ABB FPTC-01 User manual

Options for ABB drives
User’s manual
FPTC-01 thermistor protection module (option +L536)
for ACS880 drives

List of related manuals
You can find manuals and other product documents in PDF format on the
Internet. See section Document library on the Internet on the inside of the back
cover. For manuals not available in the Document library, contact your local ABB
representative.
Drive hardware manuals Code (EN)
ACS880-01 hardware manual 3AUA0000078093
ACS880-04 hardware manual 3AUA0000128301
ACS880-04 drive module packages hardware manual 3AUA0000138495
ACS880-11 hardware manual 3AXD50000045932
ACS880-31 hardware manual 3AXD50000045933
ACS880-14 and -34 hardware manual 3AXD50000022021
ACS880-04XT (500 to 1200 kW) hardware manual 3AXD50000025169
ACS880-04F drive modules hardware manual 3AXD50000034664
ACS880-M04 hardware manual 3AXD50000028613
ACS880-07 (45 to 630 kW) hardware manual 3AUA0000105718
ACS880-07 (560 to 2800 kW) hardware manual 3AUA0000143261
ACS880-17 (160 to 3200 kW) hardware manual 3AXD50000020436
ACS880-17 (45...400 kW) hardware manual 3AXD50000035158
ACS880-37 (160 to 3200 kW) hardware manual 3AXD50000020437
ACS880-37 (45...400 kW) hardware manual 3AXD50000035159
ACS880-104 inverter modules hardware manual 3AUA0000104271
ACS880-104LC inverter modules hardware manual 3AXD50000045610
ACS880-107 inverter units hardware manual 3AUA0000102519
Drive firmware manuals
ACS880 primary control program firmware manual 3AUA0000085967
Option manuals and guides
FSO-12 safety functions module user's manual 3AXD50000015612
FSO-21 safety functions module user’s manual 3AXD50000015614
FSE-31 pulse encoder interface module user’s manual 3AXD50000016597
FPTC-01 thermistor protection module (option +L536)
user’s manual
3AXD50000027750
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.
Drive PC tool manuals
Drive composer start-up and maintenance PC tool
user's manual
3AUA0000094606
General safety guides
Functional safety; Technical guide No. 10 3AUA0000048753
Safety and functional safety; A general guide 1SFC001008B0201
ABB Safety information and solutions www.abb.com/safety
Potentially explosive atmospheres. The basics you need
to know about motors and drives
3AUA0000037223

8. Start-up and acceptance test
User’s manual
FPTC-01 thermistor protection module
(option +L536) for ACS880 drives
3AXD50000027750 Rev C
EN
EFFECTIVE: 2018-03-22
2018 ABB Oy
All Rights Reserved.
1. Safety
Table of contents
5. Mechanical installation
6. Electrical installation

Table of contents 5
Table of contents
1. Safety
Contents this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . 10
Other warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2. Introduction to the manual
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3. Hardware description
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XFLT input (Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XWRN input (Warning). . . . . . . . . . . . . . . . . . . . . . . . . . 22
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FPTC-02 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . 25
ATEX markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Option +Q971. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SMT function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4. Option description and instructions
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6 Table of contents
ACS880-01/04/04XT/04F/M04/11/31/14/34/104 drives and
modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cabinet-built drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
The ATEX-certified Safe disconnection function . . . . . . . . . . . . 31
Resetting the safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Indications of the safety function . . . . . . . . . . . . . . . . . . . . . . . . 33
Switching frequency limitation . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fault reaction function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
FPTC-02 module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
STO function in the drive/inverter modules . . . . . . . . . . . . . 35
FSO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5. Mechanical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . 37
Unpacking and examining the delivery . . . . . . . . . . . . . . . . . . . . 37
Installing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6. Electrical installation
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Necessary tools and instructions . . . . . . . . . . . . . . . . . . . . . . . . 41
General cabling instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Terminal designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Wiring example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wiring example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Wiring example 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Wiring example 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7. Parameter settings
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drive/inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Other recommended settings . . . . . . . . . . . . . . . . . . . . . . . . 54
FSO module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
General parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Table of contents 7
Parameters related to the STO function . . . . . . . . . . . . . . . 58
Parameters related to the SSE function . . . . . . . . . . . . . . . 61
FSE module and safety pulse encoder parameters . . . . . . 62
Additional notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Mechanical brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
8. Start-up and acceptance test
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Acceptance test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9. Fault tracing
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Reporting failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
FPTC-02 module replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fault and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10. Maintenance
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Proof test interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Residual risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Intentional misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
11. Technical data
Contents of this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Dimension drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Isolation areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Motor thermistor connection . . . . . . . . . . . . . . . . . . . . . . . . 80
STO output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Safety data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Safety block diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8 Table of contents
Response times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Relevant failure modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
General rules, notes and definitions . . . . . . . . . . . . . . . . . . . . . . 86
Validation of the safety functions . . . . . . . . . . . . . . . . . . . . . 86
Validation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Acceptance test reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Competence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Reporting problems and failures related to safety functions 87
Related standards and directives . . . . . . . . . . . . . . . . . . . . . . . . 88
Compliance with the European Machinery Directive . . . . . . . . . 89
Compliance with the European ATEX Directive . . . . . . . . . . . . . 89
ATEX certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
TÜV Nord certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Providing feedback on ABB manuals . . . . . . . . . . . . . . . . . . . . . 99
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . 99

Safety 9
1
Safety
Contents this chapter
The chapter contains the warning symbols used in this manual and
the safety instructions which you must obey when you install or
connect an option module to a drive. If you ignore the safety
instructions, injury, death or damage can occur. Read this chapter
before you start the installation.
Use of warnings
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. The manual uses these warning symbols:
Electricity warning tells you about hazards from
electricity which can cause injury or death, or damage to
the equipment.

10 Safety
General warning tells you about conditions, other than
those caused by electricity, which can cause injury or
death, or damage to the equipment.
Safety in installation and maintenance
These instructions are for all who install or connect an option
module to a drive and need to open its front cover or door to do the
work.
WARNING! Obey these instructions. If you ignore them,
injury or death, or damage to the equipment can occur.
•If you are not a qualified electrician, do not do installation or
maintenance work.
•Disconnect the drive from all possible power sources. After you
have disconnected the drive, always wait for 5 minutes to let
the intermediate circuit capacitors discharge before you
continue.
•Disconnect all dangerous voltages connected to other
connectors or parts in reach. For example, it is possible that
230 V AC is connected from outside to a relay output of the
drive.
•Always use a multimeter to make sure that there are no parts
under voltage in reach. The impedance of the multimeter must
be at least 1 Mohm.

Safety 11
Other warnings
WARNING! The Safe torque off (STO) feature of ACS880
drives cannot prevent the intermediate DC current from
flowing through, and heating up, the motor in case a short
circuit occurs in the output stage of the drive. The supplier must
take this into account when planning the protection of the
installation.
WARNING! ACS880 cabinet-built drives: Never connect,
test or measure a drive based on the diagrams of this
manual. Each delivery is unique. Before starting the work
on the electric circuits of a drive, always refer to the delivery-
specific circuit diagrams.

12 Safety

Introduction to the manual 13
2
Introduction to the manual
Contents of this chapter
This chapter gives basic information on the manual.
Applicability
This manual applies to the FPTC-01 module and to the Safe motor
temperature safety function which uses the FPTC-01 module
(option +L536).

14 Introduction to the manual
Compatibility
The FPTC-01 module is compatible with:
•ACS880-01/04/04XT/04F/M04/11/31/14/34/104 drives and
modules
•ACS880-07/17/37 cabinet-built single drives
•ACS880 multidrives
•FSO-12 safety functions module
•FSO-21 safety functions module
•ACS880 primary control program version 2.10 or later
•Other control programs: Check the compatibility with your
local ABB representative.
•ACS880 liquid-cooled drives, modules and multidrives: Check
the compatibility with your local ABB representative.

Introduction to the manual 15
Target audience
This manual is intended for people who plan the installation, install,
start up, use and service the option module. Before you do work on
the module, read this manual and the applicable drive manual that
contains the hardware and safety instructions for the product in
question.
You are expected to know the fundamentals of electricity, wiring,
electrical components and electrical schematic symbols and Ex
regulations.
The manual is written for readers worldwide. Both SI and imperial
units are shown.

16 Introduction to the manual
Contents of the manual
The manual consists of these chapters:
•Safety contains the safety instructions which you must obey
when you install the module.
•Introduction to the manual (this chapter) introduces the
manual.
•Hardware description gives a short description of the module.
•Option description and instructions describes the Safe motor
temperature function implemented with the module and the
drive Safe torque off function.
•Mechanical installation contains a delivery checklist and
instructions on installing the module.
•Electrical installation contains instructions on wiring the
module.
•Parameter settings lists the parameters related to the safety
function.
•Start-up and acceptance test contains instructions on starting
up the module and the acceptance test for the Safe motor
temperature function.
•Fault tracing shows how to trace faults with the status LEDs on
the module.
•Technical data contains the technical data of the module, the
safety data and relevant certificates and Declarations of
Conformity.
Related documents
•Product manuals, see the inside of the front cover.
•ACS880 cabinet-built drives: Circuit diagrams delivered with
the drive.

Introduction to the manual 17
Terms and abbreviations
Term/abbreviation Description
Cat. Category. 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.
CCF Common cause failure (EN ISO 13849-1)
DC Diagnostic coverage (%) (EN ISO 13849-1)
DI Digital input
DO Digital output
DTC Direct torque control
EMC Electromagnetic compatibility
Ex An IEC term used in the context of explosive
atmospheres
Ex d Type of protection, flameproof enclosures
(EN/IEC 60079-1)
Ex e Type of protection, increased safety
(EN 60079-7:2007 and IEC 60079-7:2006), to be
replaced with Ex eb
Ex eb, Ex ec Types of protection, increased safety
(IEC 60079-7:2015)
Ex motors Motors used in explosive atmospheres
Ex nA Type of protection, non-sparking enclosures
(EN/IEC 60079-15:2010), to be replaced with Ex ec
FEA-03 F-series extension adapter module
FPTC-01 Thermistor protection module
FSE-31 Pulse encoder interface module which can be used
in safety applications
FSO Safety functions module (FSO-12 or FSO-21)
FSO-12 Safety functions module which does not support the
use of safety encoders

18 Introduction to the manual
FSO-21 Safety functions module which supports the FSE-31
module and the use of safety encoders
GND Ground
HFT Hardware fault tolerance. (EN/IEC 62061,
IEC 61508)
MTTFDMean time to dangerous failure: (The total number
of life units) / (the number of dangerous, undetected
failures) during a particular measurement interval
under stated conditions (EN ISO 13849-1)
PELV Protected extra-low voltage (IEC 60364-4-41)
PFDavg Average probability of dangerous failure on demand
(IEC 61508, EN/IEC 61800-5-2, EN/IEC 62061)
PFH Average frequency of dangerous failures per hour
[1/h]
(IEC 61508, EN/IEC 61800-5-2, EN/IEC 62061)
PL Performance level (levels are: a, b, c, d and e).
Corresponds to SIL. (EN ISO 13849-1)
PTC Positive temperature coefficient
SAR Safe acceleration range. In the FSO module, there
are two sets of SAR parameters (SAR0 and SAR1)
that are used to define and/or monitor the
deceleration ramp in safety functions.
Safety system Whole safety system including, for example, human
interface, FPTC-01 module, FSO module, drive and
sensors.
SBC Safe brake control. A safety function in the FSO
module.
SC Systematic capability (IEC 61508)
SFF Safe failure fraction (%) (IEC 61508).
SIL Safety integrity level (levels are: 1, 2, 3, and 4).
Corresponds to PL. (IEC 61508)
SILCL SIL claim limit. Maximum SIL that can be claimed for
a safety function or subsystem. (EN/IEC 62061)
SMT Safe motor temperature. (EN/IEC 61800-5-2)
Term/abbreviation Description

Introduction to the manual 19
SS1 Safe stop 1 (EN/IEC 61800-5-2).
A safety function in the FSO module.
SSE Safe stop emergency. A safety function in the FSO
module.
STO Safe torque off. (EN/IEC 61800-5-2)
In this manual, this term is used in two different
contexts:
• the STO circuit in the drive (the drive STO
function)
• the STO safety function in the FSO module.
Stop category 0 Uncontrolled stop (EN/IEC 60204-1)
Stop category 1 Controlled stop (EN/IEC 60204-1)
T1 Proof test interval (IEC 61508). T1 is a parameter
used to define the probabilistic failure rate (PFH or
PFDavg) for the safety function or subsystem.
Performing a proof test at a maximum interval of T1
is 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 T1
values stated cannot be regarded as a guarantee or
warranty. See also section Proof test interval on
page 74.
XFLT PTC input for the Safe motor temperature (SMT)
fault in the FPTC module
XWRN PTC input for a motor temperature warning in the
FPTC module
Zone Potentially explosive atmosphere. Hazardous areas
are divided into zones, according to the degree of
hazard. The degree of hazard is defined according
to the probability of the occurrence of explosive
atmospheres.
Term/abbreviation Description

20 Introduction to the manual
Exclusion of liability
ABB is not responsible for the implementation, verification and
validation of the overall safety system. It is the responsibility of the
end user (or other party) who is responsible for the overall system,
system safety and compliance with Ex regulations.
The end user (or other responsible party) must make sure that the
entire implementation complies with all relevant standards,
directives and local electrical code, and that the system is tested,
verified and validated correctly.