioning in Online Mode 28

5.5 Commissioning Test 32

5.5.1 Performing the Commissioning Test 32

5.6 Operation 33

5.7 Commissioning Setup Examples 34

6 Configuring the Safety Option 35

6.1 PROFIsafe Configuration 35

6.1.1 Telegram Configuration 35

6.1.2 Safety Functions Configuration 36

6.1.3 Password Protection 36

6.2 Status over Fieldbus 37

6.2.1 Safety Option Reset via Control Word 37

6.2.2 Safety Option Status 38

6.3 Reset Function 41

6.3.1 Reset Input (DI2) 41

6.4 Configuring PROFIsafe with Siemens Step 7 42

6.4.1 Configuring the Hardware 42

6.4.1.1 Watchdog Time 45

6.5 Configuring PROFIsafe with Siemens TIA Portal 45

6.5.1 Configuring the Hardware 45

6.5.2 Programming Safety Functions with Siemens Step 7 and TIA Portal 47

7 Parameter Setup 48

7.1 About Safety Parameters 48

7.2 Parameter Lists 48

7.2.1 Parameter Group 42-2* Safe Input 48

7.2.2 Parameter Group 42-3* General 49

ContentsInstallation Guide | VLT®Safety Option MCB 152

7.2.3 Parameter Group 42-6* Safe Fieldbus 50

7.2.4 Parameter Group 42-8* Status 51

7.2.5 Parameter Group 42-9* Special 52

7.2.6 Parameter Group 600-** PROFIsafe 52

7.2.7 Parameter Group 0-6* Password 53

8 Application Examples 54

8.1 Connecting Safe Digital Inputs 54

9 Maintenance, Diagnostics, and Troubleshooting 57

9.1 Maintenance and Service 57

9.1.1 Yearly Test 57

9.2 Repair and Troubleshooting 58

9.2.1 Removing the Safety Option (FC 302 only) 58

9.2.2 Replacing the Safety Option (FC 302 only) 59

9.2.3 Mismatch of Safety Option Parameters (FC 302 only) 60

9.2.3.1 Transferring Parameter 60

9.2.4 Copying Safe Parameter Configuration 60

9.3 Error Conditions 61

9.3.1 Error Descriptions 61

9.4 LCP Messages 68

9.4.1 LCP Status Messages 69

10 Specifications 72

10.1 Consumption 72

10.2 Inputs 72

10.2.1 Digital Inputs 72

10.3 Output 72

10.3.1 Digital Output (Safe Output) 72

10.3.2 24 V Supply Output 72

10.4 Other Specifications 73

10.4.1 Connector Cable Dimensions 73

10.4.2 Reset Characteristics 73

10.4.3 Response Time 73

10.4.4 Safety Characteristic Data 73

11 Appendix 76

11.1 Abbreviations 76

11.2 Conventions 77

ContentsInstallation Guide | VLT®Safety Option MCB 152

1 Introduction

1.1 Purpose of this Installation Guide

This manual provides information for safe installation and commissioning of a VLT® Safety Option MCB 152 for PROFIsafe

communication

The Installation Guide is intended for use by qualified personnel only. Personnel must be familiar with the VLT® drive series.

Read and follow this Installation Guide before installation, and ensure that instructions for safe installation are observed. Always keep

these instructions available with the drive.

1.2 Trademarks

VLT® is a registered trademark for Danfoss A/S.

1.3 Additional Resources

More information resources are available to understand advanced drive functions and programming.

• The VLT® AutomationDrive FC 301/FC 302 and the VLT® Decentral Drive FCD 302 Operating Guides provide information required to

install and commission the drive for given applications.

• The VLT® PROFINET MCA 120 Installation Guide provides instructions on how to install the PROFINET option.

• VLT® Motion Control Tool MCT 10 Operating Guide describes how to configure the safety option via the MCT 10 Set-up Software.

• VLT® Frequency Converters Safe Torque Off Operating Guide describes the use of VLT® FC Series drives in functional safety

applications.

Technical documentation for other product options is available at www.danfoss.com.

1.4 Document Version

This Installation Guide is regularly reviewed and updated. All suggestions for improvement are welcome.

The original language of this manual is English.

Table 1: Document Version

Revision Remarks

AN327351953089, version 0101 Now also available for VLT® Decentral Drive FCD 302.

Changed from Operating Guide to Installation Guide.

1.5 Product Overview

1.5.1 Intended Use

VLT® Safety Option MCB 152 is designed to activate and deactivate safety functions of a drive through the PROFIsafe fieldbus. Using

the fieldbus, requires the VLT® PROFINET MCA 120 option to be installed. The safety functions of the safety option are implemented

according to EN IEC 61800-5-2.

Introduction

Installation Guide | VLT®Safety Option MCB 152

AN327351953089en-000101 / 130R0578

The safety option:

• Activates safety functions on request.

• Sends status information to the safety control system via a connected PROFINET fieldbus.

• Activates the safe state when the option detects faults.

The safety control system:

• Activates safety functions via input on the safety option and/or via the safe fieldbus.

• Evaluates signals from safety devices, such as:

- E-STOP push buttons

- Non-contact magnetic switch

- Interlocking switch

- Light curtain devices

The safety devices are connected to digital inputs of the safety option or digital input of the PLC.

• Provides safe connection between the safety option and a safety control system.

• Provides fault detection on the signal between a safety control system and the safety option at activation of safety functions (short

across contacts, short circuit).

MCA 120

PROFINET

MCB 152

Safety Option

μ C

IGBT

STO

Safe PLC

Control card

Internal bus 1

Option A

Option B

Internal bus 2

e30bd977.11

Illustration 1: FC 302 with VLT® Safety Option MCB 152 and Fieldbus Option

1.5.2 Unit Features

The safety option has the following features:

Introduction

Installation Guide | VLT®Safety Option MCB 152

AN327351953089en-000101 / 130R0578| 7

• Safety functions: Safe Torque Off (STO) in accordance with EN IEC 61800-5-2

• PROFIsafe version 2.4 communication

• Two dual-channel digital inputs:

- Safety function activation

- Monitoring

- Configurable reset behavior (automatic or manual reset).

• LED status indication

• Supply voltage

- Internally supplied by the drive

- 24 V DC output for safety sensors available.

• Safe output S37

1.5.3 Items Supplied

• VLT® Safety Option MCB 152

• VLT® Safety Option MCB 152 Installation Guide

1.5.4 Compatible Drive Series

The VLT® Safety Option MCB 152 is a standard B option compatible with:

• VLT® AutomationDrive FC 302

• VLT® Decentral Drive FCD 302

1.5.5 Front View

MCB 152

Safe Option

PROFIsafe

SW. ver. xx.xx

Option B

130B9860

LED:

1 2 3 4 5 6 7 8 9 10 11 12

2 3 4

Y33/

DI1 A

GND

DI1 B

24 V

S 37

DI2 A

DI2 B

e30be100.11

Illustration 2: VLT® Safety Option MCB 152 Front View

1.5.6 Hardware and Software Requirements

The following software versions are required as a minimum when using VLT® Safety Option MCB 152:

• LCP software version 7.0

• VLT® AutomationDrive FC 302 firmware version 7.26

• VLT® Decentral Drive FCD 302 firmware version 8.23

• PROFINET software version 3.0

• VLT® Motion Control Tool MCT 10 software version 3.23. A license key is required to use the full set of features.

Introduction

Installation Guide | VLT®Safety Option MCB 152

AN327351953089en-000101 / 130R0578

1.6 Compliance and Certifications

The VLT® Safety Option MCB 152 is certified for use in safety applications up to and including:

• SIL 2 according to EN IEC 61508 and EN IEC 62061

• Performance Level PL d.

• Category 3 according to EN ISO 13849-1

Safety requirements are based on the standards valid at the time of certification. The VLT® Safety Option MCB 152 is approved for use

in safety-related applications where the de-energized state is considered to be the safe state. All examples related to I/O included in

this manual are based on achieving de-energization as the safe state.

Approvals

The MCB 152 is tested and certified by PNO.

1.7 Disposal

Do not dispose of equipment containing electrical components together with domestic waste.

Collect it separately in accordance with local and currently valid legislation.

Introduction

Installation Guide | VLT®Safety Option MCB 152

AN327351953089en-000101 / 130R0578| 9

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 Qualified Personnel

The products must only be assembled, installed, programmed, commissioned, maintained, and decommissioned by persons with

proven skills. Persons with proven skills:

• Are qualified electrical engineers, or persons who have received training from qualified electrical engineers and are suitably

experienced to operate devices, systems, plant, and machinery in accordance with the general standards and guidelines for safety

technology.

• Are familiar with the basic regulations concerning health and safety/accident prevention.

• Have read and understood the safety guidelines given in this manual and also the instructions given in the operating guide of the

drive.

• Have good knowledge of the generic and specialist standards applicable to the specific application.

2.3 Responsibilities of Users of PDS(SR)

Context:

In EN ISO 12100, risk assessment is defined as an overall process comprising a risk analysis and a risk evaluation.

Procedure

1. Carry out a hazard and risk analysis of the application according to EN ISO 12100.

2. Identify safety functions required and allocate SIL or PLr to each of the functions.

3. Identify other subsystems and validate the signals and commands from those subsystems.

4. Design appropriate safety-related control systems (hardware, software, parameterization, and more).

Safety

Installation Guide | VLT®Safety Option MCB 152

AN327351953089en-000101 / 130R0578

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