Related Manuals for ABB CPTC-02
Summary of Contents for ABB CPTC-02
- Page 1 — OPTIONS FOR ABB DRIVES CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) User's manual...
- Page 3 CPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (+L537+Q971) User's manual Table of contents 1. Safety instructions 5. Mechanical installation 6. Electrical installation 7. Start-up and validation test 3AXD50000030058 Rev D Original instructions EFFECTIVE: 2021-07-02...
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Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ............Use of warnings and notes ............ATEX/UKEX-certified motor thermal protection functions ..Instructions for functional safety circuits ........Electrical safety precautions ............. 2 Introduction to the manual Contents of this chapter ............ - Page 6 Resetting the safety function ............ Indications of the safety function ..........Switching frequency limitation ..........Fault reaction function ............... CPTC-02 module ..............STO function in the drive ............ 5 Mechanical installation Contents of this chapter ............Necessary tools and instructions ..........
- Page 7 Start-up ..................Validation test ................8 Fault tracing Contents of this chapter ............Reporting problems and failures related to safety functions ..CPTC-02 module replacement ..........Fault and warning messages ............ LED ................... 9 Maintenance Contents of this chapter ............
- Page 8 8 Table of contents Compliance with the Supply of Machinery (Safety) Regulations (UK) ................... Compliance with the ATEX Directive (EU) ........ Compliance with the UKEX Directive (UK) ....... Declaration of Conformity (EU) ..........Declaration of Conformity (UK) ..........ATEX certificate ................ UKEX certificate ................
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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: Atex/Ukex-Certified Motor Thermal Protection Functions
10 Safety instructions 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. - Page 11 Safety instructions 11 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.
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Page 12: Electrical Safety Precautions
12 Safety instructions 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. - Page 13 Safety instructions 13 • 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.
- Page 14 14 Safety instructions 6. Install temporary grounding as required by the local regulations. 7. Ask for a permit to work from the person in control of the electrical installation work.
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Page 15: Introduction To The Manual
Introduction to the manual Contents of this chapter This chapter gives basic information on the manual. Applicability This manual is applicable to the CPTC-02 module and to the Safe motor temperature safety (SMT) function which uses the CPTC-02 module (option +L537+Q971). Compatibility The CPTC-02 module is compatible with: •... -
Page 16: Target Audience
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, Ex regulations and system safety. -
Page 17: Terms And Abbreviations
3AUA0000037223 - What you need to know Option manuals ACS-AP-x assistant control panels user’s manual 3AUA0000085685 CPTC-02 ATEX-certified thermistor protection module, 3AXD50000030058 Ex II (2) GD (+L537+Q971) user’s manual CPTC-02 ATEX-certified thermistor protection module, 3AXD10001243391 Instructions for pairing the module with an ATEX-certi-... - Page 18 The categories are: B, 1, 2, 3 and 4. (EN ISO 13849-1) Common cause failure (%) (EN ISO 13849-1) CPTC-02 Multifunction extension module (external 24 V and ATEX/UKEX-certified PTC interface) Diagnostic coverage (EN ISO 13849-1)
- Page 19 Introduction to the manual 19 Term Description Proof test interval. Defines the probabilistic failure rate (PFH or PFD ) 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.
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Page 21: Hardware Description
Safe motor temperature (SMT) safety function as defined in IEC/EN 61800-5-2. The CPTC-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... -
Page 22: External Power Supply Interface
Thus, the drive control unit is Protective Extra Low Voltage (PELV) compatible also when the CPTC-02 module and a thermistor protection circuit are installed. ￭ External power supply interface The module has an external power supply interface, which can be used to power up the drive control unit if the drive power supply fails. -
Page 23: Markings
SSSS: Number that starts every week from 0001 WS: Manufacturing location ABB MRP code of the module 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... -
Page 24: Drive
￭ Drive SMT function When the CPTC-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 to ensure the ATEX/UKEX compliance of the safety circuit. - Page 25 Hardware description 25 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 de- clares that the product conforms with The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regula- tions 2016 (+ amendment SI 2019 No.
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Page 27: Option Description
Overview To implement the Safe motor temperature (SMT) function, the relay output of the CPTC-02 module must be connected to the Safe torque off (STO) input of the drive. When the motor temperature rises above the PTC sensor limit temperature, the sensor resistance increases sharply. -
Page 28: Wall-Mounted Drives And Drive Modules
Wall-mounted drives and drive modules The module is available as an add-on kit (option+L537+Q971). If you intend to retrofit the CPTC-02 module to an installed drive, you need to make sure that the ATEX/UKEX certification enables the retrofit. Contact your local ABB representative for more information. -
Page 29: Safe Disconnection Function
European ATEX (and UKEX) Product Directive. For more information on the drive STO function, see the applicable hardware manual. You can use the CPTC-02 module only when serial number of the drive starts with 1, 4, 7, 8, M or Y. -
Page 30: Indications Of The Safety Function
The certificate of the Ex motor typically requires that you set a minimum limit for the switching frequency of the drive. For ABB Ex motors, use parameter 95.15 to set the required minimum switching frequency. For more information, see the drive firmware manual. -
Page 31: Sto Function In The Drive
Option description 31 it sends a request to the drive control unit to stop modulation, and activates the drive STO function. ￭ STO function in the drive The STO function in the drive 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 33: Mechanical Installation
• Screwdriver and a set of suitable bits 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: • CPTC-02 module • mounting screw • STO cable... -
Page 34: Installing The Module
34 Mechanical installation • ATEX/UKEX label (with the ATEX/UKEX classification markings) • this manual. 3. Make sure that there are no signs of damage to the items. Installing the module Install the module to Option slot 2 of the drive control unit. See the drive hardware manual. -
Page 35: Electrical Installation
Electrical installation 35 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 or maintenance work. -
Page 36: Necessary Tools And Instructions
• Screwdriver with a set of suitable bits • Cabling tools Selecting the location for the drive Install the drive, the CPTC-02 module, and the STO circuit outside any potentially explosive atmosphere. Consider the ambient conditions specification in the drive hardware manual. -
Page 37: Terminal Designations
3. Install the drive, including the components of the ATEX-certified motor thermal protection function, outside the potentially explosive atmosphere. 4. For the sensor connection, ABB recommends to use shielded twisted-pair cable. This type of cable decreases electromagnetic interference in the sensor circuit. -
Page 38: Ptc Sensor Input
38 Electrical installation Note: Only frames R0…R5 need CPTC-02 to be supplied by an external power supply, frames R6…R9 have corresponding terminals 40 and 41 on the control unit. Marking Description 24V AC/DC + External 24 V (AC/DC) input 24V AC/DC - in... -
Page 39: Motor Thermistor Connection Example
PTC thermistor and wiring are reinforced/double insulated, voltages on the PTC wiring are within SELV limits. If the motor PTC circuit is not reinforced/double insulated (that is, it is basic insulated), it is mandatory to use reinforced/double insulated wiring between the motor PTC and CPTC-02 PTC terminal. -
Page 40: Relay Output Connection
￭ Relay output connection Connect the drive STO circuit to the relay output of the module as shown in this figure. In the cabinet-installed drives, the wiring is done at the factory. CPTC-02 RO PTC C PTC B OUT1 OUT2... -
Page 41: Power Supply Connection
Electrical installation 41 An alternative connection with an external activation switch, for example a manually operated switch, an emergency stop push button, or the contacts of a safety relay. CPTC-02 RO PTC C PTC B OUT1 OUT2 SGND Activation switch ￭... - Page 42 42 Electrical installation WARNING! Do not connect the +24 V AC cable to the control unit ground when the control unit is powered using an external 24 V AC supply.
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Page 43: Start-Up And Validation Test
Start-up and validation test 43 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 44: Validation Procedure
44 Start-up and validation test ￭ Validation procedure You must do the validation test using the checklist given in this manual and the validation test plan of the complete safety system: • at the initial start-up of the safety function •... -
Page 45: Start-Up
• Make sure that the value of parameter 15.02 Detected extension module is CPTC-02 • Set parameter 15.01 Extension module type to CPTC-02. You can now see the parameters of the extension module in parameter group 15 I/O extension module. See the firmware manual. - Page 46 0 = Off 1 = On This parameter is automatically set to On, when CPTC-02 module is connected to the drive. If the module is removed from the drive, the parameter remains On, and the drive will trip to a fault. User must set...
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Page 47: Validation Test
Make sure that the drive is ready for use, that is, you have done the tasks of the drive start-up procedure. See the drive hardware manual. Make sure that the CPTC-02 module is installed and started up as in- structed in this manual. - Page 48 48 Start-up and validation test Action Make sure that the drive STO function is configured and validated. See the hardware manual. Checks and settings with no voltage connected Stop the drive and do the steps in section Electrical safety precau- tions (page 12) before you start the work.
- Page 49 Start-up and validation test 49 Action Make sure that you cannot start the drive before you reset the drive. Reset the drive. Make sure that you cannot reset and restart the drive before the resistance in the PTC input decreases to less than 1.6 kohm (that is, the thermistor wires are reconnected).
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Page 51: Fault Tracing
LED on the module. Reporting problems and failures related to safety functions Contact ABB. CPTC-02 module replacement If there is a failure in the CPTC-02 module, you must replace it with a new one. Do not try to repair the module. -
Page 52: Fault And Warning Messages
CPTC-02 not Safe motor temperature is Power down the control found enabled (35.31) but the unit and make sure that the CPTC-02 module is not module is correctly inserted in the option slot. detected (parameter 15.02 Detected extension module) 4991... -
Page 53: Led
(shown by parameter 15.02 Detected extension module) and that has been configured either by the user or drive (parameter 15.01 Extension module type). The CPTC-02 module has one diagnostic LED. Color Description Green The module is powered up. -
Page 55: 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 the CPTC-02 module, modify parameters, or restore parameters to their factory default values: • Use only ABB-approved spare parts. -
Page 56: Proof Test
12 months. This is a recommendation and depends on the required (not achieved) SIL/PL. For example, contactors, breakers, safety relays, contactor relays, emergency stop buttons, switches, etc. are typically safety devices which have electromechanical outputs. The CPTC-02 module... -
Page 57: Functional Safety Components
The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information. Competence The person who does the maintenance and proof test activities of... -
Page 58: Intentional Misuse
58 Maintenance potential hazards. Thus, the warnings for the residual risks must be given to the operators. 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. -
Page 59: Technical Data
Technical data 59 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 60: Dimension Drawing
60 Technical data Dimension drawing The dimensions are shown in millimeters and inches. Installation: Into Option slot 2 on the drive control unit Degree of protection: IP20 Package: Cardboard... -
Page 61: Isolation Areas
Technical data 61 Isolation areas The following figure shows the different isolation areas of the module. Dashed line: reinforced insulation (IEC 61800-5-1). Connections ￭ Motor thermistor connection (60…61) • Maximum wire size: 1.5 mm (16 AWG) • Maximum wire length: 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 (328 ft). -
Page 62: Relay Output (Sto) Connection (62
62 Technical data • Supported standards: DIN 44081 and DIN 44082 • Number of PTC thermistors: 1…6 in series (in both inputs) • Triggering threshold: 3.6 kohm ±10% • Recovery threshold: 1.6 kohm ±10% • PTC terminal voltage: < 5.0 V •... -
Page 63: Safety Data
Technical data 63 Safety data The CPTC-02 module is a type A safety component as defined in IEC 61508-2. The table gives the safety data for the SMT function. The calculations are based on the worst case data of the drive Safe torque off (STO) function. -
Page 64: Response Times
Drive STO Response times • CPTC-02 module: less than 10 ms • SMT function: the response time of the PTC sensor + CPTC-02 module (< 10 ms) + drive STO (< 50 ms) Relevant failure modes • The SMT function activates when not necessary (safe failure) •... -
Page 65: Compliance With The Machinery Directive (Eu)
Technical data 65 EN ISO 13849- Safety of machinery – Safety-related parts of control sys- 2:2012 tems – Part 2: Validation EN 60204-1:2018 Safety of machinery – Electrical equipment of machines – IEC 60204-1:2016 Part 1: General requirements IEC 61326-3- Electrical equipment for measurement, control and labor- 1:2017 atory use –... -
Page 66: Compliance With The Atex Directive (Eu)
66 Technical data This function complies with designated standards such as EN 61800-5-2. The declaration of conformity is shown below. Compliance with the ATEX Directive (EU) The safety function of this manual (option +L537+Q971) is within the scope of the ATEX product directive 2014/34/EU as a protective system. -
Page 67: Declaration Of Conformity (Eu)
Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Frequency converters/Frequency converter components With CPTC-02 module: ACS580-01/-04/-07 ACH580-01/-31/-34/-04/-07 ACQ580-01/-31/-34/-04/-07 identified with serial numbers beginning with 1, 4, 8, M or Y... - Page 68 68 Technical data If you need the Declaration of Conformity in an official language of the European Union other than English, contact ABB.
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Page 69: Declaration Of Conformity (Uk)
Hiomotie 13, 00380 Helsinki, Finland. Phone: +358 10 22 11 declare under our sole responsibility that the following products: Frequency converters/Frequency converter components With CPTC-02 module: ACS580-01/-04/-07 ACH580-01/-31/-34/-04/-07 ACQ580-01/-31/-34/-04/-07 identified with serial numbers beginning with 1, 4, 8, M or Y... -
Page 70: Atex Certificate
70 Technical data ATEX certificate ATEX certificate for the Safe motor temperature function with the CPTC-02 module and ACx580 drive series. - Page 71 Technical data 71...
- Page 72 72 Technical data...
- Page 73 Technical data 73...
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Page 74: Ukex Certificate
Equipment Thermal motor protection system for converter drive ACS580, ACH580 and ACQ580 series Manufacturer ABB Oy Drives Hiomotie 13, Address 00380 Helsinki, Finland The equipment is specified in the description of this certificate and the documents to which it refers. - Page 75 Technical data 75 CML 21UKEX9301 Issue 0 Description For product description refer to attached certificate EESF 20 ATEX 051, Issue 0. Certificate history and evaluation reports Issue Date Associated report Notes Issue of the prime certificate. EESF 20 ATEX 051, Issue 0 is attached and 21 June 2021 R14004D/00 shall be referred to in conjunction with this...
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Page 76: Tüv Nord Certificate
76 Technical data TÜV Nord certificate The TÜV Nord certificate for the CPTC-02 module and ACx580 drive series is shown below. - Page 77 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. Product training For information on ABB product training, navigate to new.abb.com/service/training.
- Page 78 3AXD50000030058D © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.