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Danfoss VACON OPTEA

Danfoss VACON OPTEA
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Operating Guide
VACONĀ® NXP Advanced Safety Options
OPTBL, OPTBM, OPTBN
drives.danfoss.com

Table of Contents

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Danfoss VACON OPTEA Specifications

General IconGeneral
BrandDanfoss
ModelVACON OPTEA
CategoryDC Drives
LanguageEnglish

Summary

Introduction to Vacon NXP Advanced Safety Options

Purpose of the Manual

Describes the manual's purpose for VACONĀ® Advanced Safety Options used with VACONĀ® NXP AC drives.

Additional Resources for Drive and Optional Equipment

Lists available resources, manuals, standards, and software for the drive and option boards.

Manual and Software Version

Details manual revisions, new features, firmware, and hardware versions.

Approvals and Certificates

Presents the TÜV certificate and EC Declaration of Conformity for the VACON® Advanced Safety Option Card.

Product Overview

Introduces safety functions (STO, SS1, SS2, etc.) and supported safe fieldbuses.

Terms and Abbreviations

Defines abbreviations and terms used in the manual for clarity and understanding.

Safety

Safety Symbols

Explains safety symbols used in the manual for hazard indication.

Danger and Warnings

Details hazardous situations, including shock hazards from components and terminals.

Cautions and Notices

Provides cautions regarding drive damage from incorrect measurements, spare parts, or grounding.

Grounding

Explains grounding requirements for the AC drive according to standards and directives.

Overview of the System

Using the Advanced Safety Options

Describes how the Advanced Safety Option board implements safety functions and its integration with the AC drive.

The Safe State

Defines the safe state and how it's achieved, typically with Safe Torque Off (STO).

Integration and Interfaces to Other Systems

Discusses the system designer's responsibility for integration, risk assessment, and interfaces.

Determining the Achieved Safety Level

Explains how to determine the safety level, considering the whole safety chain.

Advanced Safety Option Variants

Details supported slots for option board revisions and available connectors.

Input Configuration

Explains the configuration of the 4 two-terminal digital inputs for safety functions.

Output Configuration

Details the configuration of the 2 two-terminal digital outputs for safety functions and custom logic.

Option Board OPTBL

Describes the OPTBL option board for use without an encoder for speed measurement.

Option Board OPTBM

Details the OPTBM option board with a digital pulse TTL/HTL encoder interface for closed-loop control.

Option Board OPTBN

Describes the OPTBN option board with a Sin/Cos type encoder interface for closed-loop control.

Closed-loop Control with OPTBM

Explains how to use OPTBM for closed-loop control, noting features and differences.

Closed-loop Control with OPTBN

Details using OPTBN for closed-loop control, including features and differences.

Speed Measurement

Lists supported safety speed sensors like Sin/Cos encoder, digital pulse encoder, and proximity sensor.

Standard Speed Sensors and Combinations

Shows achievable safety levels with different speed sensor combinations without certificates.

Speed Discrepancy with Multiple Speed Sources

Discusses the behavior when speed values from multiple sources exceed allowed deviation.

Encoders

Explains the encoder interface boards, signal connections, and closed-loop control usage.

Proximity sensors

Details connecting two proximity sensors to the safe I/O for speed measurement.

Encoder Signal Verification

Explains how the board verifies encoder signal correctness and diagnostic coverage.

Usage of Only One Speed Sensor

Discusses fault models to consider when using a single speed sensor.

Estimated Speed

Recommends using estimated speed as a second channel for diagnostics.

Estimated Speed and Gear Systems

Explains setting the ratio between sensor speed and estimated speed for gear systems.

Estimated Speed and External Accelerative Forces

Analyzes consequences of estimated speed usage with external forces.

Storage of Parameters

Explains parameter backup locations on the option board, control board, and PC.

Storing a Parameter File Backup

Provides instructions to store a parameter file backup from the Advanced Safety Option.

Restoring a Parameter File from Backup

Gives instructions to restore a parameter file from backup to the Advanced Safety Option.

Advanced Safety Options with the NXP Drive

Lists required drive component versions for using the Advanced Safety Option board.

Compatibility with Drive Applications

Discusses compatibility of the Advanced Safety Option board with drive applications.

Option Board Menu on the Control Panel

Explains how to use the control panel menu to manage the option board.

Fault Types

Classifies faults (critical, resettable, violation, warning) for the Advanced safety option board.

Installation

Installation Safety

Provides warnings before installing the option board, including shock hazards.

Installing the Option Board

Gives step-by-step instructions for installing the option board in VACONĀ® NXP drives.

VACON Safe Tool

Functions of the VACON Safe Tool

Lists the functions of the VACON Safe tool for parameterization and monitoring.

The Parameter File

Explains parameter files, their states (unverified, verified, validated), and transfer.

User Levels and Password Management

Describes the two-level password system (Admin, Service) for parameter protection.

Setting the Parameters

Details the 4-step process for parameterizing the Advanced safety option board using VACON Safe.

Saving a Verified Parameter File to the Option Board

Instructions for saving a verified parameter file to the option board.

Online Monitoring

Explains how to view the status and execution of safety functions and I/O via VACON Safe.

Safety Functions

General Information

Categorizes safety functions into safe stopping and safe monitoring functions.

Safety Function States

Describes the three states of safety functions: inactive, active, and reached.

Activation of a Safety Function

Explains how safety functions are activated via digital inputs or safe fieldbus.

Violation of a Safety Function

Details causes of violations and the two types of violation responses.

Acknowledgment of a Safety Function

Explains how to acknowledge safety functions (automatic/manual) and their sources.

Start-up Acknowledgment

How acknowledgment signal permits STO release after start-up.

Reset of a Safety Function

Explains using reset signals to deactivate STO and reset faults.

Ramps

Describes ramp monitoring for safety functions and parameterization options.

Safe Stopping Functions

Introduces safe stopping functions that stop and monitor motor stopping.

Introduction to the STO and SBC Functions

Introduces Safe Torque Off (STO) and Safe Brake Control (SBC) functions.

The STO Function Used without the SBC Function

Explains STO activation when SBC is not used.

The STO Function Used with the SBC Function

Details STO and SBC behavior based on SBC parameters and order.

The STO and SBC Signals

Describes the activation and deactivation signals for STO and SBC functions.

SS1 - Safe Stop 1

Introduces SS1 function for monitoring motor deceleration and activating STO(+SBC).

Time Monitoring

Explains the Time Monitoring mode for SS1, including STO activation and SBC Speed.

Zero Speed Monitoring

Details Zero Speed Monitoring for SS1, including STO activation and SS1 td2.

Ramp Monitoring

Describes Ramp Monitoring for SS1, including parameter selection and violation response.

The SS1 Signals

Details the activation and deactivation signals for the SS1 function.

SS2 - Safe Stop 2 and SOS - Safe Operating Stop

Introduces SS2 for motor deceleration and SOS for monitoring motor shaft position.

Time Monitoring

Explains Time Monitoring for SS2, including SOS activation and SS2 t1.

Zero Speed Monitoring

Details Zero Speed Monitoring for SS2, including SOS activation and SS2 td2.

Ramp Monitoring

Describes Ramp Monitoring for SS2, including parameter selection and violation response.

The SOS Safety Function

Explains the SOS function for monitoring shaft rotation and its deviation limits.

The SS2 and SOS Signals

Details the activation and deactivation signals for SS2 and SOS functions.

SQS - Safe Quick Stop

Introduces SQS function with modes SQS-STO, SQS-SS1, SQS-SS2 and its violation response.

The SQS Modes

Explains SQS modes (STO, SS1, SS2) and their behavior relative to independent functions.

The SQS Signals

Details the activation and deactivation signals for SQS functions.

Safe Monitoring Functions

Introduces functions monitoring speed, position, or acceleration, often without direction consideration.

SLS - Safe Limited Speed

Explains SLS for monitoring motor speed against limits and its deceleration monitoring.

Introduction to the SLS Function

Explains SLS for monitoring motor speed against limits and its deceleration monitoring.

Time Monitoring

Details Time Monitoring for SLS, including SLS t1 and violation response.

Ramp Monitoring

Describes Ramp Monitoring for SLS, including parameter selection and violation response.

The Speed Limit Selection of the SLS Function

Explains how SLS selects speed limits from digital inputs or fieldbus based on priority.

The SLS Signals

Details the activation and deactivation signals for SLS functions.

SMS - Safe Maximum Speed

Introduces SMS for monitoring motor speed against parameterized limits, independently for rotation directions.

Introduction to the SMS Function

Introduces SMS for monitoring motor speed against parameterized limits, independently for rotation directions.

The Maximum Speed Monitoring

Explains how maximum speed monitoring starts and operates when SMS is active.

The SMS Signals

Details the activation and deactivation signals for SMS functions.

SSR - Safe Speed Range

Introduces SSR for monitoring motor speed within a parameterized range (max/min).

Introduction to the SSR Function

Introduces SSR for monitoring motor speed within a parameterized range (max/min).

Time Monitoring

Details Time Monitoring for SSR, including SSR t1 and violation response.

Ramp Monitoring

Describes Ramp Monitoring for SSR, including parameter selection and violation response.

The SSR Signals

Details the activation and deactivation signals for SSR functions.

SSM - Safe Speed Monitor

Introduces SSM for signaling motor speed within set limits, with a safe output.

Introduction to the SSM Function

Introduces SSM for signaling motor speed within set limits, with a safe output.

Speed Monitoring

Explains maximum and minimum speed monitoring for SSM, and disabling monitoring.

The SSM Safe Output

Describes how the SSM safe output state is determined by motor speed and function activity.

The SSM Signals

Details the activation and deactivation signals for SSM functions.

Combinations of Safety Functions

Discusses how multiple active safety functions monitor limits and potential unexpected violations.

Safe Fieldbuses

PROFIsafe

Introduces PROFIsafe as a safety protocol over PROFIBUS/PROFINET, ensuring communication validity.

Requirements and Restrictions for PROFIsafe

Lists required components and versions for using PROFIsafe with the Advanced safety option board.

Overview of the PROFIsafe System

Illustrates the PROFIsafe system architecture with safety PLC and VACON NXP components.

The PROFIsafe Frame

Describes the structure of the PROFIsafe frame, including I/O data and CRC.

Parameterization for PROFIsafe

Details PROFIsafe parameter requirements and cyclic communication for safety.

General Information on Parameterization

Details PROFIsafe parameter requirements and cyclic communication for safety.

PROFIsafe Watchdog Time

Explains the F-Parameter F WD Time for determining watchdog time.

PROFIsafe Safety Function Response Time (SFRT)

Defines SFRT and provides formula for calculation.

PROFIdrive on PROFIsafe

Discusses PROFIdrive on PROFIsafe compatibility and drive application usage.

General Information on PROFIdrive on PROFIsafe

Discusses PROFIdrive on PROFIsafe compatibility and drive application usage.

PROFIsafe over PROFIBUS

Explains PROFIsafe data structure in PROFIBUS messages.

PROFIsafe over PROFINET

Describes PROFIsafe data placement in PROFINET slots.

Data Mapping for PROFIdrive on PROFIsafe

Details telegrams used for controlling AC drive safety with PROFIsafe.

Safety Control Word 1 (SSTW1)

Describes the bits and signals in Safety Control Word 1.

Safety Status Word 1 (SZSW1)

Explains Safety Status Word 1 used with S_STW1 for Standard Telegram 30.

Safety Control Word 2 (SSTW2)

Describes Safety Control Word 2, offering more safety functions and SLS limit selection.

Safety Status Word 2 (SZSW2)

Explains Safety Status Word 2 for Standard Telegram 31, including SLS limits and SSM status.

VACON Safety Control Word (VSCW)

Defines the vendor-specific VACON Safety Control Word for full fieldbus access.

VACON Safety Status Word (VSSW)

Describes VACON Safety Status Word for input data and function statuses.

Parameter List

General Parameters

Lists parameters for file name, creator, date, company, and comment.

Common Safety Function Parameters

Defines common parameters for safety functions like Zero Speed and Drive Acknowledgment.

Speed Measurement Parameters

Lists parameters for selecting encoder type, power supply, and signal settings.

Ramp Parameters

Lists parameters for defining acceleration and deceleration ramps for safety functions.

Estimated Speed Parameters

Lists parameters related to estimated speed, like Coast Stop Time.

Safe IO Parameters

Details parameters for configuring digital inputs and outputs for safety functions.

PROFIsafe Parameters

Lists PROFIsafe specific parameters like fieldbus type, source, destination, and watchdog time.

STO and SBC Parameters

Defines parameters for STO and SBC functions, including acknowledgment mode and speed settings.

SS1 Parameters

Lists parameters for SS1 function, including acknowledgment mode, monitoring, ramps, and timing.

SS2 and SOS Parameters

Defines parameters for SS2 and SOS functions, including acknowledgment mode, monitoring, and ramps.

SQS Parameters

Lists parameters for SQS function, including acknowledgment mode, type, monitoring, and timing.

SLS Parameters

Details parameters for SLS function, including acknowledgment, ramps, timing, and speed limits.

SMS Parameters

Lists parameters for SMS function, including acknowledgment mode and speed limits.

SSR Parameters

Defines parameters for SSR function, including acknowledgment, ramps, and speed limits.

SSM Parameters

Lists parameters for SSM function, including acknowledgment mode, always active, timing, and speed limits.

Validation Parameters

Lists parameters for validating the system, including tester name, company, date, and comment.

Commissioning and Validation

Preparing for Commissioning

Provides information and steps for preparing the commissioning process.

Procedures Before the First Start-up of the System with the Option

Lists procedures to follow before the initial system start-up with the option board.

Doing the First Start-up After the Installation of the Option Board

Outlines steps for the initial start-up after installing the option board.

Commissioning Check List

Provides a checklist to verify correct installation and parameterization of the option board.

Validating the Parameter File

Explains how to validate the parameter file stored in the option board using VACON Safe.

Checklist before Taking the System into Use

Lists conditions that must be met before the system can be put into use.

Bypassing Safety Features

Warns about bypassing safety features and advises careful consideration.

Operation and Maintenance

Gathering Diagnostic Data

Lists sources for gathering diagnostic data for troubleshooting and support.

Periodic Testing

Recommends periodic testing for certain components and states requirements for safety levels.

Resetting the Password

Explains how to reset passwords using the control panel or factory reset.

Factory Reset

Details the factory reset procedure for the option board and its effects.

Software Update

Guides on updating the option board firmware, including precautions and tools.

Updating the Firmware

Provides a procedure for updating the option board firmware using VACON Loader.

Replacing the Option Board

Gives instructions for replacing the option board, including safety precautions and parameter management.

Replacement of Other Components of the Safety System

Advises considering effects of changes to other safety system components.

Disposal

Provides guidelines for disposing of the option board and its components responsibly.

Technical Data

Safety Data

Lists general safety characteristics like SIL, PL, and HFT for the option board variants.

Safe InputOutput Data

Details the specifications for safe input and output data, including voltage, current, and debounce times.

Speed Measurement Data

Compares speed sources and their allowed deviations.

SinCos Encoder Data

Provides technical data for Sin/Cos encoders, including voltage, current, and frequency.

Digital Pulse Encoder Data

Lists technical data for Digital Pulse encoders (HTL, TTL), including voltage and signals.

Proximity Sensor Data

Details technical specifications for proximity sensors, including supported types and operating frequency.

Estimated Speed Data

Provides details on supported motor types and estimation error for estimated speed.

Safe Fieldbus Data

Lists data related to safe fieldbus communication, including protocols and telegrams.

Environmental Data

Provides environmental data for operating and storing the AC drive and option board.

Fault Tracing

Presentation of Faults on the Control Board

Explains the syntax and fields used for presenting faults on the control panel and PC tools.

Fault Codes

Details various fault codes (F20, F8, F46, F47, F48) and their causes/troubleshooting.

Configuration Examples

General Information

Introduces configuration examples for different safety functions, emphasizing system preparation.

Emergency Stop Using the STO Function

Provides an example configuration for emergency stop using STO with OPTBL and OPTAF.

SS1 Used with STO(+SBC)

Details a configuration example using SS1 with STO(+SBC) in OPTBL for ramp control.

SS1 Without a Direct Support of the Drive Application

Explains SLS speed limiting using external frequency reference when drive app lacks support.

Light Curtain Control of SLS

Describes a configuration using SQS-SS1 and SLS with a light curtain for motor control.

SLS without a Direct Support of the Drive Application

Explains SLS speed limiting using external frequency reference when drive app lacks support.

Using an Output of the Option Board to Control the Access to an Area

Shows a configuration using SLS and SQS with an output to control an external door lock.

PROFIdrive over PROFIsafe Using PROFIBUS or PROFINET

Details a configuration for PROFIdrive over PROFIsafe using OPTBN/OPTEA with STO, SS1, SLS, SQS.

A Proximity Sensor for Speed Measurement

Presents a configuration example using one proximity sensor for speed measurement with OPTBL.

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