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.
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.
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: •...
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.
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.
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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...
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).
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.
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.
■ 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.
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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.
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.
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.
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.
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.
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) •...
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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.
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.
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.
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).
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.
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...
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...
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.
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...
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.
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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-...
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.
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.
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).
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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...
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...
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.
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.
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.
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 •...
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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.
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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.
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:...
(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).
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: •...
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.
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.
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.
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...
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.
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.
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.
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) •...
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 –...
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...
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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...
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...
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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.
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).
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.