ABB FPTC-01 User manual

—

OPTIONS FOR ABB DRIVES

FPTC-01 thermistor protection module

(option +L536) for ACS880 drives

User's manual

FPTC-01 thermistor protection module

(option +L536) for ACS880 drives

User's manual

Table of contents

1. Safety instructions

5. Mechanical installation

6. Electrical installation

8. Start-up and validation test

3AXD50000027750 Rev D

EN

EFFECTIVE: 2020-11-18

Table of contents

1 Safety instructions

9Contents of this chapter ............................................................

9Use of warnings and notes .......................................................

10Instructions for functional safety circuits ...................................

12Electrical safety precautions .....................................................

2 Introduction to the manual

15Contents of this chapter ............................................................

15Applicability ...............................................................................

15Compatibility .............................................................................

16Target audience ........................................................................

16Exclusion of liability ...................................................................

16Related manuals .......................................................................

18Terms and abbreviations ...........................................................

3 Hardware description

21Contents of this chapter ............................................................

21Product overview ......................................................................

22Operation basics .................................................................

22XFLT input (Fault) ........................................................

22XWRN input (Warning) .................................................

23Layout .................................................................................

24Markings ...................................................................................

4 Option description and instructions

25Contents of this chapter ............................................................

25Overview ...................................................................................

26

Wall-mounted drives, drive modules and inverter

modules ..............................................................................

26Cabinet-built drives .............................................................

27Commissioning the drive for a motor in a hazardous area .......

27Resetting the safety function ....................................................

27Indications of the safety function ..............................................

Table of contents 5

28Fault reaction function ...............................................................

28FPTC-01 module ................................................................

29STO function in the drive/inverter .......................................

29FSO module .......................................................................

5 Mechanical installation

31Contents of this chapter ............................................................

31Necessary tools and instructions ..............................................

31Unpacking and examining the delivery .....................................

32Installing the module .................................................................

6 Electrical installation

35Contents of this chapter ............................................................

35Warnings ...................................................................................

36Necessary tools and instructions ..............................................

36General wiring instructions .......................................................

37Terminal designations ...............................................................

37PTC sensor inputs ....................................................................

37XFLT input ..........................................................................

38XWRN input ........................................................................

38Wiring examples .......................................................................

40Wiring example 1 ................................................................

41Wiring example 2 ................................................................

42Wiring example 3 ................................................................

43Wiring example 4 ................................................................

44Wiring example 5 ................................................................

7 Parameter settings

45Contents of this chapter ............................................................

45Drive / inverter ...........................................................................

47Switching frequency limitation ............................................

48Other recommended settings .............................................

48FSO module ..............................................................................

50General parameters ............................................................

51Parameters for the STO function ........................................

54Parameters for the SSE function ........................................

55FSE module and safety encoder parameters .....................

6 Table of contents

27

57Notes ..................................................................................

58Mechanical brake control ..........................................................

8 Start-up and validation test

59Contents of this chapter ............................................................

59Validation of the safety functions ..............................................

59Competence .......................................................................

60Validation procedure ...........................................................

60Validation test reports .........................................................

61Validation test ............................................................................

9 Fault tracing

65Contents of this chapter ............................................................

65Reporting problems and failures related to safety functions .....

65FPTC-01 module replacement ..................................................

66Fault and warning messages ....................................................

68LEDs .........................................................................................

10 Maintenance

69Contents of this chapter ............................................................

69Safety circuit maintenance ........................................................

70Proof test ...................................................................................

70Proof test interval ......................................................................

71Competence ..............................................................................

71Residual risk .............................................................................

71Intentional misuse .....................................................................

71Decommissioning ......................................................................

11 Technical data

73Contents of this chapter ............................................................

74Dimension drawing ...................................................................

74Isolation areas ...........................................................................

76Connections ..............................................................................

76Motor thermistor connection ...............................................

76STO output connection .......................................................

77Ambient conditions ....................................................................

77Safety data ................................................................................

Table of contents 7

78Safety block diagrams ...............................................................

79Two-channel configurations ................................................

80One-channel configurations ...............................................

81Response times ........................................................................

81Relevant failure modes .............................................................

82Related standards and directives .............................................

82Compliance with the European Machinery Directive ................

84TÜV Nord certificate ..................................................................

Further information

8 Table of contents

27

1

Safety instructions

Contents of this chapter

This chapter contains the safety instructions which you must obey

when you install, operate and do maintenance on the safety functions

of a drive.

Use of warnings and notes

Warnings tell you about conditions which can cause injury or death,

or damage to the equipment. They also tell you how to prevent the

danger. Notes draw attention to a particular condition or fact, or give

information on a subject.

The manual uses these warning symbols:

WARNING!

Electricity warning tells about hazards from electricity which

can cause injury or death, or damage to the equipment.

Safety instructions 9

WARNING!

General warning tells about conditions, other than those

caused by electricity, which can cause injury or death, or

damage to the equipment.

WARNING!

Electrostatic sensitive devices warning tells you about the risk

of electrostatic discharge which can cause damage to the

equipment.

Instructions for functional safety circuits

WARNING!

Obey the safety instructions of the drive. If you ignore

them, injury or death, or damage to the equipment can

occur.

This manual does not contain the complete safety instructions of the

drive. It only includes the instructions related to the scope of this

manual. The general instructions are given in this section and the

option-specific instructions in the applicable chapter.

If the motor thermal protection function is used with an Ex motor,

obey all safety regulations required with application of Ex motors in

Zone 1/21 (equipment category 2) or Zone 2/22 (equipment category

2 or 3) and the requirements of IEC/EN 60079-14.

In addition to this manual:

• for ACS880 single drives, see the drive hardware manual

• for ACS880 air-cooled multidrives, multidrive modules and single

drive modules, see ACS880 multidrive cabinets and modules

safety instructions (3AUA0000102301 [English])

10 Safety instructions

28

• for ACS880 liquid-cooled multidrives, multidrive modules and

single drive modules, see ACS880 liquid-cooled multidrive

cabinets and modules safety instructions (3AXD50000048633

[English]).

WARNING!

The safety function described in this manual does not isolate

the main circuit or auxiliary circuit from the power supply. Do

not do work on the drive, motor cable or motor before you

have isolated the drive system from all power supplies and

measured that there are no dangerous voltages. Before you

start the work, do the steps in section Electrical safety

precautions (page 12).

WARNING!

If a short-circuit occurs in the output stage of the drive, the

STO function does not prevent the intermediate DC current

from flowing through and heating up the motor. The system

integrator must take this into account when planning the

protection of the installation.

Safety instructions 11

Electrical safety precautions

These electrical safety precautions are for all personnel who do work

on the drive, motor cable or motor.

WARNING!

Obey these instructions. If you ignore them, injury or death,

or damage to the equipment can occur.

If you are not a qualified electrical professional, do not do

installation or maintenance work.

Go through these steps before you begin any installation or

maintenance work.

1. Clearly identify the work location and equipment.

2. Disconnect all possible voltage sources. Make sure that

re-connection is not possible. Lock out and tag out.

• Open the main disconnecting device of the drive.

• If you have a permanent magnet motor connected to the

drive, disconnect the motor from the drive with a safety switch

or by other means.

• Disconnect all dangerous external voltages from the control

circuits.

• After you disconnect power from the drive, always wait 5

minutes to let the intermediate circuit capacitors discharge

before you continue.

3. Protect any other energized parts in the work location against

contact.

4. Take special precautions when close to bare conductors.

12 Safety instructions

28

5. Measure that the installation is de-energized.

• Before and after measuring the installation, verify the

operation of the voltage tester on a known voltage source.

• Make sure that the voltage between the drive input power

terminals (L1, L2, L3) and the grounding (PE) busbar is zero.

• Make sure that the voltage between the drive output terminals

(T1/U, T2/V, T3/W) and the grounding (PE) busbar is zero.

• Make sure that the voltage between the drive DC terminals

(UDC+ and UDC-) and the grounding (PE) terminal is zero.

In cabinet-built drives, measure between the drive DC

busbars (+ and -) and the grounding (PE) busbar.

6. Install temporary grounding as required by the local regulations.

7. Ask the person in control of the electrical installation work for a

permit to work.

Safety instructions 13

14

2

Introduction to the manual

Contents of this chapter

This chapter gives basic information on the manual.

Applicability

This manual is applicable to the FPTC-01 module and to the Safe

motor temperature safety (SMT) function which uses the FPTC-01

module (option +L536).

Compatibility

The FPTC-01 module is compatible with:

• ACS880-01/11/31 drives

• ACS880-04/04XT/04F/04FXT/M04/14/34 drive modules

• ACS880-104/104LC inverter modules

• ACS880-07/07LC/17/17LC/37/37LC cabinet-built drives

Introduction to the manual 15

• ACS880-107/107LC inverter units

• FSO-12 and FSO-21 safety functions modules

• ACS880 primary control program version 2.10 or later. For the

compatibility of other control programs, contact your local ABB

representative.

Target audience

This manual is intended for people who plan the installation, install,

start up, use and service the module. Before you do work on the

module, read this manual and the applicable drive manual that

contains the hardware and safety information for the product in

question. You are expected to know the fundamentals of electricity,

wiring, electrical components, electrical schematic symbols, functional

safety, and Ex regulations.

Exclusion of liability

ABB is not responsible for the implementation, verification and

validation of the overall safety system. It is the responsibility of the

system integrator (or other party) who is responsible for the overall

system and system safety.

The system integrator (or other responsible party) must make sure

that the entire implementation complies with the instructions in this

manual, all relevant standards, directives and local electrical code,

and that the system is tested, verified and validated correctly.

Related manuals

CodeName

Drive hardware

3AUA0000078093ACS880-01 hardware manual

3AXD50000045932ACS880-11 hardware manual

3AXD50000045933ACS880-31 hardware manual

16 Introduction to the manual

CodeName

3AUA0000128301ACS880-04 drive modules (200 to 710 kW, 300 to 700

hp) hardware manual

3AUA0000138495ACS880-04 single drive module packages (560 to 2200

kW) hardware manual

3AXD50000034664ACS880-04F drive modules hardware manual

3AXD50000025169ACS880-04XT drive module packages (500 to 1200

kW) hardware manual

3AXD50000274444ACS880-04FXT drive module packages hardware

manual

3AXD50000028613ACS880-M04 drive hardware manual

3AXD50000035160ACS880-14 drive modules (132 to 400 kW) hardware

manual

3AXD50000035191ACS880-34 drive modules (132 to 400 kW) hardware

manual

3AXD50000022021ACS880-14 and -34 single drive module packages

hardware manual

3AUA0000105718ACS880-07 drives (45 to 710 kW) hardware manual

3AUA0000143261ACS880-07 drives (560 to 2800 kW) hardware manual

3AXD50000569786ACS880-07LC drives hardware manual

3AXD50000020436ACS880-17 drives (160 to 3200 kW) hardware manual

3AXD50000035158ACS880-17 drives (45 to 400 kW, 60 to 450 hp) hard-

ware manual

3AXD50000250295ACS880-17LC drives hardware manual

3AXD50000020437ACS880-37 drives (160 to 3200 kW) hardware manual

3AXD50000035159ACS880-37 drives (45…400 kW, 60…450 hp) hard-

ware manual

3AXD50000251407ACS880-37LC drives hardware manual

Inverter hardware

3AUA0000104271ACS880-104 inverter modules hardware manual

3AXD50000045610ACS880-104LC inverter modules hardware manual

3AUA0000102519ACS880-107 inverter units hardware manual

3AXD50000196111ACS880-107LC inverter units hardware manual

Drive firmware

3AUA0000085967ACS880 primary control program firmware manual

Introduction to the manual 17

CodeName

PC tools

3AUA0000094606Drive composer start-up and maintenance PC tool

user's manual

Safety

3AUA0000048753Functional safety; Technical guide No. 10

www.abb.com/safetyABB Safety information and solutions

3AUA0000037223Motors and drives in potentially explosive atmospheres

- What you need to know

Option manuals

3AUA0000085685ACS-AP-x assistant control panels user’s manual

3AXD50000015612FSO-12 safety functions module user's manual

3AXD50000015614FSO-21 safety functions module user’s manual

3AXD50000016597FSE-31 pulse encoder interface module user’s manual

3AXD50000027750FPTC-01 thermistor protection module (option +L536)

user’s manual

Manuals and quick guides for I/O extension modules,

fieldbus adapters, etc.

See www.abb.com/drives/documents for all manuals on the Internet.

Terms and abbreviations

DescriptionTerm

Classification of the safety-related parts of a control system

in respect of their resistance to faults and their subsequent

behavior in the fault condition, and which is achieved by the

structural arrangement of the parts, fault detection and/or by

their reliability. The categories are: B, 1, 2, 3 and 4. (EN ISO

13849-1)

Cat.

Common cause failure (%) (EN ISO 13849-1)CCF

Diagnostic coverage (EN ISO 13849-1)DC

Digital inputDI

Frequency converter for controlling AC motorsDrive

Frequency converter enclosed in a metal frame or enclosure.

Intended for cabinet installation.

Drive module

Electromagnetic compatibilityEMC

18 Introduction to the manual

DescriptionTerm

An IEC term used in the context of explosive atmospheres

(IEC 60079)

Ex

Type of protection, flameproof enclosures (IEC/EN 60079-1)Ex d

Types of protection, increased safety (IEC/EN 60079-7)Ex eb, Ex ec

Motors used in explosive atmospheresEx motors

Optional I/O extension adapterFEA-03

Optional thermistor protection moduleFPTC-01

Optional pulse encoder interface module for safety encoderFSE-31

Safety functions module which supports the FSE-31 module

and the use of safety encoders

FSO-21

Safety functions module which does not support the use of

encoders

FSO-12

Hardware fault tolerance (IEC 61508)HFT

Inverter bridge, related components and drive DC link capa-

citors enclosed in a metal frame or enclosure. Intended for

cabinet installation.

Inverter module

Inverter module(s) under control of one control unit, and re-

lated components. One inverter unit typically controls one

motor.

Inverter unit

Mean time to dangerous failure: (Total number of life units)

/ (Number of dangerous, undetected failures) during a partic-

ular measurement interval under stated conditions (EN ISO

13849-1)

MTTF

D

Average probability of dangerous failure on demand (IEC

61508)

PFD

avg

Average frequency of dangerous failures per hour (IEC

61508)

PFH

Performance level. Levels a...e correspond to SIL (EN ISO

13849-1)

PL

Periodic test performed to detect failures in the safety func-

tion. The target of the proof test is to ensure that the safety

function still operates correctly and is able to achieve the

safe state. (IEC 61508, IEC 62061)

Proof test

Safe acceleration rangeSAR

Safe brake controlSBC

Systematic capability (IEC 61508)SC

Safe failure fraction (%) (IEC 61508)SFF

Introduction to the manual 19

DescriptionTerm

Safety integrity level (1...3) (IEC 61508)SIL

Maximum SIL (level 1...3) that can be claimed for a safety

function or subsystem (IEC/EN 62061)

SILCL

Safe motor temperature (IEC/EN 61800-5-2)SMT

Safe stop 1 (IEC/EN 61800-5-2)SS1

Safe stop emergencySSE

Safe torque off (IEC/EN 61800-5-2)STO

There are three categories of stop functions defined by

IEC/EN 60204-1:

• stop category 0: an uncontrolled stop where power to

the machine actuators is removed immediately (for ex-

ample, STO)

• stop category 1: a controlled stop where the machine

actuators have power for stopping, after which the power

is removed (SS1)

• stop category 2: a controlled stop where the machine

actuators continue to have power (SS2).

Stop category

Proof test interval. Defines the probabilistic failure rate (PFH

or PFD

avg

) for the safety function or subsystem. Performing

a proof test at a maximum interval of T

1

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 T

1

values given cannot be regarded as a guarantee or

warranty.

T

1

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 T

M

values

given cannot be regarded as a guarantee or warranty.

(EN ISO 13849-1, IEC 61800-5-2)

T

M

Confirmation by, for example, analysis that the safety system

meets the functional safety requirements of the specific ap-

plication.

Validation

Confirmation by, for example, testing that the safety system

meets the requirements set by the specification.

Verification

Potentially explosive atmosphere. Hazardous areas are di-

vided into zones, based on the frequency and duration of the

occurrence of an explosive atmosphere. (IEC/EN 60079)

Zone

20 Introduction to the manual

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ABB FPTC-01 User manual

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