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ABB FPTC-01 User Manual
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ABB FPTC-01 User Manual

ABB FPTC-01 User Manual

Fptc-01 thermistor protection module (option +l536) for acs880 drives
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FPTC-01 thermistor protection module (option +L536)
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  • Page 1 Options for ABB drives User’s manual FPTC-01 thermistor protection module (option +L536) for ACS880 drives...
  • Page 2 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.
  • Page 3 User’s manual FPTC-01 thermistor protection module (option +L536) for ACS880 drives Table of contents 1. Safety 5. Mechanical installation 6. Electrical installation 8. Start-up and acceptance test 3AXD50000027750 Rev C  2018 ABB Oy All Rights Reserved. EFFECTIVE: 2018-03-22...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1. Safety Contents this chapter ........9 Use of warnings .
  • Page 6 6 Table of contents ACS880-01/04/04XT/04F/M04/11/31/14/34/104 drives and modules ........30 Cabinet-built drives .
  • Page 7 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 .
  • Page 8 Product training ........99 Providing feedback on ABB manuals ..... 99...

  • Page 9: Safety

    Safety 9 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.

  • Page 10: Safety In Installation And Maintenance

    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.

  • Page 11: Other Warnings

    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.
  • Page 12 12 Safety...

  • Page 13: Introduction To The Manual

    Introduction to the manual 13 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).

  • Page 14: Compatibility

    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 •...

  • Page 15: Target Audience

    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.

  • Page 16: Contents Of The Manual

    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. •...

  • Page 17: Terms And Abbreviations

    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 Safety functions module (FSO-12 or FSO-21)
  • Page 18 Safety system Whole safety system including, for example, human interface, FPTC-01 module, FSO module, drive and sensors. Safe brake control. A safety function in the FSO module.
  • Page 19 Introduction to the manual 19 Term/abbreviation Description Safe stop 1 (EN/IEC 61800-5-2). A safety function in the FSO module. Safe stop emergency. A safety function in the FSO module. Safe torque off. (EN/IEC 61800-5-2) In this manual, this term is used in two different contexts: •...

  • Page 20: Exclusion Of Liability

    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.

  • Page 21: Hardware Description

    Therefore, the drive control board is PELV compatible also when the FPTC-01 module and a thermistor protection circuit are installed. For more information on isolation areas of the module and...

  • Page 22: Operation Basics

    When the motor temperature rises above the PTC sensor limit temperature, the sensor resistance increases sharply. The module sends a warning indication to the drive. For the resistance limits and other technical details of the FPTC-01 module, see chapter Technical...
  • Page 23 Hardware description 23  Layout XSTO2 XWRN XSTO1 XFLT...
  • Page 24 24 Hardware description Item Description Retaining clips Lock Diagnostics LEDs (see section LEDs on page 72) 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 25: Markings

    Hardware description 25 Markings The type designation label is attached on the back side of the FPTC-01 module. An example label and description of the label contents are shown below. Item Description Type Serial number of format RYWWSSSS, where Component revision: A, B, C, …...
  • Page 26 26 Hardware description...
  • Page 27 Hardware description 27...
  • Page 28 28 Hardware description...
  • Page 29 Hardware description 29...

  • Page 30: Option Description And Instructions

    Overview To implement the Safe motor temperature (SMT) function, you can connect the FPTC-01 module directly to the drive Safe torque off (STO) circuit, or you can use it together with an FSO module. The FSO safety functions module (FSO-12 or FSO-21) is an optional device used with the ACS880 drives to implement safety functions.

  • Page 31: Cabinet-Built Drives

    30 Option description and instructions  ACS880-01/04/04XT/04F/M04/11/31/14/34/104 drives and modules The module is available as a factory-installed option (+L536) or as an add-on kit for drives and modules. For the kit, the user: • installs the option module to an option slot of the drive control unit, and sets the related drive parameters •...

  • Page 32: Resetting The Safety Function

    When the XWRN input detects a motor overtemperature situation, the FPTC-01 module generates a warning to the drive. This is not a safety-related function and does not need a reset.

  • Page 33: Indications Of The Safety Function

    32 Option description and instructions Indications of the safety function An indication of the safety function can come from several sources: 1. LED indications on the FPTC-01 module: • The Fault LED is red when motor temperature is outside the allowed (safe) temperature range (XFLT input).

  • Page 34: Switching Frequency Limitation

    (see page 53). For Ex motors supplied by other motor manufactures, 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 35: Fault Reaction Function

    Fault reaction function  FPTC-01 module The FPTC-01 module has a fault reaction function. When the module detects an internal fault or fault in the temperature sensor circuit, it gives a request to the drive control unit to stop modulation and activates the drive STO function.
  • Page 36 Option description and instructions 35...
  • Page 37 36 Option description and instructions...

  • Page 38: Mechanical Installation

    For a complete list of tools, see the applicable drive hardware manual. Unpacking and examining the delivery 1. Open the option package. 2. Make sure that the package contains: • FPTC-01 module • STO cable • this manual. 3. Make sure that there are no signs of damage.

  • Page 39: Installing The Module

    See the applicable drive manual for further instructions on how to install the module to the drive. Note: Do not install the FPTC-01 module on an FEA-03 F-series extension adapter. The diagnostics of the module requires that you install it directly on the drive control unit.
  • Page 40 Mechanical installation 39...
  • Page 41 40 Mechanical installation...

  • Page 42: Electrical Installation

    Electrical installation 41 Electrical installation Contents of this chapter This chapter contains instructions on wiring the module. Warnings WARNING! Obey the safety instructions. See chapter Safety. If you ignore the safety instructions injury or death can occur. Make sure that the drive is disconnected from the input power during installation.

  • Page 43: General Cabling Instructions

    42 Electrical installation General cabling instructions 1. For the STO circuit wiring, use the type of cable specified in the appropriate drive or inverter module hardware manual (except when an FSO module or other safety relays are installed in the STO command chain). 2.

  • Page 44: Terminal Designations

    Electrical installation 43 Terminal designations Marking Description XSTO1 STO channel 1 In, +24 V DC in for STO Out, +24 V DC out for STO XSTO2 STO channel 2 In, +24 V DC in for STO Out, +24 V DC out for STO XFLT PTC FAULT (SMT function) In, 0...+5 V DC...

  • Page 45: Wiring

    44 Electrical installation Wiring This section presents five ways to connect the FPTC-01 module to the drive STO terminals. Wiring example 1 (see page 45): The STO outputs of the FPTC-01 module are connected directly to the STO terminals of the drive.
  • Page 46 Electrical installation 45 Note: If you use a one-channel connection, make sure that you can reach the required safety integrity level (SIL). Note: Only the XFLT input of the FPTC module is shown in the examples. The XWRN input is not safety-related and does not activate the drive STO function.
  • Page 47 46 Electrical installation  Wiring example 2 With an FSO module, two-channel connection. This connection is SIL2 capable (redundancy between STO channels). Control unit FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 X111 motor Ex Zone X113 X114...
  • Page 48 Electrical installation 47  Wiring example 3 With an external safety relay, two-channel connection. This connection is SIL2 capable (redundancy between STO channels). Control unit FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 External safety relay motor Ex Zone...
  • Page 49 48 Electrical installation  Wiring example 4 One-channel connection. This connection is SIL1 capable (no redundancy between STO channels). Control unit FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 motor Ex Zone If necessary, you can connect an external device (eg, an emergency stop button) between the XSTO input of the control unit and the XSTO2 output of the FPTC module.
  • Page 50 Electrical installation 49  Wiring example 5 With an FSO module, one-channel connection. This connection is SIL1 capable (no redundancy between STO channels). Control unit FPTC XSTO XSTO1 SGND XSTO2 XFLT SLOT X100 1/2/3 X111 motor Ex Zone X113 X114...
  • Page 51 50 Electrical installation...

  • Page 52: Parameter Settings

    Parameter settings 51 Parameter settings Contents of this chapter This chapter contains the drive and FSO module parameter settings. Drive/inverter Use the Drive composer PC tool or the control panel to set the parameter values. This table lists the parameters related to the safety function in ACS880 primary control program.
  • Page 53 This parameter value does not affect the SMT function, but this is the recommended setting (see section Indications of the safety function page 33). For the cabinet-built drives, ABB has set this value at the factory. 35.30 FPTC Activates FPTC modules installed on the control configuration word unit of the drive.
  • Page 54 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. Note: For non-ABB Ex motors, contact your local ABB representative.

  • Page 55: Other Recommended Settings

    54 Parameter settings  Other recommended settings We recommend that you also set these parameters to improve the safety of the application: • minimum and maximum speeds (parameter group 30) • maximum current, power and torque (group 30) • acceleration and deceleration times •...

  • Page 56: Fso Module

    Parameter settings 55 FSO module If you use an FSO module with the FPTC-01 module, set and check the FSO parameters listed in this section. You need the Drive composer pro PC tool to set the FSO module parameters, and a password to be able to download the configuration to the FSO module from Drive composer pro.

  • Page 57: General Parameters

    56 Parameter settings  General parameters Set these FSO parameters always when you use the FSO module with the FPTC-01 module. Index Name Example Description value FSOGEN. Stop None Sets the digital output that indicates completed the completion of any stop function.
  • Page 58 Parameter settings 57 Index Name Example Description value FSOGEN. Warning Sets the type of the event that the indication ext FSO module generates and sends to request the drive after external requests that end to a successful activation of the drive STO function (STO, SSE or SS1).

  • Page 59: Parameters Related To The Sto Function

    58 Parameter settings  Parameters related to the STO function These parameters are related to the STO function of the FSO module. With stop category 0, the FSO module activates the STO function in overtemperature situations. In addition, the FSO module can activate the STO function in fault situations.
  • Page 60 Parameter settings 59 Index Name Example Description value STO.13 Restart delay 2000 ms Sets the time after which the restart after STO of the drive is allowed after the FSO module has activated the STO function and opened the drive STO circuit.
  • Page 61 60 Parameter settings Index Name Example Description value I/O settings SAFEIO. DI X113:4 Sets the diagnostic pulse of digital diag pulse input X113:4 on or off. on/off On: The input monitors that it receives test pulses. In this example (see page 49), the STO request is connected to this digital input.

  • Page 62: Parameters Related To The Sse Function

    Parameter settings 61  Parameters related to the SSE function These parameters are related to the Safe stop emergency (SSE) function of the FSO module. The safety function described in this manual does not use this function, but the FSO module can activate the SSE function in internal fault situations Index Name...

  • Page 63: Fse Module And Safety Pulse Encoder Parameters

    62 Parameter settings  FSE module and safety pulse encoder parameters Set these parameters only when you use a safety pulse encoder and the FSE-31 pulse encoder interface module with the FSO-21 module. Index Name Example Description value 200.231 FSE 3X act Version 1 Activates the FSE-31 encoder and par interface and shows the version of the...
  • Page 64 Parameter settings 63 Index Name Example Description value 92.01 Encoder 1 HTL1 Activates or deactivates the type communication with the safety pulse encoder interface module 1 and sets the type for the safety pulse encoder. 92.02 Encoder 1 Module 1 Sets the safety pulse encoder source interface module that the safety pulse encoder 1 is connected to.

  • Page 65: Additional Notes

    64 Parameter settings  Additional notes ACS880-07/17/37 drives with the option +Q978 In motor overtemperature situations, the FSO module also opens the main contractor/circuit breaker. ACS880-07/17/37 drives with the option +Q978 or +Q979 The FSO module is configured so that after the safety function activation, the user must reset the FSO manually with the emergency stop reset button.

  • Page 66: Start-Up And Acceptance Test

    Start-up and acceptance test 65 Start-up and acceptance test Contents of this chapter This chapter contains the start-up instructions and the acceptance test for the safety function. Note: Only a competent person with expertise and knowledge of the safety function as well as functional safety and Ex regulations can do the start-up and adjust the related settings (IEC 61508-1 clause 6).

  • Page 67: Acceptance Test

    66 Start-up and acceptance test Acceptance test You need the Drive composer PC tool or the control panel to perform the acceptance test. Initial status: Make sure that the drive is ready for use, that is, you have done the tasks of the drive start-up procedure. See the hardware manual.
  • Page 68 Start-up and acceptance test 67 Action Make sure that the correct indications are activated: • the SMT fault and other indications depending on the parameter settings and if an FSO module is installed (see section Indications of the safety function on page 33).
  • Page 69 68 Start-up and acceptance test...

  • Page 70: Fault Tracing

    You must report any failures of the FPTC-01 and FSO modules and the drive Safe torque off function to ABB. FPTC-01 module replacement If the FPTC-01 module fails to operate, you have to replace it with a new one. You cannot repair the module.

  • Page 71: Fault And Warning Messages

    70 Fault tracing Fault and warning messages The fault and warning messages in the ACS880 primary control program are these: Code Name Cause What to do (hex) Faults 4991 Safe motor The FPTC module in 1. Check the cooling of the temperature 1 option slot 1 indicates motor.
  • Page 72 Fault tracing 71 Code Name Cause What to do (hex) Warnings A497 Motor The FPTC module in 1. Check the cooling of the temperature 1 option slot 1 has motor. activated a motor (Editable 2. Check the motor load temperature warning in message text) and drive ratings.

  • Page 73: Leds

    72 Fault tracing LEDs The FPTC-01 module has three diagnostic LEDs. Name Color Description FAULT The motor temperature is outside the allowed temperature range and the drive STO is active, or there is no PTC sensor connected to the XFLT input (safety related).

  • Page 74: Maintenance

    Maintenance 73 Maintenance Contents of this chapter This chapter gives maintenance instructions. Maintenance After the operation of the safety circuit has been tested at start-up, it does not need any maintenance during its specified lifetime, but the safety circuit must be tested periodically to keep the SIL/PL capability valid.

  • Page 75: Proof Test Interval

    74 Maintenance If you change any wirings or components after the start-up, replace the FPTC-01 module, modify drive or FSO parameters or restore parameters to their factory default values, you must: • Use only ABB approved spare parts. • Register the change to the change log for the safety circuit or logbook of the machine.

  • Page 76: Competence

    SIL/PL. For example, contactors, breakers, safety relays, contactor relays, emergency stop buttons, switches etc. are typically safety devices which contain electromechanical outputs. The FPTC-01 and FSO modules and the STO circuit of the drive do not contain electromechanical outputs. Competence...
  • Page 77 76 Maintenance...

  • Page 78: Technical Data

    Technical data 77 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 79: Dimension Drawing

    78 Technical data Dimension drawing The dimensions are in millimeters and [inches].

  • Page 80: Isolation Areas

    Technical data 79 Isolation areas This figure describes 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.

  • Page 81: Connections

    80 Technical data Connections  Motor thermistor connection • Wire size max. 2.5 mm • Length max. 700 m (2300 ft) (1400 m [4600 ft] for the whole loop) • With the specified cable type: Detection of a short-circuited PTC sensor or cable is not guaranteed after 100 m (330 ft). •...

  • Page 82: Safety Data

    Technical data 81 Safety data The FPTC-01 module is a type A safety component as defined in IEC 61508-2. The table gives the safety data for the SMT function with different configurations. The calculations are based on the worst case data of the drive Safe torque off (STO) function.
  • Page 83 82 Technical data Two-channel configurations One-channel configurations SIL / SILCL 2 SFF (%) >90 >90 >90 >60 >60 PFH (1/h) 5.51 E-09 5.58 E-09 5.51 E-09 7.71E-09 8.29 E-09 (T1 = 20a) 4.82 E-05 4.91 E-05 4.82 E-05 6.21E-05 6.75 E-05 (T1 = 2 a) 1.21E-04 1.22E-04...

  • Page 84: Safety Block Diagrams

    Technical data 83 Safety block diagrams The components that are included in the safety data calculations are shown in the safety block diagrams below. Note: The failure rate of the PTC sensor is not included in the calculations. Two-channel configurations This diagram applies to configuration 1.

  • Page 85: Response Times

    Note: The failure rate of the safety encoder is not included in the calculation. Response times • FPTC-01module: less than 10 ms • SMT function: the response time of the PTC sensor + FPTC-01 module (<10 ms) + FSO module (<50 ms) + drive STO (<50 ms)

  • Page 86: Relevant Failure Modes

    Technical data 85 Relevant failure modes • The SMT function trips spuriously (safe failure) • The SMT function does not activate when requested A fault exclusion on the failure mode “short-circuit on printed circuit board” has been made (EN 13849-2, table D.5). The analysis is based on the assumption that one failure occurs at one time.

  • Page 87: General Rules, Notes And Definitions

    86 Technical data General rules, notes and definitions  Validation of the safety functions You must do an acceptance test (validation) to validate the correct operation of safety functions.  Validation procedure You must do the acceptance test using the checklist given in chapter Start-up and acceptance test:...

  • Page 88: Acceptance Test Reports

     Ambient conditions For the environmental limits for the safety function and the drive, refer to the hardware manual of your drive.  Reporting problems and failures related to safety functions Contact your local ABB representative.

  • Page 89: Related Standards And Directives

    88 Technical data Related standards and directives Standard Name IEC 61508:2010 Functional safety of electrical/electronic/ programmable electronic safety-related systems. Part 1 – General requirements Part 2 – Requirements for electrical/electronic/ programmable electronic safety-related systems EN 61800-5-2:2007 Adjustable speed electrical power drive systems –...

  • Page 90: Compliance With The European Machinery Directive

    Technical data 89 Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive. However, the drive internal safety function of this manual (option +L536) is in the scope of the Machinery Directive as a safety component.
  • Page 91 90 Technical data...
  • Page 92 Technical data 91...
  • Page 93 92 Technical data...
  • Page 94 Technical data 93 Note: If the Declaration of Conformity is needed in any other official language of European Union than in English, contact ABB.
  • Page 95 94 Technical data...

  • Page 96: Tüv Nord Certificate

    Technical data 95 TÜV Nord certificate TÜV Nord certificate for the FPTC-01 module and ACS880 drive series is attached below.
  • Page 97 96 Technical data...
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  • Page 107: 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/searchchannels.
  • Page 108 Contact us www.abb.com/drives www.abb.com/drivespartners 3AXD50000027750 Rev C (EN) 2018-03-23...

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