ABB FPTC-01 User manual

—
OPTIONS FOR ABB DRIVES
FPTC-01 thermistor protection module
(option +L536) for ACS880 drives
User's manual

FPTC-01 thermistor protection module
(option +L536) for ACS880 drives
User's manual
Table of contents
1. Safety instructions
5. Mechanical installation
6. Electrical installation
8. Start-up and validation test
3AXD50000027750 Rev D
EN
EFFECTIVE: 2020-11-18

Table of contents
1 Safety instructions
9Contents of this chapter ............................................................
9Use of warnings and notes .......................................................
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 .......................................................................
18Terms and abbreviations ...........................................................
3 Hardware description
21Contents of this chapter ............................................................
21Product overview ......................................................................
22Operation basics .................................................................
22XFLT input (Fault) ........................................................
22XWRN input (Warning) .................................................
23Layout .................................................................................
24Markings ...................................................................................
4 Option description and instructions
25Contents of this chapter ............................................................
25Overview ...................................................................................
26
Wall-mounted drives, drive modules and inverter
modules ..............................................................................
26Cabinet-built drives .............................................................
27Commissioning the drive for a motor in a hazardous area .......
27Resetting the safety function ....................................................
27Indications of the safety function ..............................................
Table of contents 5

28Fault reaction function ...............................................................
28FPTC-01 module ................................................................
29STO function in the drive/inverter .......................................
29FSO module .......................................................................
5 Mechanical installation
31Contents of this chapter ............................................................
31Necessary tools and instructions ..............................................
31Unpacking and examining the delivery .....................................
32Installing the module .................................................................
6 Electrical installation
35Contents of this chapter ............................................................
35Warnings ...................................................................................
36Necessary tools and instructions ..............................................
36General wiring instructions .......................................................
37Terminal designations ...............................................................
37PTC sensor inputs ....................................................................
37XFLT input ..........................................................................
38XWRN input ........................................................................
38Wiring examples .......................................................................
40Wiring example 1 ................................................................
41Wiring example 2 ................................................................
42Wiring example 3 ................................................................
43Wiring example 4 ................................................................
44Wiring example 5 ................................................................
7 Parameter settings
45Contents of this chapter ............................................................
45Drive / inverter ...........................................................................
47Switching frequency limitation ............................................
48Other recommended settings .............................................
48FSO module ..............................................................................
50General parameters ............................................................
51Parameters for the STO function ........................................
54Parameters for the SSE function ........................................
55FSE module and safety encoder parameters .....................
6 Table of contents
27

57Notes ..................................................................................
58Mechanical brake control ..........................................................
8 Start-up and validation test
59Contents of this chapter ............................................................
59Validation of the safety functions ..............................................
59Competence .......................................................................
60Validation procedure ...........................................................
60Validation test reports .........................................................
61Validation test ............................................................................
9 Fault tracing
65Contents of this chapter ............................................................
65Reporting problems and failures related to safety functions .....
65FPTC-01 module replacement ..................................................
66Fault and warning messages ....................................................
68LEDs .........................................................................................
10 Maintenance
69Contents of this chapter ............................................................
69Safety circuit maintenance ........................................................
70Proof test ...................................................................................
70Proof test interval ......................................................................
71Competence ..............................................................................
71Residual risk .............................................................................
71Intentional misuse .....................................................................
71Decommissioning ......................................................................
11 Technical data
73Contents of this chapter ............................................................
74Dimension drawing ...................................................................
74Isolation areas ...........................................................................
76Connections ..............................................................................
76Motor thermistor connection ...............................................
76STO output connection .......................................................
77Ambient conditions ....................................................................
77Safety data ................................................................................
Table of contents 7

78Safety block diagrams ...............................................................
79Two-channel configurations ................................................
80One-channel configurations ...............................................
81Response times ........................................................................
81Relevant failure modes .............................................................
82Related standards and directives .............................................
82Compliance with the European Machinery Directive ................
84TÜV 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.
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.
If the motor thermal protection function is used with an Ex motor,
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) and the requirements of IEC/EN 60079-14.
In addition to this manual:
• for ACS880 single drives, see the drive hardware manual
•for ACS880 air-cooled multidrives, multidrive modules and single
drive modules, see ACS880 multidrive cabinets and modules
safety instructions (3AUA0000102301 [English])
10 Safety instructions
28

• for ACS880 liquid-cooled multidrives, multidrive modules and
single drive modules, see ACS880 liquid-cooled multidrive
cabinets and modules safety instructions (3AXD50000048633
[English]).
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).
WARNING!
If a short-circuit occurs in the output stage of the drive, the
STO function does not prevent the intermediate DC current
from flowing through and heating up the motor. The system
integrator must take this into account when planning the
protection of the installation.
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.
• 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.
• 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.
12 Safety instructions
28

5. Measure that the installation is de-energized.
• 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.
• Make sure that the voltage between the drive DC terminals
(UDC+ and UDC-) and the grounding (PE) terminal is zero.
In cabinet-built drives, measure between the drive DC
busbars (+ and -) and the grounding (PE) busbar.
6. Install temporary grounding as required by the local regulations.
7. Ask the person in control of the electrical installation work for a
permit to work.
Safety instructions 13

14

2
Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual is applicable to the FPTC-01 module and to the Safe
motor temperature safety (SMT) function which uses the FPTC-01
module (option +L536).
Compatibility
The FPTC-01 module is compatible with:
• ACS880-01/11/31 drives
• ACS880-04/04XT/04F/04FXT/M04/14/34 drive modules
• ACS880-104/104LC inverter modules
• ACS880-07/07LC/17/17LC/37/37LC cabinet-built drives
Introduction to the manual 15

• ACS880-107/107LC inverter units
• FSO-12 and FSO-21 safety functions modules
• ACS880 primary control program version 2.10 or later. For the
compatibility of other control programs, contact your local ABB
representative.
Target audience
This manual is intended for people who plan the installation, install,
start up, use and service the module. Before you do work on the
module, read this manual and the applicable drive manual that
contains the hardware and safety information for the product in
question. 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 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
3AUA0000078093ACS880-01 hardware manual
3AXD50000045932ACS880-11 hardware manual
3AXD50000045933ACS880-31 hardware manual
16 Introduction to the manual

CodeName
3AUA0000128301ACS880-04 drive modules (200 to 710 kW, 300 to 700
hp) hardware manual
3AUA0000138495ACS880-04 single drive module packages (560 to 2200
kW) hardware manual
3AXD50000034664ACS880-04F drive modules hardware manual
3AXD50000025169ACS880-04XT drive module packages (500 to 1200
kW) hardware manual
3AXD50000274444ACS880-04FXT drive module packages hardware
manual
3AXD50000028613ACS880-M04 drive hardware manual
3AXD50000035160ACS880-14 drive modules (132 to 400 kW) hardware
manual
3AXD50000035191ACS880-34 drive modules (132 to 400 kW) hardware
manual
3AXD50000022021ACS880-14 and -34 single drive module packages
hardware manual
3AUA0000105718ACS880-07 drives (45 to 710 kW) hardware manual
3AUA0000143261ACS880-07 drives (560 to 2800 kW) hardware manual
3AXD50000569786ACS880-07LC drives hardware manual
3AXD50000020436ACS880-17 drives (160 to 3200 kW) hardware manual
3AXD50000035158ACS880-17 drives (45 to 400 kW, 60 to 450 hp) hard-
ware manual
3AXD50000250295ACS880-17LC drives hardware manual
3AXD50000020437ACS880-37 drives (160 to 3200 kW) hardware manual
3AXD50000035159ACS880-37 drives (45…400 kW, 60…450 hp) hard-
ware manual
3AXD50000251407ACS880-37LC drives hardware manual
Inverter hardware
3AUA0000104271ACS880-104 inverter modules hardware manual
3AXD50000045610ACS880-104LC inverter modules hardware manual
3AUA0000102519ACS880-107 inverter units hardware manual
3AXD50000196111ACS880-107LC inverter units hardware manual
Drive firmware
3AUA0000085967ACS880 primary control program firmware manual
Introduction to the manual 17

CodeName
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
3AXD50000015612FSO-12 safety functions module user's manual
3AXD50000015614FSO-21 safety functions module user’s manual
3AXD50000016597FSE-31 pulse encoder interface module user’s manual
3AXD50000027750FPTC-01 thermistor protection module (option +L536)
user’s manual
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
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
Diagnostic coverage (EN ISO 13849-1)DC
Digital inputDI
Frequency converter for controlling AC motorsDrive
Frequency converter enclosed in a metal frame or enclosure.
Intended for cabinet installation.
Drive module
Electromagnetic compatibilityEMC
18 Introduction to the manual

DescriptionTerm
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
Optional I/O extension adapterFEA-03
Optional thermistor protection moduleFPTC-01
Optional pulse encoder interface module for safety encoderFSE-31
Safety functions module which supports the FSE-31 module
and the use of safety encoders
FSO-21
Safety functions module which does not support the use of
encoders
FSO-12
Hardware fault tolerance (IEC 61508)HFT
Inverter bridge, related components and drive DC link capa-
citors enclosed in a metal frame or enclosure. Intended for
cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and re-
lated components. One inverter unit typically controls one
motor.
Inverter unit
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
Periodic test performed to detect failures in the safety func-
tion. The target of the proof test is to ensure that the safety
function still operates correctly and is able to achieve the
safe state. (IEC 61508, IEC 62061)
Proof test
Safe acceleration rangeSAR
Safe brake controlSBC
Systematic capability (IEC 61508)SC
Safe failure fraction (%) (IEC 61508)SFF
Introduction to the manual 19

DescriptionTerm
Safety integrity level (1...3) (IEC 61508)SIL
Maximum SIL (level 1...3) that can be claimed for a safety
function or subsystem (IEC/EN 62061)
SILCL
Safe motor temperature (IEC/EN 61800-5-2)SMT
Safe stop 1 (IEC/EN 61800-5-2)SS1
Safe stop emergencySSE
Safe torque off (IEC/EN 61800-5-2)STO
There are three categories of stop functions defined by
IEC/EN 60204-1:
• stop category 0: an uncontrolled stop where power to
the machine actuators is removed immediately (for ex-
ample, STO)
• stop category 1: a controlled stop where the machine
actuators have power for stopping, after which the power
is removed (SS1)
• stop category 2: a controlled stop where the machine
actuators continue to have power (SS2).
Stop category
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
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)
Zone
20 Introduction to the manual