ABB FPTC-02 User manual

—
ABB INDUSTRIAL DRIVES
FPTC-02 ATEX-certified thermistor
protection module, Ex II (2) GD (option
+L537+Q971) for ACS880 drives
User's manual

FPTC-02 ATEX-certified thermistor
protection module, Ex II (2) GD (option
+L537+Q971) for ACS880 drives
User's manual
Table of contents
1. Safety instructions
5. Mechanical installation
6. Electrical installation
8. Start-up and acceptance test
3AXD50000027782 Rev E
EN
EFFECTIVE: 2020-02-28
© 2020 ABB Oy. All Rights Reserved.

Table of contents
1 Safety instructions
9Contents of this chapter ............................................................
9Use of warnings and notes .......................................................
10ATEX-certified motor thermal protection functions ...................
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 ......................................................................
21General ...............................................................................
22Operation basics .................................................................
22XFLT input (Fault) ........................................................
22XWRN input (Warning) .................................................
23Layout .................................................................................
24Markings ...................................................................................
24Module ................................................................................
24Type designation label .................................................
25ATEX markings ............................................................
25Drive ...................................................................................
25Option +Q971 ...............................................................
26SMT function ................................................................
4 Option description and instructions
29Contents of this chapter ............................................................
Table of contents 5

29Overview ...................................................................................
30Drives and modules ............................................................
30Cabinet-built drives .............................................................
31The ATEX-certified Safe disconnection function .......................
31Commissioning the drive for a motor in a hazardous area .......
31Resetting the safety function ....................................................
32Indications of the safety function ..............................................
33Fault reaction function ...............................................................
33FPTC-02 module ................................................................
33STO function in the drive/inverter modules ........................
33FSO module .......................................................................
5 Mechanical installation
35Contents of this chapter ............................................................
35Necessary tools and instructions ..............................................
35Unpacking and examining the delivery .....................................
36Installing the module .................................................................
6 Electrical installation
39Contents of this chapter ............................................................
39Warnings ...................................................................................
40Necessary tools and instructions ..............................................
40General wiring instructions .......................................................
41Terminal designations ...............................................................
41Wiring ........................................................................................
43Wiring example 1 ................................................................
44Wiring example 2 ................................................................
45Wiring example 3 ................................................................
46Wiring example 4 ................................................................
47Wiring example 5 ................................................................
7 Parameter settings
49Contents of this chapter ............................................................
49Drive / inverter ...........................................................................
52Switching frequency limitation ............................................
53Other recommended settings .............................................
6 Table of contents
27

53FSO module ..............................................................................
55General parameters ............................................................
56Parameters for the STO function ........................................
59Parameters for the SSE function ........................................
60FSE module and safety pulse encoder parameters ...........
62Notes ..................................................................................
62Mechanical brake control ..........................................................
8 Start-up and acceptance test
65Contents of this chapter ............................................................
65Validation of the safety functions ..............................................
65Competence .......................................................................
66Validation procedure ...........................................................
66Acceptance test reports ......................................................
67Acceptance test ........................................................................
9 Fault tracing
71Contents of this chapter ............................................................
71Reporting problems and failures related to safety functions .....
71FPTC-02 module replacement ..................................................
72Fault and warning messages ....................................................
74LEDs .........................................................................................
10 Maintenance
75Contents of this chapter ............................................................
75Safety circuit maintenance ........................................................
76Proof test interval ......................................................................
77Competence ..............................................................................
77Residual risk .............................................................................
77Intentional misuse .....................................................................
77Decommissioning ......................................................................
11 Technical data
79Contents of this chapter ............................................................
80Dimension drawing ...................................................................
80Isolation areas ...........................................................................
Table of contents 7

81Connections ..............................................................................
81Motor thermistor connection ...............................................
82STO output connection .......................................................
82Ambient conditions ....................................................................
82Safety data ................................................................................
84Safety block diagrams ...............................................................
84Two-channel configurations ................................................
85One-channel configurations ...............................................
86Response times ........................................................................
86Relevant failure modes .............................................................
87Related standards and directives .............................................
88Compliance with the European Machinery Directive ................
88Compliance with the European ATEX Directive ........................
91ATEX certificate ........................................................................
94TÜV 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-certified motor thermal protection functions
Only qualified specialists are permitted to install, control and maintain
the ATEX-certified motor thermal protection functions (see
EN/IEC 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).
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.
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 functions described in this manual do not disconnect the
voltage of the main and auxiliary circuits from the drive. Do
not do work on the drive, motor cable or motor when they are
energized. 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.
• 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.)
• Close the grounding switch or switches ([Q9], option +F259)
if present. Do not use excessive force as the switch has
electromagnetic interlocking.
•If the drive is equipped with a DC/DC converter unit (optional):
Open the DC switch-disconnector ([Q11], option +F286) of
the DC/DC converter. Open the disconnecting device of the
energy storage connected to the DC/DC converter unit
(outside 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.
•In the liquid cooling unit (if present), open the motor protective
circuit breaker(s) of the cooling pumps.
12 Safety instructions
28

• 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 any 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. 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).
• Use a multimeter with an impedance greater than 1 Mohm.
• Make sure that the voltage between the drive input power
terminals (L1, L2, L3) and the grounding (PE) busbar is close
to 0 V.
•Make sure that the voltage between the drive output terminals
(T1/U, T2/V, T3/W) and the grounding (PE) busbar is close
to 0 V.
• Make sure that the voltage between the drive DC busbars
(+ and -) and the grounding (PE) busbar is close to 0 V.
• Make sure that the voltage between the drive DC terminals
(R+/UDC+ and UDC-) and the grounding terminal (PE) is
close to 0 V.
WARNING!
The busbars inside the cabinet of liquid-cooled drives are
partially coated. Measurements made through the coating
are potentially unreliable, so only measure at uncoated
portions. Note that the coating does not constitute a safe
or touch-proof insulation.
Safety instructions 13

6. If the drive is not equipped with a grounding switch, 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.
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 FPTC-02 module and to the Safe
motor temperature safety (SMT) function which uses the FPTC-02
module (option +L537+Q971).
Compatibility
The FPTC-02 module is compatible with:
• ACS880-01/11/31 drives
• ACS880-04/04XT/04F/04FXT/M04/14/34 drive modules
• ACS880-104/104LC inverter modules
• ACS880-07/17/37 and ACS880-17LC/37LC cabinet-built single
drives
• ACS880-107/107LC inverter units
• FSO-12 and FSO-21 safety functions modules
Introduction to the manual 15

• ACS880 primary control program version 2.10 or later. For the
compatibility of other control programs, contact your local ABB
representative.
Target audience
The manual is intended for people who install, start-up, 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 and ATEX/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
3AUA0000138495ACS880-04 drive module packages hardware manual
3AXD50000045932ACS880-11 hardware manual
3AXD50000045933ACS880-31 hardware manual
3AXD50000022021ACS880-14 and -34 single drive module packages
hardware manual
3AXD50000034664ACS880-04F drive modules hardware manual
3AUA0000105718ACS880-07 drives (45 to 710 kW) hardware manual
16 Introduction to the manual

CodeName
3AUA0000143261ACS880-07 drives (560 to 2800 kW) 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
PC tools
3AUA0000094606Drive composer start-up and maintenance PC tool
user's manual
Safety
3AUA0000048753Functional safety; Technical guide No. 10
1SFC001008B0201Safety and functional safety; A general guide
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
3AXD50000027782FPTC-02 ATEX-certified thermistor protection module,
Ex II (2) GD (option +L537 +Q971) user’s manual
Introduction to the manual 17

CodeName
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
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
Diagnostic coverage (EN ISO 13849-1)DC
Digital inputDI
Direct torque control, a motor control methodDTC
Electromagnetic compatibilityEMC
An IEC term used in the context of explosive atmospheres
(IEC 60079)
Ex
Type of protection, flameproof enclosures (EN/IEC 60079-1)Ex d
Types of protection, increased safety (EN/IEC 60079-7)Ex eb, Ex ec
Motors used in explosive atmospheresEx motors
Optional I/O extension adapterFEA-03
Optional ATEX-certified thermistor protection module for po-
tentially explosive atmospheres
FPTC-02
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
18 Introduction to the manual

DescriptionTerm
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
Safe acceleration rangeSAR
Safe brake controlSBC
Systematic capability (IEC 61508)SC
Safe failure fraction (%) (IEC 61508)SFF
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 (EN/IEC 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:
• stop category 0: an uncontrolled stop where power to
the machine actuators is removed immediately (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
Introduction to the manual 19

DescriptionTerm
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)
TM
Potentially explosive atmosphere. Hazardous areas are di-
vided into zones, based on the frequency and duration of the
occurrence of an explosive atmosphere. (EN/IEC 60079)
Zone
20 Introduction to the manual