ABB FPTC-02 User manual

—
OPTIONS FOR ABB 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 validation test
3AXD50000027782 Rev H
EN
Original instructions
EFFECTIVE: 2023-16-11

Table of contents
1 Safety instructions
9Contents of this chapter ........................................................................
9Use of warnings and notes .....................................................................
9ATEX/UKEX-certified motor thermal protection functions .............................
10Instructions for functional safety circuits ...................................................
2 Introduction to the manual
11Contents of this chapter ........................................................................
11Applicability ........................................................................................
11Compatibility ......................................................................................
11Target audience ...................................................................................
12Exclusion of liability ..............................................................................
12Related manuals ..................................................................................
13Terms and abbreviations .......................................................................
3 Hardware description
15Contents of this chapter ........................................................................
15Product overview .................................................................................
15Operation basics ..............................................................................
15XFLT input (Fault) .........................................................................
16XWRN input (Warning) ....................................................................
17Layout ...........................................................................................
18Markings ............................................................................................
18Module ...........................................................................................
18Type designation label ...................................................................
18ATEX/UKEX markings ....................................................................
19Drive .............................................................................................
19SMT function ...............................................................................
19Option +Q971 ...............................................................................
4 Option description and instructions
21Contents of this chapter ........................................................................
21Overview ............................................................................................
21Wall-mounted drives, drive modules and inverter modules ..........................
22Cabinet-built drives ..........................................................................
22Safe disconnection function ...................................................................
22Commissioning the drive for a motor in a hazardous area ..............................
23Resetting the safety function ..................................................................
23Indications of the safety function ............................................................
23Fault reaction function ..........................................................................
23FPTC-02 module ...............................................................................
24STO function in the drive/inverter ........................................................
24FSO module ....................................................................................
Table of contents 5

5 Mechanical installation
25Contents of this chapter ........................................................................
25Necessary tools and instructions .............................................................
25Unpacking and examining the delivery ......................................................
25Installing the module ............................................................................
6 Electrical installation
27Contents of this chapter ........................................................................
27Warnings ...........................................................................................
27Necessary tools and instructions .............................................................
28General wiring instructions .....................................................................
28Terminal designations ...........................................................................
28PTC sensor inputs ................................................................................
28XFLT input ......................................................................................
29XWRN input .....................................................................................
29Wiring examples ..................................................................................
30Wiring example 1 ..............................................................................
31Wiring example 2 ..............................................................................
32Wiring example 3 ..............................................................................
33Wiring example 4 ..............................................................................
34Wiring example 5 ..............................................................................
7 Parameter settings
35Contents of this chapter ........................................................................
35Drive / inverter ....................................................................................
37Switching frequency limitation ............................................................
37Other recommended settings ..............................................................
37FSO module ........................................................................................
38General parameters ..........................................................................
39Parameters for the STO function ..........................................................
41Parameters for the SSE function ..........................................................
41FSE module and safety encoder parameters ...........................................
42Notes ............................................................................................
43Mechanical brake control .......................................................................
8 Start-up and validation test
45Contents of this chapter ........................................................................
45Validation of the safety functions ............................................................
45Competence ....................................................................................
45Validation procedure .........................................................................
46Validation test reports .......................................................................
46Validation test .....................................................................................
9 Fault tracing
49Contents of this chapter ........................................................................
49Reporting problems and failures related to safety functions ...........................
49FPTC-02 module replacement .................................................................
49Fault andwarning messages ...................................................................
50LEDs .................................................................................................
6 Table of contents

10 Maintenance
51Contents of this chapter ........................................................................
51Safety circuit maintenance .....................................................................
51Proof test ...........................................................................................
51Proof test interval ................................................................................
52Functional safety components ................................................................
52Competence .......................................................................................
52Residual risk .......................................................................................
53Intentional misuse ................................................................................
53Decommissioning ................................................................................
11 Technical data
55Contents of this chapter ........................................................................
56Dimension drawing ..............................................................................
57Isolation areas .....................................................................................
57Connections .......................................................................................
57Motor thermistor connection ..............................................................
58STO output connection ......................................................................
58Ambient conditions ..............................................................................
58Safety data .........................................................................................
59Safety block diagrams ...........................................................................
59Two-channel configurations ................................................................
60One-channel configurations ................................................................
61Response times ...................................................................................
61Relevant failure modes ..........................................................................
61Related standards and directives .............................................................
62Compliance with the Machinery Directive (EU) ............................................
62Compliance with the Supply of Machinery (Safety) Regulations (UK) .................
62Compliance with the ATEX Directive (EU) ...................................................
62Compliance withthe UKEX Directive(UK) ...................................................
63Declaration ofConformity (EU) ................................................................
65Declaration of Conformity (UK) ...............................................................
67ATEX certificate ...................................................................................
69UKEX certificate ...................................................................................
71TÜV Nord certificate .............................................................................
Further information
Table of contents 7

8

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.
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).
1
Safety instructions 9

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. If you are not a qualified
electrical professional, do not do installation, commissioning or
maintenance work.
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])
•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 electrical safety precautions in the drive safety instructions.
10 Safety instructions
3

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
• ACS880-07/07LC/17/17LC/37/37LC cabinet-built drives
• 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 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,
2
Introduction to the manual 11

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
3AUA0000078093ACS880-01 hardware manual
3AXD50000045932ACS880-11 hardware manual
3AXD50000045933ACS880-31 hardware manual
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) hardware manual
3AXD50000250295ACS880-17LC drives hardware manual
3AXD50000020437ACS880-37 drives (160 to 3200 kW) hardware manual
3AXD50000035159ACS880-37 drives (45…400 kW, 60…450 hp) hardware 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
12 Introduction to the manual

CodeName
Drive firmware
3AUA0000085967ACS880 primary control program firmware manual
PC tools
3AUA0000094606Drive composer start-up and maintenance PC tool user's manual
Safety
www.abb.com/safetyABB Safety information and solutions
3AXD50001096700FPTC-02 pairing instruction
3AUA0000037223Motors and drives in potentially explosive atmospheres - What you need
to know
ht-
tps://new.abb.com/drives/seg-
ments/motors-and-drives-in-
potentially-explosive-atmo-
spheres
Using motors with drives in potentially explosive atmospheres
Option manuals
3AUA0000085685ACS-AP-I, -S, -W and ACH-AP-H, -W 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
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 referred to as the ATEX
directives (from "Atmosphères Explosibles")
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 detec-
tion 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
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
Introduction to the manual 13

DescriptionTerm
Optional ATEX-certified thermistor protection module for potentially 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 encodersFSO-12
Hardware fault tolerance (IEC 61508)HFT
Inverter bridge, related components and drive DC link capacitors enclosed in
a metal frame or enclosure. Intended for cabinet installation.
Inverter module
Inverter module(s) under control of one control unit, and related 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 particular 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 a safety-related system so that,
if necessary, a repair can restore the system to an “as new” condition or as
close as practical to this condition. (IEC 61508, IEC 62061)
Proof test
Safe acceleration rangeSAR
Safe brake controlSBC
Systematic capability (IEC 61508)SC
Safe failure fraction (%) (IEC 61508)SFF
Safety integrity level (1…3) (IEC 61508, IEC 62061, IEC 61800-5-2)SIL
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 example, 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 in-
terval 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 T1
values 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 Explos-
ive 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 application.
Validation
Confirmation by, for example, testing that the safety system meets the re-
quirements set by the specification.
Verification
Potentially explosive atmosphere. Hazardous areas are divided into zones,
based on the frequency and duration of the occurrence of an explosive atmo-
sphere. (IEC/EN 60079-10)
Zone
14 Introduction to the manual

Hardware description
Contents of this chapter
This chapter gives a short description of the module.
Product overview
The FPTC-02 module together with the drive/inverter STO implements the Safe motor
temperature (SMT) safety function as defined in IEC/EN 61800-5-2.
The FPTC-02 module is Type Examined as a protective device within the scope of the
European ATEX (and UKEX) Product Directive. This allows the use of the module in
temperature protection of motors in explosive atmospheres (Ex motors).
Inside the module, there is reinforced insulation between the motor thermistor
connection and the other terminals of the module. The insulation forms a reliable
protective separation between the motor main circuit and the drive control circuits.
Thus, the drive control unit is Protective Extra Low Voltage (PELV) compatible also
when the FPTC-02 module and a thermistor protection circuit are installed.
￭Operation basics
The module includes two PTC sensor inputs:
•XFLT activates the ATEX/UKEX-certified SIL/PL capable SMT safety function by
activating the drive Safe torque off (STO) function. This input is a safety-related
input and can be used for protection function purposes.
•XWRN generates a warning to the drive. This is not a safety-related input and can
only be used for indication purposes.
XFLT input (Fault)
When the motor temperature rises above the PTC sensor temperature limit, the sensor
resistance increases sharply. This indicates overtemperature to the FPTC-02 module.
3
Hardware description 15

The FPTC-02 module then activates the SMT function by opening the drive Safe torque
off (STO) circuit. This activates the drive STO function.
The STO function disables the control voltage of the power semiconductors of the
drive output stage. This prevents the drive from generating the torque required to
rotate the motor. If the motor is running when the STO function is activated, it coasts
to a stop.
XWRN input (Warning)
When the motor temperature increases above the PTC sensor temperature limit, the
sensor resistance increases sharply. The FPTC-02 module sends a warning indication
to the drive. The XWRN input is not safety-related and does not activate the drive STO
function.
For the resistance limits and other technical details of the FPTC-02 module, see the
technical data.
16 Hardware description

￭Layout
1
1
2
4
3
XSTO2
XSTO1
XWRN
XFLT
Retaining clips1
Lock2
Diagnostics LEDs3
Mounting screw4
2-pin detachable terminal block for PTC warning (non-safety related)XWRN
2-pin detachable terminal block for PTC fault (safety related)XFLT
2-pin detachable terminal block for STO output 1XSTO1
2-pin detachable terminal block for STO output 2XSTO2
Hardware description 17

Markings
￭Module
Type designation label
3AXD50000017196A5450043WS ROHS
ABB OY FPTC-02 SN:A5450043WS CODE:3AXD50000017196
1 2 3
4 5
Type1
Serial number in format RYWWSSSSWS, where:2
R: Component revision
Y: Last digit of the manufacturing year (for example, 5 = 2015)
WW: Manufacturing week (for example, 01 = week 1)
SSSS: Number that starts every week from 0001
WS: Manufacturing location
ABB MRP code of the module3
Combined ABB MRP code, serial number and manufacturing location4
RoHS mark5
ATEX/UKEX markings
The markings on the module show the ATEX/UKEX classification of the FPTC-02
module.
12 3 4
Specific marking of explosion protection1
Equipment group II: Product for surface industry (other than mining applications)2
Equipment category 2. Parentheses show that the module must be installed outside the potentially
explosive atmosphere.
3
Certified for use in explosive atmospheres caused by:4
G = gases, vapors or mists, D = dust.
18 Hardware description

￭Drive
SMT function
When the FPTC-02 module is delivered as an add-on kit, the package contains a sticker
to show the ATEX/UKEX classification of the Safe motor temperature (SMT) function.
The user must attach this sticker near the type designation label of the drive/inverter
to ensure the ATEX/UKEX compliance of the safety circuit.
In the factory-installed options, this sticker is already attached to the drive/inverter
module at the factory.
In the cabinet-built drives, this sticker is attached to the cabinet door at the factory.
1 2 3 4 5 6
7
CE marking with Notified Body identification: The manufacturer declares that the product conforms
with ATEX Product Directive 2014/34/EU.
1
Notified Body: Eurofins Expert Services
UKCA marking with Approved Body identification: The manufacturer declares that the product
conforms with The Equipment and Protective Systems Intended for Use in Potentially Explosive
Atmospheres Regulations 2016 (+ amendment SI 2019 No. 696).
2
Approved Body: Eurofins E&E CML Limited
Specific marking of explosion protection3
Equipment group II: Product for surface industry (other than mining applications)4
Equipment category 2. Parentheses show that the drive (or inverter unit) must be installed outside
the potentially explosive atmosphere.
5
Certified for use in explosive atmospheres caused by:6
G = gases, vapors or mists, D = dust.
Certificate references7
3AXD50000003122 E
Option +Q971
When the FPTC-02 module is ordered as a factory-installed option, some products
have an additional sticker attached to the drive/inverter module to signify ATEX/UKEX
classification of the Safe disconnection function (option +Q971). This sticker and the
ATEX/UKEX certification reference are not mandatory with the FPTC-02 module.
Hardware description 19

1 2 3 4 5 6
7
CE marking with Notified Body identification: The manufacturer declares that the product conforms
with ATEX Product Directive 2014/34/EU.
1
Notified Body: Eurofins Expert Services
UKCA marking with Approved Body identification: The manufacturer declares that the product
conforms with The Equipment and Protective Systems Intended for Use in Potentially Explosive
Atmospheres Regulations 2016 (+ amendment SI 2019 No. 696).
2
Approved Body: Eurofins E&E CML Limited
Specific marking of explosion protection3
Equipment group II: Product for surface industry (other than mining applications)4
Equipment category 2. Parentheses show that the drive (or inverter unit) must be installed outside
the potentially explosive atmosphere.
5
Certified for use in explosive atmospheres caused by:6
G = gases, vapors or mists, D = dust.
Certificate references7
The option code +Q971 is included in the type designation label of the drive. In
cabinet-built drives, this is on the cabinet door. In cabinet-built drives, there is no
separate ATEX/UKEX classification label for the Safe disconnection function.
20 Hardware description