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

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)

MTTF

D

Mean 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)

PFD

avg

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

PFD

avg

) 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.

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ABB FPTC-01 User manual

ABB FPTC-01 User manual

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