User Guide for Danfoss models including: 131B0799, AB361177609013, FC-302 Frequency Converter, FC-302, Frequency Converter, Converter

Encoder-less Safety using DOLD Module

Functional Safety Application Guide

Danfoss 131B0799 FC-302 Frequency Converter – Hasuka Automation


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AB361177609013en-000101 ?v=1738587738
ENGINEERING TOMORROW
Functional Safety Application Guide
Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor VACON® and VLT® FC-series
vlt-drives.danfoss.com

Contents

Functional Safety Application Guide

Contents

1 Introduction

2

1.1 Purpose

2

1.2 Scope

2

1.3 Abbreviations

2

2 Safety Functions SLS and SSR

3

3 SLS and SSR Implementation

4

3.1 Circuit Diagram

5

3.2 Safety Function Operation and Timing

11

3.2.1 Initial Conditions

11

3.2.2 Fault Handling

11

3.2.3 SLS Operation

11

3.2.4 SSR operation

11

3.3 Parameters and Configuration

13

4 Ordering Data for DOLD Components

16

4.1 Frequency Monitor

16

5 Functional Safety-related Data

17

5.1 SIL Calculation

17

Index

18

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Introduction
1 1 1 Introduction

Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

1.1 Purpose
This manual describes how to implement the safety functions Safely Limited Speed (SLS) or Safe Speed Range (SSR) using DOLD UH 6937 frequency monitor without encoder.

The DOLD module can be used with the following products:
· VLT® HVAC Drive FC 102 · VLT® Refrigeration Drive FC 103 · VLT® AQUA Drive FC 202 · VLT® Midi Drive FC 280 · VLT® AutomationDrive FC 301 · VLT® AutomationDrive FC 302 · VACON® 100 Industrial · VACON® 100 Flow · VACON® NXP Liquid Cooled · VACON® NXP System Drive · VACON® NXP Air Cooled · VACON® NXP Common DC Bus · VACON® NXP Liquid Cooled Enclosed Drive · VACON® NXP Liquid Cooled Common DC Bus
1.2 Scope

This manual is intended for application designers, for realizing safe speed functions of frequency converters without encoder feedback, using an external frequency monitor.
1.3 Abbreviations

PL

Performance Level

SIL

Safety Integrity Level

SLS

Safely Limited Speed

SSR

Safe Speed Range

STO

Safe Torque Off

Table 1.1 List of Abbreviations

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2 Safety Functions SLS and SSR
The Safely Limited Speed (SLS) function monitors the speed to a set limit value without any encoder feedback, see Illustration 2.1. The frequency of the motor is measured and compared to the limit value. If the measured value is more than the set value, then the safety output relay is deactivated to trigger the STO function.
Speed

130BF781.10

SLS limit

Time

Illustration 2.1 SLS Function

The Safe Speed Range (SSR) function monitors the speed within a given range or outside a given range. See Illustration 2.2.

Speed

SSR upper limit SSR lower limit

130BF782.10

Monitoring within the given range: If the frequency is within the given speed range, the STO signal is not active. If the measured frequency is outside the given speed range, the relay output triggers the STO function of the frequency converter.
Monitoring outside the given range: If the frequency is outside the defined speed range, the STO signal is not active. If the measured frequency lies inside the limits, the relay output triggers the STO function of the frequency converter.
In the standard module variant 0, 1 of the following monitoring functions is selected:
· Over frequency · Under frequency · Inside range · Outside range
The variant 1 module has extra selection inputs for selecting 4 frequency modes during the operation.
NOTICE
If the frequency converter does not have an integrated STO function, the relay outputs can be used to activate the motor contactors to cut off the power to the motor.

22

Time
Illustration 2.2 SSR Function

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Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

3 SLS and SSR Implementation

33

The SLS safety function implementation is based on the STO function and the following safety-related components:
· Frequency monitor (3rd party DOLD UH 6937)
The UH 6937 frequency module does not have safe inputs to activate and deactivate the safety functions. In variant 0, the module always monitors the frequency. The monitoring can only be muted by selecting the parameter in the display. In variant 1, there are 4 digital safe inputs available to select different frequency modes, and 1 of the combinations is the muting function.
· Noise suppression filter for measuring relays (3rd
party DOLD LG 5130), optional These filters are only required if there is measurement errors after complete installation.
· Third-party functional safety system or fail-safe
PLC ( SIL2), optional A fail-safe PLC is required to implement the safety logic based on the status of the relay outputs of a frequency module. One of the use cases is, that the relay output status is ignored as long as the safety door is locked for SLS speed. Once the door is opened, the safety relay output is used to activate the STO of the frequency converter for speed limit violations.
The circuit example in chapter 3.1 Circuit Diagram shows the DOLD UH 6937 used with a Danfoss frequency converter FC-series or VACON® series.
The auxiliary voltage 24 V is connected to terminals A1­A2. Any 24 V PELV or SELV supply can be used. If no additional devices are supplied via terminal 12 or 13 (+24 V), A1 can be connected to terminal 12 or 13. A2 can be connected to terminal 20 (0 V).
Terminals E1a, E1b, E2L, E2H, E3L, and E3H form the measuring input. For low voltages (AC 8­280 V), the measuring voltage is connected to E1a­E2L and E1b­E3L. For higher voltages (AC 16­600 V), the measuring voltage is connected to E1a­E2H and E1b­E3H.
When monitoring single-phase AC voltage, the terminals E1a­E2L or E1a­E2H should be connected directly to the frequency converter. The terminals E1b­E3L or E1b­E3H should be connected directly to the motor connection terminals.

NOTICE
Separate wires in separate cables with spacing in between have to be used for each of the frequency inputs. When monitoring 3-phase AC voltages, these terminals have to be wired directly to the motor connection terminals.
WARNING
RISK OF DEATH AND SERIOUS INJURY
If external forces act on the motor, for example in case of vertical axis (suspended loads) the motor must be equipped with extra measures for fall protection. For example, install extra mechanical brakes.
The noise filter (LG 5130) has 4 inductances connected in series in each path for the 3 phases (input L1/L2/L3). This provides broad band filtering up to high frequencies. If the PE is connected, a Y-capacitor connected to PE is activated and provides increased filtering (T-filter).
The noise filter is connected via its input terminals L1/L2/L3 to the frequency converter output and the frequency monitor device to the filter outputs L1'/L2'/L3'.
By connecting the noise filter between the frequency converter and the measuring frequency monitor device, the current flowing via the coupling capacitances is reduced. The reduction happens because the filter elements create a rising impedance with a rising frequency. This prevents disturbance or damage on the connected device. Protection as shown in Illustration 3.5.
It is not mandatory to connect the PE to the frequency monitor device terminals, but it increases the filter effect.
Chapter 3.2 Safety Function Operation and Timing includes the SLS operation and timing.

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3.1 Circuit Diagram
Illustration 3.1 shows the UH 6937 Circuit diagram. The relay contacts 13­14 and 23­24 can be used as STO input to the frequency converter.

+FIELD PE/GND

L1 L2 L3

24 V DC 0 V DC

PE/GND PE/GND

135 -FC1
_F
246

Remove the jumper wire between control terminals 12, 37, 38 in the frequency converter.

-TA1 VLT FC 280
Frequency
converter

99(PE) 96(U) 97(V) 98(W)

95(PE) 91(L1) 92(L2) 93(L3)

Ensure that the STO cables are shielded if they are longer than 20 m (65.6 ft) or outside the cabinet.

12 37 38 55
U
V U
W

1 -FC31
2

13 -SF8 E RESET 14

-U2 E1a 13 14 23 24

A1+ A2

E2L

E2H

UH6937

E1b

E3L E3H GND

RES T1 T2 RF 38 48

PE/GND

+FIELD

PE/GND

-WD1
SH
-MA1

BN BK GY
U1 V1 W1 M 3~ PE/GND

NSGAFÖU 1.8/3 kV BK min. 2.5 mm2 (14 AWG)

Illustration 3.1 FC 280 and UH 6937 Wiring Diagram

130BF784.10

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Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

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+FIELD PE/GND

L1 L2 L3

-FC1

135

24 V DC 0 V DC

24 6

-TA1 NX Series Frequency Converter

L1 L2 L3

PE/GND

PE/GND U V W
U V
U W

NSGAFÖU 1.8/3 kV BK min. 2.5 mm2 (14 AWG)

1

1

1

-FC33

-FC32 -FC31

2

2

2

13

-SF8 RESET

14

-U2

E1a

13

E2L

E2H

E1b

E3L

E3H GND

14

23 A1+ A2

RES T1 T2 RF

UH6937 24

38 48

+FIELD

-WD1 SH
-MA1
PE/GND

BN BK GY
U1 V1 W1 M 3~ PE/GND

PE/GND
SH PE/GND

-WGB1

12 34

1

2

34

SD1+ SD1- SD2+ SD2-

-AG2 OPTAF IFS+2XRO+PTC SLOT B

21 22 23 RO1 NC RO1 C RO1 NO

25 26 RO2 C RO2 NO

28 29 TI1+ TI1-

ON X10

UNCUT X12

Thermistor short circuit supervision

Illustration 3.2 NX Drive, OPT-AF, and UH 6937 Wiring Diagram

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Functional Safety Application Guide

+FIELD PE/GND

L1 L2 L3

135 -FC1
246

PE/GND

-TA1 VLT FC 302 frequency converter

95(PE) 91(L1) 92(L2) 93(L3)

12 or 13 37

99(PE) 96(U) 97(V) 98(W)

PE/GND

U
V U
W

+FIELD

-WD1
SH

BN BK GY

U1 V1 W1
-MA1 3M~ PE/GND

PE/GND

24 V DC 0 V DC

Remove the jumper wire between control terminals 37 and 12 or 13 in the frequency converter.
Use short-circuit protected cable (if not inside an IP54 installation cabinet)

1
-FC 31 2

13 -SF8 RESET 14

-U2 E1a

13 14

23

24

A1+ A2

E2L

E2H

UH6937

E1b

E3L E3H GND

RES T1

T2

RF

38

48

PE/GND

NSGAFÖU 1.8/3 kV BK min. 2.5 mm² (14 AWG)

Illustration 3.3 FC 302 and UH 6937 Wiring Diagram

130BF790 .10

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+FIELD PE/GND

L1 L2 L3

-FC1

135

24 V DC 0 V DC

24 6

-TA1 VACON 100 frequency converter

L1 L2 L3

PE/GND

PE/GND U V W
U
V U

NSGAFÖU 1.8/3 kV BK min. 2.5mm2 (14 AWG)

1

1

1

-FC33

-FC32 -FC31

2

2

2

13

-SF8 RESET

14

-U2

E1a

13

E2L

E2H

E1b

E3L

E3H GND

14

23 A1+ A2

RES T1 T2 RF

UH6937 24

38 48

+FIELD

-WD1 SH
-MA1
PE/GND

BN BK GY
U1 V1 W1
M 3~
PE/GND

PE/GND
SH PE/GND

-WGB1

12 34

-AB1 SLOT C, D, E OPT-BJ

1

2

3

4

STO1+ STO1- STO2+ STO2-

25

26

CO

NO

RO1 Contact

28

29

TI1+ TI1-

TI1 Thermistor Input

Supervision ON (default) Supervision OFF

STO board not activated X23 STO board activated (default)

X10

Short circuit supervision

STO board activation

Illustration 3.4 VACON® 100, OPT-BJ, and UH 6937 Wiring Diagram

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Illustration 3.5 shows the LG 5130 Circuit Diagram with noise filtering between the 3 phases of the frequency converter and the frequency monitor UH 6937.

130BF783.10

PE

L1 L2 L3

Motor Protection

33

FU

L1

L1'

LG5130

L2

L2'

L1

L1'

LG5130

L3

L3'

M 3~

Illustration 3.5 LG 5130 Circuit Diagram

E1a E2H
UH6937 E1b E3H

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A1 + A2 GND

E2H E2L E2a E3H E3L E1b

A1 + A2 GND

E2H E2L E2a E3H E3L E1b

13 23 K1 K2
14 24

13 23 K1 K2
14 24

T1 RES T2 RF

13 14 23 24

GND 38 48

M10823_d

T1 RES T2 RF A1 A 13 14 23 24 + GND 38 48 SW1 SW2 SW3 SW4
M10823_d

UH6937

UH6937/__1

Terminal designation A1+ A2 E1a, E1b, E2L, E2H, E3L, E3H GND 13, 14, 23, 24 38, 48 T1, T2 RES, RF, SW1, SW2, SW3, SW4 A+, A GND

Signal designation 24 V DC 0 V Frequency measuring inputs Reference potential for semiconductor monitoring output and control outputs Forcibly guided NO contacts for release circuit Semiconductor-monitoring output Control output Control input Analog output

Illustration 3.6 Terminals Description

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Functional Safety Application Guide

3.2 Safety Function Operation and Timing
The safe speed monitoring has to be configured for the speed limits in the frequency converters applications. The customer is responsible for defining the speed limits on the risk assessment. The commissioning test report is made available for the final assessment and for future references.
3.2.1 Initial Conditions
If the safe speed limit monitor is configured without the start-up delay and the RF feedback circuit is closed, it is active immediately after the power-on.
3.2.2 Fault Handling
When faults are detected on or in the device, they are indicated with a message in the display. If the fault requires a reset of the device, the alarm and the associated diagnostic message has to be acknowledged first. Press the left key for approximately 3 s to initiate a reset of the device.
NOTICE
If a system failure is detected again after restart, the device must be replaced and sent back to the manufacturer.
3.2.3 SLS Operation
Typically, the SLS safety function is used for safe speed monitoring according to a defined speed limit. In this case, the SLS function defines the speed limit where it is considered safe for personal interaction with the machine. As long as the frequency of the frequency converter is within the defined limit, the STO function is not active. When the output frequency goes beyond the limit value, STO is immediately activated so the motor coasts and comes to a standstill. This coasting time must be considered before allowing the access to the dangerous zone.
The safe output on the frequency monitor UH 6937 is active and the output relays remain closed, as long as the actual speed is lower than the safe speed limit parameter (SLS limit).
If the actual speed exceeds the safe speed limit parameter (SLS limit), speed output relays are opened, and the safe output signal is removed.
If an internal fault occurs, the SLS safety function can be configured for automatic reset. If the function is configured for a manual reset, the RESET input should be provided for normal operation after removing the limit violations.

The module UH 6937 always monitors the configured frequency limits. The frequency module does not have its own safe inputs, therefore a third-party functional safety system, for example a fail-safe PLC system, is used. It activates the safe function when a safe function is demanded. This means that more safety logic can be prepared based on the status of the frequency module relays in the PLC. For example, the PLC logic controls the access to the dangerous zone via its output signal (door control). The SLS output (relays) is connected to the failsafe PLC's safety input. The access is allowed as long as the frequency is below the SLS limit. If the speed limit is exceeded, the STO of the frequency converter is immediately activated via the fail-safe PLC output to bring the system to a safe state.
The input frequency is compared to the setting value. As the device measures the cycle duration, the fastest frequency measurement is possible. Should the overfrequency function be set, the output relay switches to the alarm mode when the set response parameter value exceeds the defined value in the alarm-delay function (tV). Should the frequency decrease to a value below the response parameter, minus the set hysteresis, the output relay is activated after the expiry of the reset delay time period(tF). It then returns to its preset allowed supervisory state. The underfrequency function means that the output relay switches to the alarm mode when the set response parameter value drops below the set alarm-delay function(tV) time period. When the frequency returns to the range governed by the response parameter, plus the set hysteresis, the output relay returns to the preset allowed state after the expiry of the reset-delay time period(tF).
3.2.4 SSR operation
The SSR function is used for speed monitoring within or outside of a defined speed range.
In the internal window function mode, the output relay switches to the alarm setting when the frequency exceeds the preset allowed range of both the upper and lower response parameters, minus and/or plus the preset hysteresis values (upper response parameter minus and/or the lower response parameter plus the relative hysteresis values). The output relay again switches back to the preset allowed range after the expiry of the reset-delay time period (tF).
In the external window function mode, the monitoring function acts inversely to the internal window function.
Should the manual reset function be activated, the output relay remains in alarm mode when the frequency returns to the preset allowed range. A reset of the saved

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Output relay K1/K2 130BF785.10

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parameter is possible when the reset input is activated or the auxiliary voltage is shut down.
When a start-up delay time period (tA) is set, the set startup delay time period expires initially when the auxiliary voltage of the equipment is switched on and the "RF" feedback circuit is closed. The start-up delay time period also expires after a reset of the manual reset mode. During this time period, a frequency evaluation is disabled and

the output relays remain at the preset allowed setting. The start-up delay function can, for example, override an alarm message during the start-up stage of a generator or electric motor. Should the feedback circuit not be closed after a reset (in the manual reset mode), the equipment goes into a safe error state.
The frequency monitoring operation is shown in Illustration 3.7.

n

} Overfrequency

Threshold Hysteresis

} Hysteresis
Underfrequency Threshold

U
UH (A1/A2)

Alarm memory

Monitoring function

tA

"Overfrequency"

tV

tF

tV

tF

Monitoring function

tA

"Underfrequency"

tV

tF

Monitoring function "Inside range"
Illustration 3.7 Frequency Monitor Timing

tA

tV

tF

tV

tF

tF

M11332
tA = Start-up delay, tV = Alarm delay, t F= Response delay

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3.3 Parameters and Configuration
The equipment can be configured via the display and the setting keys on the display. See Illustration 3.8.
To enter the parameterization-mode on the device, follow these steps:
1. Press and hold the [OK] key.
2. Press the [Reset] key.
3. A display test follows and has to be acknowledged using the [OK] key, when it was successful.
4. It is now possible to change the parameterization. Before the device adopts changed parameters, they must be confirmed once more for safety reasons.

Follow the installation guide from the manufacturer for a detailed description. Table 3.1 shows a default configuration of the frequency monitor.
The safe speed limit parameter (SLS limit) is configured to the upper limit parameter of frequency mode 1. The lower limit is configured to 0.0 Hz.

33

130BF786.10

E safemaster
DS
DOLO UH6937

ON K1/K2 ERR

t

actual frequency 100Hz

3

2

4

1

13 23 +

K1

f

K2

14 24 38

1

OK

2



3



4

Reset

Illustration 3.8 Frequency Monitor Device Display

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Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

1.
33
2.

Parameterization

1.1

Monitoring function

Overfrequency

Underfrequency

Inside range

Outside range

1.2

Limits

Frequency mode 1

Upper limit

Lower limit

Frequency mode 2 Upper limit Lower limit

Frequency mode 3 Upper limit Lower limit

Frequency mode 4

Upper limit

Lower limit

1.3

Hysteresis

5%

1.4

Time Delay

Start-up delay

Response Delay

Alarm delay

Changeover bridging

1.5

Alarm memory

Alarm memory

Automatic reset

1.6

Muting function

Activate

Deactivate

Display settings

2.1

Languages

English

Deutsch

Francais

2.2

Contrast

50

2.3

Backlight

OFF

10 s

1 min

5 min

2.4

Status indicator

Manual

10 s

1 min

5 min

X ­ ­ ­
400.0 Hz 200.0 Hz
400.0 Hz 200.0 Hz
400.0 Hz 200.0 Hz
400.0 Hz 200.0 Hz
0.0 s 0.0 s 0.1 s 0.0 s
X ­
­ X
X ­ ­
%
­ X ­ ­
X ­ ­ ­

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3.

Factory settings

Parameters

Display settings

Parameter + display settings

4.

Change tracking

Activate

5.

About UH 6937

Table 3.1 Frequency Monitor Configuration

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Ordering Data for DOLD Comp...

Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

4 Ordering Data for DOLD Components

130BF787.10

44

4.1 Frequency Monitor
The ordering information for the DOLD frequency monitor is shown in Illustration 4.1.

_ _ _ _ UH 6937 .02

/ 0 DC 24 V

Nominal voltage
0 = Standard 1 = with different frequency mode
and analogue output

Max. response value 0 = 600 Hz 1 = 1000 Hz

Type o terminals PS (plug-in screw)
pluggable terminal blocks, with screw terminals
Contacts

Type

Description

Type

Safe frequency monitor Noise suppression filter1)

UH6937.02PS DC24V LG5130

Order number 0066820
0065015

Pcs. / Pkt. 1
2

Illustration 4.1 Ordering Example

1) Even though the UH6937 has enough EMC immunity for normal conditions, the suppression filter for each channel of measurement is needed only when the frequency monitor module does not function correctly due to high EMC or high frequency noise.

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Functional Safety-related D...

Functional Safety Application Guide

5 Functional Safety-related Data

5.1 SIL Calculation
The SLS safety function consists of 3 subsystems:
· Frequency converter · Frequency monitor · Functional safety system, such as fail-safe PLC
These have different safety-related data.

The values for the fail-safe PLC must be at least the shown values in Table 5.3.

IEC 61508 EN 62061 EN/ISO 13849: 2006 EN 61800-5-2 PFH

SIL2 SILCL 2 PL d Category 3 SIL2 1x10-10/h

Table 5.1 Subsystem VLT® AutomationDrive FC 302

IEC 61508 EN 62061 EN/ISO 13849: 2006 PFH

SIL3 SILCL 3 PL e Category 4 4.43x10-10/h

Table 5.2 Subsystem Frequency Monitor

IEC 61508 EN 62061 EN/ISO 13849: 2006 EN 61800-5-2 PFH

SIL2 SILCL 2 PL d Category 3 SIL2 <9.1x10-8/h

Table 5.3 Subsystem Fail-safe PLC

IEC 61508 EN 62061 EN/ISO 13849: 2006 EN 61800-5-2 PFH
Table 5.4 SLS Safety Function

SIL2 SILCL 2 PL d Category 3 SIL2 < 1x10-7/h

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Index

Encoder-less Safety Functions SLS, SSR using DOLD Frequency Monitor

Index
D
DIN EN/ISO 13849: 2006..................................................................... 17 DOLD LG 5130.......................................................................................... 4 DOLD UH 6937......................................................................................... 4
E
EN 61800-5-2.......................................................................................... 17 EN 62061.................................................................................................. 17 External window function................................................................. 11
F
Fail-safe PLC............................................................................................... 4 Fault handling........................................................................................ 11 Frequency monitor configuration.................................................. 13
I
IEC 61508................................................................................................. 17 Inside range.............................................................................................. 3 Internal window function.................................................................. 11
O
Outside range........................................................................................... 3 Overfrequency......................................................................................... 3
P
PFH............................................................................................................. 17
S
Safe Torque Off......................................................................................... 3 SIL calculation........................................................................................ 17 SLS operation......................................................................................... 11 SSR operation......................................................................................... 11 STO............................................................................................................... 3
see also Safe Torque Off
T
Terminal 12................................................................................................ 4 Terminal 13................................................................................................ 4 Terminal 20................................................................................................ 4 Terminal description.............................................................................. 5 Terminals E1a, E1b, E2L, E2H, E3L, E3H............................................ 4
U
Underfrequency...................................................................................... 3

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Functional Safety Application Guide

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Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
Danfoss A/S Ulsnaes 1 DK-6300 Graasten vlt-drives.danfoss.com

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References

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