ABB CPTC-02 User manual

—
OPTIONS FOR ABB DRIVES
CPTC-02 ATEX-certified thermistor
protection module, Ex II (2) GD
(+L537+Q971)
User's manual

CPTC-02 ATEX-certified thermistor
protection module, Ex II (2) GD
(+L537+Q971)
User's manual
Table of contents
1. Safety instructions
5. Mechanical installation
6. Electrical installation
7. Start-up and validation test
3AXD50000030058 Rev D
EN
Original instructions
EFFECTIVE: 2021-07-02

Table of contents
1 Safety instructions
9Contents of this chapter ............................................................
9Use of warnings and notes .......................................................
10ATEX/UKEX-certified motor thermal protection functions .........
10Instructions for functional safety circuits ...................................
12Electrical safety precautions .....................................................
2 Introduction to the manual
15Contents of this chapter ............................................................
15Applicability ...............................................................................
15Compatibility .............................................................................
16Target audience ........................................................................
16Exclusion of liability ...................................................................
16Related manuals .......................................................................
17Terms and abbreviations ...........................................................
3 Hardware description
21Contents of this chapter ............................................................
21Product overview ......................................................................
22External power supply interface .........................................
22Layout .................................................................................
23Markings ...................................................................................
23Module ................................................................................
23Type designation label .................................................
23ATEX/UKEX markings ..................................................
24Drive ...................................................................................
24SMT function ................................................................
4 Option description
27Contents of this chapter ............................................................
27Overview ...................................................................................
28Wall-mounted drives and drive modules ............................
28Cabinet-installed drives ......................................................
Table of contents 5

29Safe disconnection function ......................................................
29Commissioning the drive for a motor in a hazardous area .......
29Resetting the safety function ....................................................
30Indications of the safety function ..............................................
30Switching frequency limitation ..................................................
30Fault reaction function ...............................................................
30CPTC-02 module ................................................................
31STO function in the drive ....................................................
5 Mechanical installation
33Contents of this chapter ............................................................
33Necessary tools and instructions ..............................................
33Unpacking and examining the delivery .....................................
34Installing the module .................................................................
6 Electrical installation
35Contents of this chapter ............................................................
35Warnings ...................................................................................
36Necessary tools and instructions ..............................................
36Selecting the location for the drive ............................................
36General wiring instructions .......................................................
37Terminal designations ...............................................................
37Motor thermistor connection ...............................................
37Relay output connection .....................................................
37External power supply ........................................................
38PTC sensor input ......................................................................
38Wiring examples .......................................................................
39Motor thermistor connection example ................................
40Relay output connection .....................................................
41Power supply connection ...................................................
7 Start-up and validation test
43Contents of this chapter ............................................................
43Validation of the safety functions ..............................................
43Competence .......................................................................
44Validation procedure ...........................................................
44Validation test reports .........................................................
6 Table of contents
27

45Start-up .....................................................................................
47Validation test ............................................................................
8 Fault tracing
51Contents of this chapter ............................................................
51Reporting problems and failures related to safety functions .....
51CPTC-02 module replacement .................................................
52Fault and warning messages ....................................................
53LED ...........................................................................................
9 Maintenance
55Contents of this chapter ............................................................
55Safety circuit maintenance ........................................................
56Proof test ...................................................................................
56Proof test interval ......................................................................
57Functional safety components ..................................................
57Competence ..............................................................................
57Residual risk .............................................................................
58Intentional misuse .....................................................................
58Decommissioning ......................................................................
10 Technical data
59Contents of this chapter ............................................................
60Dimension drawing ...................................................................
61Isolation areas ...........................................................................
61Connections ..............................................................................
61Motor thermistor connection (60…61) ................................
62Relay output (STO) connection (62…63) ...........................
62External power supply (40…41) .........................................
62Ambient conditions ....................................................................
63Safety data ................................................................................
63Safety block diagram ................................................................
64Response times ........................................................................
64Relevant failure modes .............................................................
64Related standards and directives .............................................
65Compliance with the Machinery Directive (EU) ........................
Table of contents 7

65
Compliance with the Supply of Machinery (Safety) Regulations
(UK) ...........................................................................................
66Compliance with the ATEX Directive (EU) ................................
66Compliance with the UKEX Directive (UK) ...............................
67Declaration of Conformity (EU) .................................................
69Declaration of Conformity (UK) .................................................
70ATEX certificate ........................................................................
74UKEX certificate ........................................................................
76TÜV Nord certificate ..................................................................
Further information
8 Table of contents
27

1
Safety instructions
Contents of this chapter
This chapter contains the safety instructions which you must obey
when you install, operate and do maintenance on the safety functions
of a drive.
Use of warnings and notes
Warnings tell you about conditions which can cause injury or death,
or damage to the equipment. They also tell you how to prevent the
danger. Notes draw attention to a particular condition or fact, or give
information on a subject.
The manual uses these warning symbols:
WARNING!
Electricity warning tells about hazards from electricity which
can cause injury or death, or damage to the equipment.
Safety instructions 9

WARNING!
General warning tells about conditions, other than those
caused by electricity, which can cause injury or death, or
damage to the equipment.
WARNING!
Electrostatic sensitive devices warning tells you about the risk
of electrostatic discharge which can cause damage to the
equipment.
ATEX/UKEX-certified motor thermal protection
functions
Only qualified specialists are permitted to install, control and maintain
the ATEX/UKEX-certified motor thermal protection functions (see
IEC/EN 60079-14). Obey all safety regulations required with
application of Ex motors in Zone 1/21 (equipment category 2) or Zone
2/22 (equipment category 2 or 3).
Instructions for functional safety circuits
WARNING!
Obey the safety instructions of the drive. If you ignore
them, injury or death, or damage to the equipment can
occur.
This manual does not contain the complete safety instructions of the
drive. It only includes the instructions related to the scope of this
manual. The general instructions are given in this section and the
option-specific instructions in the applicable chapter.
10 Safety instructions
28

WARNING!
The safety function described in this manual does not isolate
the main circuit or auxiliary circuit from the power supply. Do
not do work on the drive, motor cable or motor before you
have isolated the drive system from all power supplies and
measured that there are no dangerous voltages. Before you
start the work, do the steps in section Electrical safety
precautions (page 12).
Safety instructions 11

Electrical safety precautions
These electrical safety precautions are for all personnel who do work
on the drive, motor cable or motor.
WARNING!
Obey these instructions. If you ignore them, injury or death,
or damage to the equipment can occur.
If you are not a qualified electrical professional, do not do
installation or maintenance work.
Go through these steps before you begin any installation or
maintenance work.
1. Clearly identify the work location and equipment.
2. Disconnect all possible voltage sources. Make sure that
re-connection is not possible. Lock out and tag out.
• Open the main disconnecting device of the drive.
• Open the charging switch if present.
• Open the disconnector of the supply transformer. (The main
disconnecting device in the drive cabinet does not disconnect
the voltage from the AC input power busbars of the drive
cabinet.)
• Open the auxiliary voltage switch-disconnector (if present),
and all other possible disconnecting devices that isolate the
drive from dangerous voltage sources.
• If you have a permanent magnet motor connected to the
drive, disconnect the motor from the drive with a safety switch
or by other means.
12 Safety instructions
28

• Disconnect all dangerous external voltages from the control
circuits.
• After you disconnect power from the drive, always wait 5
minutes to let the intermediate circuit capacitors discharge
before you continue.
3. Protect any other energized parts in the work location against
contact.
4. Take special precautions when close to bare conductors.
5. Measure that the installation is de-energized. Use a quality
voltage tester. If the measurement requires removal or
disassembly of shrouding or other cabinet structures, obey the
local laws and regulations applicable to live working (including –
but not limited to – electric shock and arc protection).
• Before and after measuring the installation, verify the
operation of the voltage tester on a known voltage source.
• Make sure that the voltage between the drive input power
terminals (L1, L2, L3) and the grounding (PE) busbar is zero.
•Make sure that the voltage between the drive output terminals
(T1/U, T2/V, T3/W) and the grounding (PE) busbar is zero.
Important! Repeat the measurement also with the DC voltage
setting of the tester. Measure between each phase and
ground. There is a risk of dangerous DC voltage charging
due to leakage capacitances of the motor circuit. This voltage
can remain charged even long time after the drive power off.
The measurement discharges the voltage.
• Make sure that the voltage between the drive DC terminals
(UDC+ and UDC-) and the grounding (PE) terminal is zero.
Note: If cables are not connected to the drive DC terminals,
measuring the voltage from the DC terminal screws can give
incorrect results.
Safety instructions 13

6. Install temporary grounding as required by the local regulations.
7. Ask for a permit to work from the person in control of the electrical
installation work.
14 Safety instructions
28

2
Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual is applicable to the CPTC-02 module and to the Safe
motor temperature safety (SMT) function which uses the CPTC-02
module (option +L537+Q971).
Compatibility
The CPTC-02 module is compatible with:
• ACS580-01/-04, ACH580-01/-04/-31/-34, and
ACQ580-01/-04/-31/-34 wall-mounted drives and drive modules
to be installed in user-defined cabinet
•ACS580-07, ACH580-07, and ACQ580-07 cabinet-installed drives
• ACS580 standard control program version 1.70 or later
Introduction to the manual 15

• ACH580 HVAC control program version 2.05 or later
• ACQ580 pump control program version 2.05 or later
Target audience
This manual is intended for people who install, commission, use and
service the ATEX-certified thermistor protection module of the drive.
Read the manual before working on the drive. You are expected to
know the fundamentals of electricity, wiring, electrical components,
electrical schematic symbols, functional safety, and Ex regulations.
Exclusion of liability
ABB is not responsible for the implementation, verification and
validation of the overall safety system. It is the responsibility of the
system integrator (or other party) who is responsible for the overall
system, Ex regulations and system safety.
The system integrator (or other responsible party) must make sure
that the entire implementation complies with the instructions in this
manual, all relevant standards, directives and local electrical code,
and that the system is tested, verified and validated correctly.
Related manuals
CodeName
Drive hardware
3AXD50000044794ACS580-01 (0.75 to 250 kW) hardware manual R1-R9
3AXD50000015497ACS580-04 drive modules (200 to 500 kW) hardware
manual
3AXD50000045815ACS580-07 drives hardware manual
3AXD50000044839ACH580-01 (0.75 to 250 kW) hardware manual R1-R9
3AXD50000048685ACH580-04 drive modules (250 to 500 kW) hardware
manual
3AXD50000045816ACH580-07 hardware manual
3AXD50000037066ACH580-31 hardware manual
16 Introduction to the manual

CodeName
3AXD50000419708ACH580-34 hardware manual
3AXD50000044862ACQ580-01 (0.75 to 250 kW) hardware manual R1-R9
3AXD50000048677ACQ580-04 hardware manual
3AXD50000045817ACQ580-07 hardware manual
3AXD50000045935ACQ580-31 hardware manual
3AXD50000420025ACQ580-34 hardware manual
Drive firmware
3AXD50000016097ACS580 standard control program firmware manual
3AXD50000027537ACH580 HVAC control program firmware manual
3AXD50000035867ACQ580 pump control program firmware manual
PC tools
3AUA0000094606Drive composer start-up and maintenance PC tool
user's manual
Safety
3AUA0000048753Functional safety; Technical guide No. 10
www.abb.com/safetyABB Safety information and solutions
3AUA0000037223Motors and drives in potentially explosive atmospheres
- What you need to know
Option manuals
3AUA0000085685ACS-AP-x assistant control panels user’s manual
3AXD50000030058CPTC-02 ATEX-certified thermistor protection module,
Ex II (2) GD (+L537+Q971) user’s manual
3AXD10001243391CPTC-02 ATEX-certified thermistor protection module,
Instructions for pairing the module with an ATEX-certi-
fied drive
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.
See www.abb.com/drives/documents for all manuals on the Internet.
Terms and abbreviations
DescriptionTerm
ACS580, ACH580 or ACQ580ACx580
Introduction to the manual 17

DescriptionTerm
Directives 2014/34/EU and 1999/92/EC are commonly re-
ferred to as the ATEX directives (from "Atmosphères Explos-
ibles")
ATEX
Classification of the safety-related parts of a control system
in respect of their resistance to faults and their subsequent
behavior in the fault condition, and which is achieved by the
structural arrangement of the parts, fault detection and/or by
their reliability. The categories are: B, 1, 2, 3 and 4. (EN ISO
13849-1)
Cat.
Common cause failure (%) (EN ISO 13849-1)CCF
Multifunction extension module (external 24 V and
ATEX/UKEX-certified PTC interface)
CPTC-02
Diagnostic coverage (EN ISO 13849-1)DC
Digital inputDI
Electromagnetic compatibilityEMC
An IEC term used in the context of explosive atmospheres
(IEC 60079)
Ex
Type of protection, flameproof enclosures (IEC/EN 60079-1)Ex d
Types of protection, increased safety (IEC/EN 60079-7)Ex eb, Ex ec
Motors used in explosive atmospheresEx motors
Hardware fault tolerance (IEC 61508)HFT
Mean time to dangerous failure: (Total number of life units)
/ (Number of dangerous, undetected failures) during a partic-
ular measurement interval under stated conditions (EN ISO
13849-1)
MTTFD
Average probability of dangerous failure on demand (IEC
61508)
PFDavg
Average frequency of dangerous failures per hour (IEC
61508)
PFH
Performance level. Levels a...e correspond to SIL (EN ISO
13849-1)
PL
Systematic capability (IEC 61508)SC
Safe failure fraction (%) (IEC 61508)SFF
Safety integrity level (1...3) (IEC 61508)SIL
Safe motor temperature (IEC/EN 61800-5-2)SMT
Safe torque off (IEC/EN 61800-5-2)STO
18 Introduction to the manual

DescriptionTerm
Proof test interval. Defines the probabilistic failure rate (PFH
or PFDavg) for the safety function or subsystem. Performing
a proof test at a maximum interval of T1is required to keep
the SIL capability valid. The same interval must be followed
to keep the PL capability (EN ISO 13849) valid. Note that
any T1values given cannot be regarded as a guarantee or
warranty.
T1
Mission time: the period of time covering the intended use
of the safety function/device. After the mission time elapses,
the safety device must be replaced. Note that any TMvalues
given cannot be regarded as a guarantee or warranty.
(EN ISO 13849-1, IEC 61800-5-2)
TM
The Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres Regulations 2016 (+
amendment SI 2019 No. 696)
UKEX
Confirmation by, for example, analysis that the safety system
meets the functional safety requirements of the specific ap-
plication.
Validation
Confirmation by, for example, testing that the safety system
meets the requirements set by the specification.
Verification
Potentially explosive atmosphere. Hazardous areas are di-
vided into zones, based on the frequency and duration of the
occurrence of an explosive atmosphere. (IEC/EN 60079-10)
Zone
Introduction to the manual 19

20