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• 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.

4. Take special precautions when close to bare conductors.

5. Measure that the installation is de-energized. Use a quality

voltage tester. 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).

• Before and after measuring the installation, verify the

operation of the voltage tester on a known voltage source.

• Make sure that the voltage between the drive input power

terminals (L1, L2, L3) and the grounding (PE) busbar is zero.

• Make sure that the voltage between the drive output terminals

(T1/U, T2/V, T3/W) and the grounding (PE) busbar is zero.
Important! Repeat the measurement also with the DC voltage
setting of the tester. Measure between each phase and
ground. There is a risk of dangerous DC voltage charging
due to leakage capacitances of the motor circuit. This voltage
can remain charged even long time after the drive power off.
The measurement discharges the voltage.

• Make sure that the voltage between the drive DC terminals

(UDC+ and UDC-) and the grounding (PE) terminal is zero.

Note:

If cables are not connected to the drive DC terminals,

measuring the voltage from the DC terminal screws can give
incorrect results.

Safety instructions 13

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Содержание CPTC-02

Страница 1: ... OPTIONS FOR ABB DRIVES CPTC 02 ATEX certified thermistor protection module Ex II 2 GD L537 Q971 User s manual ...

Страница 2: ......

Страница 3: ...ection 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 EN Original instructions EFFECTIVE 2021 07 02 ...

Страница 4: ......

Страница 5: ...er 15 Applicability 15 Compatibility 16 Target audience 16 Exclusion of liability 16 Related manuals 17 Terms and abbreviations 3 Hardware description 21 Contents of this chapter 21 Product overview 22 External power supply interface 22 Layout 23 Markings 23 Module 23 Type designation label 23 ATEX UKEX markings 24 Drive 24 SMT function 4 Option description 27 Contents of this chapter 27 Overview ...

Страница 6: ...ling the module 6 Electrical installation 35 Contents of this chapter 35 Warnings 36 Necessary tools and instructions 36 Selecting the location for the drive 36 General wiring instructions 37 Terminal designations 37 Motor thermistor connection 37 Relay output connection 37 External power supply 38 PTC sensor input 38 Wiring examples 39 Motor thermistor connection example 40 Relay output connectio...

Страница 7: ...57 Functional safety components 57 Competence 57 Residual risk 58 Intentional misuse 58 Decommissioning 10 Technical data 59 Contents of this chapter 60 Dimension drawing 61 Isolation areas 61 Connections 61 Motor thermistor connection 60 61 62 Relay output STO connection 62 63 62 External power supply 40 41 62 Ambient conditions 63 Safety data 63 Safety block diagram 64 Response times 64 Relevant...

Страница 8: ...tions UK 66 Compliance with the ATEX Directive EU 66 Compliance with the UKEX Directive UK 67 Declaration of Conformity EU 69 Declaration of Conformity UK 70 ATEX certificate 74 UKEX certificate 76 TÜV Nord certificate Further information 8 Table of contents ...

Страница 9: ...otes 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...

Страница 10: ...tor thermal protection functions see IEC EN 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 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 This manual does not contain the complete...

Страница 11: ...rcuit 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 Before you start the work do the steps in section Electrical safety precautions page 12 Safety instructions 11 ...

Страница 12: ...ll 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 Open the auxiliary voltage switch disc...

Страница 13: ...y the operation of the voltage tester on a known voltage source Make sure that the voltage between the drive input power terminals L1 L2 L3 and the grounding PE busbar is zero Make sure that the voltage between the drive output terminals T1 U T2 V T3 W and the grounding PE busbar is zero Important Repeat the measurement also with the DC voltage setting of the tester Measure between each phase and ...

Страница 14: ...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 14 Safety instructions ...

Страница 15: ...ure safety SMT function which uses the CPTC 02 module option L537 Q971 Compatibility The CPTC 02 module is compatible with ACS580 01 04 ACH580 01 04 31 34 and ACQ580 01 04 31 34 wall mounted drives and drive modules to be installed in user defined cabinet ACS580 07 ACH580 07 and ACQ580 07 cabinet installed drives ACS580 standard control program version 1 70 or later Introduction to the manual 15 ...

Страница 16: ... or other party who is responsible for the overall system Ex regulations 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 Code Name Drive hardware 3AXD...

Страница 17: ...al Safety 3AUA0000048753 Functional safety Technical guide No 10 www abb com safety ABB Safety information and solutions 3AUA0000037223 Motors and drives in potentially explosive atmospheres What you need to know Option manuals 3AUA0000085685 ACS AP x assistant control panels user s manual 3AXD50000030058 CPTC 02 ATEX certified thermistor protection module Ex II 2 GD L537 Q971 user s manual 3AXD10...

Страница 18: ...IEC term used in the context of explosive atmospheres IEC 60079 Ex Type of protection flameproof enclosures IEC EN 60079 1 Ex d Types of protection increased safety IEC EN 60079 7 Ex eb Ex ec Motors used in explosive atmospheres Ex motors Hardware fault tolerance IEC 61508 HFT Mean time to dangerous failure Total number of life units Number of dangerous undetected failures during a partic ular mea...

Страница 19: ...t be replaced Note that any TM values given cannot be regarded as a guarantee or warranty EN ISO 13849 1 IEC 61800 5 2 TM The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016 amendment SI 2019 No 696 UKEX Confirmation by for example analysis that the safety system meets the functional safety requirements of the specific ap plication Validation...

Страница 20: ...20 ...

Страница 21: ...motor overtemperature the relay output must be connected to the Safe torque off STO input of the drive The CPTC 02 module together with the drive STO implements the 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 ...

Страница 22: ...nd 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 If you do not need the back up power supply you do not have to connect it because the module is powered from the drive control unit by default Layout 1 2 4 5 3 6 Grounding screw 1 Hole...

Страница 23: ...igit of the manufacturing year for example 5 2015 WW Manufacturing week for example 01 week 1 SSSS Number that starts every week from 0001 WS Manufacturing location ABB MRP code of the module 3 Combined ABB MRP code serial number and manufacturing location 4 RoHS mark 5 ATEX UKEX markings The markings on the module show the ATEX UKEX classification of the CPTC 02 module Hardware description 23 ...

Страница 24: ...atmospheres caused by 4 G gases vapors or mists D dust 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 In the cabinet built driv...

Страница 25: ...e Systems Intended for Use in Potentially Explosive Atmospheres Regula tions 2016 amendment SI 2019 No 696 2 Approved Body Eurofins E E CML Limited Specific marking of explosion protection 3 Equipment group II Product for surface industry other than mining ap plications 4 Equipment category 2 Parentheses show that the drive must be installed outside the potentially explosive atmosphere 5 Certified...

Страница 26: ...26 ...

Страница 27: ...ule 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 This indicates overtemperature to the CPTC 02 module The module switches the drive Safe torque off STO circuit off which activates the drive STO function The STO function disables the control voltage of the power semicon...

Страница 28: ...ts with 1 4 7 8 M or Y pairs the CPTC 02 module with an ATEX UKEX certified ACS580 ACH580 or ACQ580 drive in the ABB Drive Installed Base DIB register See Instructions for pairing the module with an ATEX certified drive 3AXD10001243391 English attaches the included ATEX UKEX label for the SMT function near the type designation label CE UKCA marking of the drive installs the option module to Option...

Страница 29: ...because the ATEX UKEX certificate of the SMT function includes also the ATEX UKEX certified Safe torque off function STO Commissioning the drive for a motor in a hazardous area Commission the drive according to the requirements and limitations set by the application the motor manufacturer s instructions drive firmware manual local laws and regulations and this manual The certificate of the Ex moto...

Страница 30: ...instructions Note The indications of the safety function are not SIL classified Switching frequency limitation 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 For Ex motors supplied by other...

Страница 31: ...he 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 For more information see the hardware and firmware manuals of the drive Option description 31 ...

Страница 32: ...32 ...

Страница 33: ...ng the module Necessary tools and instructions 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 Mechanical installation 33 ...

Страница 34: ... 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 34 Mechanical installation ...

Страница 35: ...or damage to the equipment can occur If you are not a qualified electrical professional do not do installation or maintenance work WARNING Cabinet built drives Do not connect test or measure a drive based on the diagrams in this manual Each delivery is unique Before starting the work on the electric circuits of a drive always refer to the delivery specific circuit diagrams Electrical installation ...

Страница 36: ... potentially explosive atmosphere Consider the ambient conditions specification in the drive hardware manual General wiring instructions 1 For the STO circuit wiring use the type of cable specified in the applicable drive hardware manual 2 Install only the sensor circuit into the potentially explosive atmosphere The sensor circuit in the Ex Zone must comply with the requirements for the applicable...

Страница 37: ...sor cable shields to a single grounding point outside the potentially explosive atmosphere 360 degree grounding of the cable shields at the cable entry of the drive is recommended Do not connect the cable shields to ground at the sensor end of the cable Terminal designations Motor thermistor connection Description Marking PTC connection PTC IN 60 Ground earth potential PTC IN 61 Relay output conne...

Страница 38: ...o enable the SMT function connect the PTC sensor to the PTC IN input To disable the SMT function connect a resistor 100 ohm 1 kohm W wire wound to the PTC IN input Note If you do not connect a PTC sensor or resistor to the PTC IN input the STO function stays active You cannot start the motor while the STO function is active Wiring examples Connect the external control cables to the applicable modu...

Страница 39: ...orced double insulated If the motor part of the 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 Electrical installation 39 ...

Страница 40: ...ve 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 34 35 X4 36 37 38 OUT1 OUT2 SGND IN1 IN2 62 63 RO PTC C RO PTC B CPTC 02 CCU 40 Electrical installation ...

Страница 41: ...witch an emergency stop push button or the contacts of a safety relay 34 35 X4 36 37 38 OUT1 OUT2 SGND IN1 IN2 62 63 RO PTC C RO PTC B CPTC 02 CCU K Activation switch K Power supply connection 24V AC DC in 24V AC DC in 1 40 41 CPTC 02 External power supply 24 V AC DC 1 Electrical installation 41 ...

Страница 42: ...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 42 Electrical installation ...

Страница 43: ...o make sure that the safety function operates correctly and according to the safety requirements Competence The person who does the validation test of the safety function must be a competent person with expertise and knowledge of the safety function and functional safety as required by IEC 61508 1 clause 6 and Ex regulations This person must document and sign the test procedures and report Start u...

Страница 44: ...ch operation location you must document all validation tests you must sign and store the validation test report for further reference Validation test reports You must store the signed validation test reports in the logbook of the machine and in the explosion protection document under the scope of the ATEX User Directive 1999 92 EC or The Dangerous Substances and Explosive Atmospheres Regulations 2...

Страница 45: ...he module is started up through drive parameters Use the Drive composer PC tool or the control panel to set the parameter values 1 Power up the drive 2 If no warning is shown Make sure that the value of both parameter 15 02 Detected extension module and parameter 15 01 Extension module type is CPTC 02 If warning A7AB Extension I O configuration failure is shown Make sure that the value of paramete...

Страница 46: ...ted 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 parameter to Off manually and reset the fault to continue operation without the module When the module is connected again the parameter is automatically set to On Defines hardware related settings that can be enabled and disabled by toggling the specific bits Special H...

Страница 47: ...ff the Hexagonal field weakening Hexagonal field weak ening 97 18 0 Off For ABB Ex motors parameter 95 15 is set to 1 this parameter is automatically set to Off For non ABB Ex motors when paramet er 95 15 bit 0 is not set set this parameter to Off Validation test Use the Drive composer PC tool or a control panel to do the validation test Action WARNING Obey the safety instructions of the drive If ...

Страница 48: ...e sure that the installation of the motor temperature sensor complies with the requirements for the applicable type of protection Make sure that the SIL PL of the safety function meets the target SIL PL Make sure that the wires are connected to the correct terminals and that the terminal connections are tightened to the correct torque Settings with voltage connected Make sure that you have set all...

Страница 49: ...erminals of the PTC input Make sure that the correct indications are activated the SMT fault and other indications depending on the parameter settings 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 Reset the drive Make sure that you cannot reset and restart the drive before the resistance in the PTC input...

Страница 50: ...50 ...

Страница 51: ...ault and warning messages of the drive and 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 Fault tracing 51 ...

Страница 52: ...otor has sufficient cooling 2 Make sure that the drive and the motor are compatible with each other 3 Make sure that the motor is not overloaded 4 Make sure that the drive parameter settings are correct 5 Examine the wiring of the temperature sensor If necessary repair the wiring 6 Measure the resistance of the sensor If necessary replace the sensor The CPTC 02 module indicates overtemperature 1 M...

Страница 53: ... FA82 is generated SMT circuit malfunction 5089 Warnings Check that the installed module is of the same type that the drive has detected 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 Installed option module is not the same as configured by drive parameter Extension I O configuration failure A7AB LED...

Страница 54: ...54 ...

Страница 55: ... 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 Register the change to the change log for the safety circuit If parameters were restored to the factory default values Set the parameters related to the safety function M...

Страница 56: ...k the operation of the safety function at least once a year The person responsible for the design of the complete safety function should also note the Recommendation of Use CNB M 11 050 published by the European co ordination of Notified Bodies concerning dual channel safety related systems with electromechanical outputs When the safety integrity requirement for the safety function is SIL 3 or PL ...

Страница 57: ...l of the components in the safety function circuit In practice this is economical only with larger drives that have replaceable circuit boards and other components such as relays Note that some of the components may already have been renewed earlier restarting their mission time The remaining mission time of the whole circuit is however determined by its oldest component Contact your local ABB ser...

Страница 58: ...l 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 58 Maintenance ...

Страница 59: ...tains 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 59 ...

Страница 60: ...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 60 Technical data ...

Страница 61: ...hermistor connection 60 61 Maximum wire size 1 5 mm2 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 Type Shielded twisted pair cable Draka JAMAK 1 2 1 0 5 mm2 or equivalent Tightening torque 0 5 N m 4 4 lbf in Technical data 61 ...

Страница 62: ...lay output STO connection 62 63 Maximum wire size 1 5 mm2 16 AWG Maximum wire length 30 m 98 ft for the whole loop Tightening torque 0 5 N m 4 4 lbf in Maximum contact rating 250 V AC 30 V DC 5 A Maximum breaking capacity 1000 VA External power supply 40 41 Wire size max 1 5 mm2 24 V AC DC 10 GND user potential Maximum current consumption 25 W 1 04 A at 24 V DC Ambient conditions For the environme...

Страница 63: ...1 2 years or T1 5 years low demand mode of operation PFDavg T1 2 a PFDavg T1 5 a PFH 1 h T1 20 a SFF PL SIL 1 25E 04 3 12E 04 1 43E 08 60 c 2 Mission time a CCF HFT Cat SC DC 20 N A 0 1 2 0 3AXD10000473876 Rev H The MTTFD value EN ISO 13849 1 of the CPTC 02 module 11386 years one channel connection Safety block diagram The components that are included in the safety data calculations are shown in t...

Страница 64: ...istor are not included in the failure analysis The customer is responsible for the applicability of the PTC element Related standards and directives Safety devices required for the safe functioning of equip ment with respect to explosion risks EN 50495 2010 Functional safety of electrical electronic programmable electronic safety related systems IEC 61508 2010 Part 1 General Requirements Part 2 Re...

Страница 65: ... Directive EU 2014 34 EU Supply of Machinery Safety Regulations 2008 UK The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016 amendment SI 2019 No 696 UK Compliance with the Machinery Directive EU The drive is an electronic product which is covered by the Low Voltage Directive However the drive internal safety function of this manual option L53...

Страница 66: ...ction complies with European harmonized standard EN 50495 The declaration of conformity is shown below Compliance with the UKEX Directive UK The safety function of this manual option L537 Q971 is within the scope of the The Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 2016 amendment SI 2019 No 696 as a protective system The function complies wi...

Страница 67: ...580 01 31 34 04 07 identified with serial numbers beginning with 1 4 8 M or Y ATEX certified thermistor protection Safe Motor Temperature option code L537 Q971 are in conformity with all the relevant requirements for 1 protective system of EU Directive for Equipment for Explosive atmospheres 2014 34 EU and 2 safety component of the EU Machinery Directive 2006 42 EC when the listed safety function ...

Страница 68: ...If you need the Declaration of Conformity in an official language of the European Union other than English contact ABB 68 Technical data ...

Страница 69: ...s 2008 when the listed safety function is used for safety component functionality Safety devices required for the safe functioning of equipment with respect to explosion risks Approved Body Eurofins E E CML Limited Approved Body number 2503 Address Newport Business Park New Port Road CH65 4LZ Ellesmere Port United Kingdom has assessed the conformity of the ATEX certified thermal motor protection f...

Страница 70: ...ATEX certificate ATEX certificate for the Safe motor temperature function with the CPTC 02 module and ACx580 drive series 70 Technical data ...

Страница 71: ...Technical data 71 ...

Страница 72: ...72 Technical data ...

Страница 73: ...Technical data 73 ...

Страница 74: ...ealth and Safety Requirements relating to the design and construction of equipment intended for use in potentially explosive atmospheres given in Schedule 1 of the Regulations The examination and test results are recorded in the confidential reports listed in Section 12 7 If an X suffix appears after the certificate number it indicates that the equipment is subject to specific conditions of use af...

Страница 75: ...4004D 00 Issue of the prime certificate EESF 20 ATEX 051 Issue 0 is attached and shall be referred to in conjunction with this certificate Note Drawings that describe the equipment are listed or referred to in the Annex 13 Conditions of Manufacture For conditions of manufacture refer to attached EESF 20 ATEX 051 Issue 0 Any routine tests verifications required by the ATEX certification shall be co...

Страница 76: ...TÜV Nord certificate The TÜV Nord certificate for the CPTC 02 module and ACx580 drive series is shown below 76 Technical data ...

Страница 77: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Страница 78: ...www abb com drives 3AXD50000030058D Copyright 2021 ABB All rights reserved Specifications subject to change without notice 3AXD50000030058 Rev D EN EFFECTIVE 2021 07 02 ...

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