Related Manuals for ABB FPTC-02
Summary of Contents for ABB FPTC-02
- Page 1 — OPTIONS FOR ABB DRIVES FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971) for ACS880 drives User's manual...
- Page 3 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 Original instructions EFFECTIVE: 2023-16-11...
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Page 5: Table Of Contents
FPTC-02 module ........ - Page 6 FPTC-02 module replacement ........
- Page 7 Table of contents 7 10 Maintenance Contents of this chapter ............... . Safety circuit maintenance .
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Page 9: Safety Instructions
Safety instructions 9 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. -
Page 10: Instructions For Functional Safety Circuits
10 Safety instructions 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. -
Page 11: 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: •... -
Page 12: Exclusion Of Liability
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. -
Page 13: Terms And Abbreviations
FSO-21 safety functions module user’s manual 3AXD50000015614 FSE-31 pulse encoder interface module user’s manual 3AXD50000016597 FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option 3AXD50000027782 +L537 +Q971) user’s manual Manuals and quick guides for I/O extension modules, fieldbus adapters, etc. - Page 14 14 Introduction to the manual Term Description FPTC-02 Optional ATEX-certified thermistor protection module for potentially explosive atmospheres FSE-31 Optional pulse encoder interface module for safety encoder FSO-21 Safety functions module which supports the FSE-31 module and the use of safety encoders...
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Page 15: Hardware Description
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). -
Page 16: Xwrn Input (Warning)
16 Hardware description 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. -
Page 17: Layout
Hardware description 17 Layout ￭ XSTO2 XWRN XSTO1 XFLT Retaining clips Lock Diagnostics LEDs Mounting screw XWRN 2-pin detachable terminal block for PTC warning (non-safety related) XFLT 2-pin detachable terminal block for PTC fault (safety related) XSTO1 2-pin detachable terminal block for STO output 1 XSTO2 2-pin detachable terminal block for STO output 2... -
Page 18: Markings
Combined ABB MRP code, serial number and manufacturing location RoHS mark ATEX/UKEX markings The markings on the module show the ATEX/UKEX classification of the FPTC-02 module. Specific marking of explosion protection Equipment group II: Product for surface industry (other than mining applications) Equipment category 2. -
Page 19: 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. - Page 20 20 Hardware description CE marking with Notified Body identification: The manufacturer declares that the product conforms with ATEX Product Directive 2014/34/EU. 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.
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Page 21: Option Description And Instructions
Option description and instructions Contents of this chapter This chapter describes the Safe motor temperature function implemented with the FPTC-02 module and the drive Safe torque off function and gives instructions for the user. Overview To implement the Safe motor temperature (SMT) function, you can connect the FPTC-02 module directly to the drive Safe torque off (STO) circuit, or you can use it together with an FSO module. -
Page 22: Cabinet-Built Drives
European ATEX (and UKEX) Product Directive. For more information on the drive STO function, see the applicable hardware manual. You can use the FPTC-02 module only when serial number of the drive/inverter starts with 1, 4, 7, 8, M or Y. -
Page 23: Resetting The Safety Function
This is not a safety-related function, and does not need a reset. If an FSO module is used together with the FPTC-02 module, it is possible that you must reset the safety function also with a reset button connected to the FSO module. -
Page 24: Sto Function In The Drive/Inverter
24 Option description and instructions STO function in the drive/inverter ￭ The STO function in the drive/inverter has internal fault diagnostics and a fault reaction function. The fault reaction function causes a fault trip if it detects a redundancy fault of STO control signals or an internal failure. -
Page 25: Mechanical Installation
For a complete list of tools, see the applicable drive hardware manual. Unpacking and examining the delivery Open the option package. Make sure that the package contains: • FPTC-02 module • STO cable • ATEX/UKEX label (with the ATEX/UKEX classification markings) •... - Page 26 For more information, refer to the drive hardware manual. WARNING! Do not install the FPTC-02 module on an FEA-03 F-series extension adapter. The diagnostics of the module requires that you install it directly on the control unit.
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Page 27: Electrical Installation
Electrical installation 27 Electrical installation Contents of this chapter This chapter contains instructions on wiring the module. Warnings 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. -
Page 28: General Wiring Instructions
Install the drive or inverter unit, including the components of the ATEX-certified motor thermal protection function, outside the potentially explosive atmosphere. For the sensor connection, ABB recommends to use shielded twisted-pair cable. This type of cable decreases electromagnetic interference in the sensor circuit. -
Page 29: Xwrn Input
Note: If you do not connect a PTC sensor or resistor to the XWRN input, the WARNING LED of the module stays on. Wiring examples This section shows five methods to connect the FPTC-02 module to the drive. If you use a one-channel connection, make sure that you can reach the required safety integrity level (SIL). -
Page 30: Wiring Example 1
30 Electrical installation Wiring example 1 ￭ This connection is SIL 2 capable (redundancy between STO channels). FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 Ex M Control unit Potentially explosive atmosphere If necessary, you can also connect an external device (for example, an emergency stop button) between the XSTO input of the control unit and the XSTO1 and XSTO2 outputs of the FPTC module. -
Page 31: Wiring Example 2
Electrical installation 31 Wiring example 2 ￭ With an FSO module, two-channel connection. This connection is SIL 2 capable (redundancy between STO channels). FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 X111 Ex M X113 X114 Control unit Potentially explosive atmosphere... -
Page 32: Wiring Example
32 Electrical installation Wiring example 3 ￭ With an external safety relay, two-channel connection. This connection is SIL 2 capable (redundancy between STO channels). FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 Ex M Control unit External safety relay Potentially explosive atmosphere... -
Page 33: Wiring Example 4
Electrical installation 33 Wiring example 4 ￭ One-channel connection. This connection is SIL 1 capable (no redundancy between STO channels). FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 Ex M Control unit Potentially explosive atmosphere If necessary, you can also connect an external device (for example, an emergency stop button) between the XSTO input of the control unit and the XSTO2 output of the FPTC module. -
Page 34: Wiring Example 5
34 Electrical installation Wiring example 5 ￭ With an FSO module, one-channel connection. This connection is SIL 1 capable (no redundancy between STO channels). FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 X111 Ex M X113 X114 Control unit Potentially explosive atmosphere... -
Page 35: Parameter Settings
The drive generates a warning both when the drive is running and when it is stopped. This parameter value does not have an effect on the SMT function, but this is the recommended setting. For cab- inet-built drives, ABB sets this value at the factory. - Page 36 Name Description EX motor 1 = The driven motor is an Ex motor provided by ABB for potentially explosive atmospheres. This sets the required minimum switching frequency for ABB Ex motors. For non-ABB Ex motors, contact your local ABB represent-...
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Page 37: Switching Frequency Limitation
For more information, refer to the drive firmware manual. For Ex motors supplied by other motor manufacturers, contact the motor manufacturer for the correct value and your local ABB representative for instructions on how to make the parameter setting in the drive. -
Page 38: General Parameters
38 Parameter settings If you use the FSO-21 module (+Q972) with a FSE-31 pulse encoder interface module (+L521) and safety encoder, set the parameters listed in section FSE module and safety encoder parameters (page 41). The example values are factory default values in ACS880 cabinet-built drives delivered with an FPTC module. -
Page 39: Parameters For The Sto Function
Parameter settings 39 Index Name Example value Description FSOGEN.42 Acknowledgement Sets the digital input for the acknowledgement None button input signal when parameter STO.02 has value Manual. In the safety function described in this manual, parameter STO.02 has value Automatic and this parameter has value None (no acknowledgement signal connected to the input). - Page 40 40 Parameter settings Index Name Example value Description STO.14 Time to zero speed 2000 ms Sets the time that is needed to coast the motor to with STO and mod- a standstill from maximum process speed. If this time is not known, it can be measured with the Drive Composer pro PC tool when an encoder is used for motor control (otherwise you have to make sure that the motor shaft has stopped rotating by other...
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Page 41: Parameters For The Sse Function
Parameter settings 41 Parameters for the SSE function ￭ These parameters are related to the Safe stop emergency (SSE) function of the FSO module. The safety functions described in this manual do not use this function, but the FSO module can activate the SSE function in internal fault situations. Index Name Example value... -
Page 42: Notes
42 Parameter settings Index Name Example value Description S_ENCGEN.14 Enc speed cross 1.0 rpm Sets the encoder speed cross comparison tolerance. comp tolerance This defines how much the axle speed of the motor can change within 1 ms. Adjust the default value to meet the motor in use. This parameter is used for the encoder diagnostic. -
Page 43: Mechanical Brake Control
Parameter settings 43 Mechanical brake control If you use a mechanical brake with the motor thermal protection circuit, pay special attention to the control of the mechanical brake. If the motor deceleration by the mechanical brake causes extra heat generation in the Ex zone, make sure that the use of the brake does not increase the temperature too much. -
Page 45: Start-Up And Validation Test
Start-up and validation test 45 Start-up and validation test Contents of this chapter This chapter describes the start-up, validation test procedure, and validation of the safety function. Validation of the safety functions You must do a validation test to make sure that the safety function operates correctly and according to the safety requirements. -
Page 46: Validation Test Reports
46 Start-up and validation test • after maintenance work related to the safety function • at the proof test of the safety function. The validation test must include at least the following steps: • you must have a validation test plan •... - Page 47 Make sure that the SIL/PL of the safety function meets the target SIL/PL. If SIL2 is required, make sure that the STO connection between the FPTC-02 module and drive STO is kept redundant. Make sure that the wires are connected to the correct terminals and that the terminal connections are tightened to the correct torque.
- Page 48 48 Start-up and validation test Action Make sure that the correct indications are activated: the SMT fault and other indications depend- ing on the parameter settings and if an FSO module is installed. Make sure that the STO is activated and that the motor coasts to a stop. Make sure that you cannot start the drive before you reset the drive.
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Page 49: Fault Tracing
Contact ABB. FPTC-02 module replacement If there is a failure in the FPTC-02 module, you must replace it with a new one. Do not try to repair the module. Fault and warning messages Fault and warning messages in the ACS880 primary control program:... -
Page 50: Leds
(non-safety related). See A497. 1) Editable message text For the fault and warning messages of the FSO module, see the FSO module user’s manual. LEDs The FPTC-02 module has three diagnostic LEDs. Name Color Description FAULT The motor temperature is outside the permitted temperature range and the drive STO is active, or there is no PTC sensor connected to the XFLT input (safety-related). -
Page 51: Maintenance
After the safety function is validated, it must be maintained by periodic proof testing. If you change the wiring or a component after the start-up, replace a power unit or its circuit boards, replace the FPTC-02 module, modify parameters, or restore parameters to their factory default values: •... -
Page 52: Functional Safety Components
The FPTC-02 module, the FSO module and the STO circuit of the drive do not have electromechanical outputs. Functional safety components The mission time of functional safety components is 20 years which equals the time during which failure rates of electronic components remain constant. -
Page 53: Intentional Misuse
Maintenance 53 Intentional misuse The safety circuit is not designed to protect a machine against intentional misuse. Decommissioning When you decommission the module, make sure that the safety of the machine is maintained until the decommissioning is complete. Mark clearly on the module that it is decommissioned. -
Page 55: Technical Data
Technical data 55 Technical data Contents of this chapter This chapter contains the technical data of the module, gives general rules, notes and definitions related to safety functions and lists the related standards and directives. The safety data, relevant certificates and Declarations of Conformity are also included. -
Page 56: Dimension Drawing
56 Technical data Dimension drawing The dimensions are shown in millimeters and inches. -
Page 57: Isolation Areas
Technical data 57 Isolation areas The following figure shows the different isolation areas of the module. Isolation areas A and B and the mounting screw are connected to ground. Isolation area C is in the same potential as the PTC sensor element in the motor. XSTO1 XSTO2 XWRN... -
Page 58: Sto Output Connection
For the environmental limits for the safety functions and the drive, refer to the drive hardware manual. Safety data The FPTC-02 module is a type A safety component as defined in IEC 61508-2. For the types of the drive/inverter STO and the FSO module, see the applicable hardware manual or FSO user's manual. -
Page 59: Safety Block Diagrams
2.13E-04 DC (%) Cat. Type [A/B] 3AXD10000454332 J The MTTF value (EN ISO 13849-1) of the FPTC-02 module: • 1697 years (two-channel connection) • 1703 years (one-channel connection) Safety block diagrams The components that are included in the safety data calculations are shown in the safety block diagrams below. -
Page 60: One-Channel Configurations
60 Technical data This diagram is applicable to configuration 2. See Wiring example 2 (page 31). PTC sensor FPTC module FSO module (and FSE-31 module, if used) Drive STO Note: The failure rate of the safety encoder is not included in the calculation. This diagram is applicable to configuration 3. -
Page 61: Response Times
Response times • FPTC-02 module: less than 10 ms • SMT function: the response time of the PTC sensor + FPTC-02 module (<10 ms) + FSO module (<50 ms) + drive STO (<50 ms) Relevant failure modes • The SMT function activates when not necessary (safe failure) •... -
Page 62: Compliance With The Machinery Directive (Eu)
62 Technical data EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part 2: Valida- tion EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – Part 1: General re- quirements IEC 60204-1:2021 IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use –... -
Page 63: Declaration Of Conformity (Eu)
ACS880-04, -04XT, -04F, -04FXT, -M04, -14, -34, -104, -104LC ACS880-07, -17, -37, -107, -07CLC, -07LC, -17LC, -37LC, -107LC identified with serial numbers beginning with 1 or 8 with FPTC-02 module with regard to the safety function ATEX certified thermistor protection (Safe Motor Temperature) (option code +L537... - Page 64 The products referred in this Declaration of conformity fulfil the relevant provisions of other European Union Directives which are notified in Single EU Declarations of conformity 3AXD10000497305 and 3AXD10000497831. Authorized to compile the technical file: ABB Oy, Hiomotie 13, 00380 Helsinki, Finland Helsinki, 19 Jun 2023 Signed for and on behalf of: Peter Lindgren Tomi Väisälä...
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Page 65: Declaration Of Conformity (Uk)
ACS880-04, -04XT, -04F, -04FXT, -M04, -14, -34, -104, -104LC ACS880-07, -17, -37, -107, -07CLC, -07LC, -17LC, -37LC, -107LC identified with serial numbers beginning with 1 or 8 with FPTC-02 module with regard to the safety function ATEX certified thermistor protection (Safe Motor Temperature) (option code +L537... - Page 66 Authorized to compile the technical file: ABB Limited, Daresbury Park, Cheshire, United Kingdom, WA4 4BT The products referred in this Declaration of conformity fulfil the relevant provisions of other UK Legislation which are notified in Single UK Declarations of conformity 3AXD10001346556 and 3AXD10001326405.
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Page 67: Atex Certificate
Technical data 67 ATEX certificate ATEX certificate for the Safe motor temperature function with the FPTC-02 module and ACS880 drive series (EESF 20 ATEX 050). - Page 68 68 Technical data...
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Page 69: Ukex Certificate
Technical data 69 UKEX certificate... - Page 70 70 Technical data...
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Page 71: Tüv Nord Certificate
Technical data 71 TÜV Nord certificate The TÜV Nord certificate for the FPTC-02 module and ACS880 drive series is shown below. -
Page 73: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/contact-centers. - Page 74 3AXD50000027782H © Copyright 2023 ABB. All rights reserved. Specifications subject to change without notice.