ABB FPTC-02 User manual

Brand: ABB

Model: FPTC-02

Type: 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

EFFECTIVE: 2020-02-28

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

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

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

• 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

• 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

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

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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)

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)

MTTF

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)

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 PFD

avg

) for the safety function or subsystem. Performing

a proof test at a maximum interval of T

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

values given cannot be regarded as a guarantee or

warranty.

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 T

values

given cannot be regarded as a guarantee or warranty. (EN

ISO 13849-1)

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

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ABB FPTC-02 User manual

ABB FPTC-02 User manual

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