Explosion-Proof Drives

Explosion-Proof Drives to EU Directive 94/9/EC
Edition
02/2003
Drive Engineering Practical Implementation

1056 0211 / EN
Contents
1 Purpose of Explosion Protection..................................................................... 4 2 Purpose of this Documentation ....................................................................... 5 3 Explosion Protection in Europe Today and Tomorrow ................................ 6 3.1 Useful Internet addresses ......................................................................... 7 4 The New Protection Concept ........................................................................... 8 4.1 Overview of EU Directive 94/9/EC ............................................................ 8 4.2 Overview of EU Directive 1999/92/EC .................................................... 11 5 Drives to EU Directive 94/9/EC....................................................................... 13 5.1 Conformity evaluation ............................................................................. 13 5.2 EC-type examination............................................................................... 13 5.3 Production quality assurance .................................................................. 14 5.4 Internal control of production .................................................................. 14 5.5 Declaration of conformity and CE marking.............................................. 14 5.6 Designation key for explosion-proof equipment ...................................... 15 5.7 Mechanical equipment according to EU Directive 94/9/EC..................... 17 5.8 Required accompanying documentation................................................. 18 6 Gas Explosion Protection............................................................................... 19 6.1 Categorization ......................................................................................... 19 6.2 Protection types ...................................................................................... 20 6.3 Protection type e standard for AC motors in zone 1 ............................. 23 6.4 Special features of speed-controlled AC motors..................................... 26 7 Dust Explosion Protection ............................................................................. 28 7.1 Characteristic values for dust explosion protection in accordance with EN50281-1-1:1998.................................................................................. 29 7.2 New zone classification according to EC Directive 1999/92/EC ............. 32 7.3 Standards / design regulations for dust explosion protection.................. 33 8 Application Examples ..................................................................................... 34 8.1 Transportation of sacks / standard operating conditions......................... 34 8.2 Transportation of sacks / zone 22 ........................................................... 36 8.3 Transportation of sacks / zone 1 ............................................................. 38 9 Service and Maintenance ............................................................................... 39 9.1 General maintenance.............................................................................. 40 9.2 Special maintenance............................................................................... 40 10 A Comparison of Foreign Regulations.......................................................... 41 10.1 North American regulations..................................................................... 41 11 Overview of Standards ................................................................................... 43 11.1 Figures .................................................................................................... 43 12 List of References ........................................................................................... 44 13 Glossary ........................................................................................................... 45
Practical Engineering - Explosion-Proof Drives to EU Directive 94/9/EG
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Purpose of Explosion Protection
Purpose of Explosion Protection

The purpose of explosion protection in industrial facilities consists of ensuring the safety of the personnel and related production, storage, and distribution facilities. It is impossible to completely avoid occurrences of explosive atmospheres. The majority of work processes may not be interrupted when explosive atmospheres occur. An explosive atmosphere is a mixture with air, under atmospheric conditions, of flammable substances in the form of gases, vapors, mists or dusts in which, after ignition has occurred, combustion spreads to the entire unburned mixture. This process may even stir up dust clouds due to the pressure resulting from the explosion. Explosion-proof equipment that avoids ignition sources or prevents an explosion from spreading to the entire mixture can be used in potentially explosive environments.
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Figure 1: Serious damages caused by an aluminum dust explosion [1]
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Figure 2: Gas explosion in a silo [2]
Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC
Purpose of this Documentation
Purpose of this Documentation

This volume of the series Drive Engineering Practical Implementation contains information on the European Directive 94/9/EC on the design of explosion-proof equipment and its implementation in the area of drive engineering. Here, equipment refers to electrical motors, motors with integrated frequency inverters, reduction gear units, mechanical variable speed gear units and combinations of motors, gear units, and electrical equipment that operate directly in potentially explosive atmospheres.
Additional information
As a supplement to the SEW-EURODRIVE product documentation about explosionproof drives (Figure 3), this document contains additional information and background information. Guidelines and standards publications serve as supplements, while clarifying fundamental differences with respect to current procedures. The new principles for certification, classification of areas, and project planning are explained as well as typical application examples and important rules regarding the operation of the equipment without going into details about products. Notes about deviating regulations concerning explosion protection in countries outside Europe complete this documentation.
Edition
Explosion-Proof Drives
11/2002
Price Catalog
1055 3711 / EN
51481AXX
Figure 3: "Explosion-Proof Drives" catalog
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Explosion Protection in Europe Today and Tomorrow

There have been regulations for the operation of production facilities in potentially explosive atmospheres since the beginning of industrial manufacturing. They are roughly divided into regulations on the condition of equipment and protective systems intended for use in potentially explosive atmospheres and regulations on the installation, operation and maintenance of entire systems with special considerations for the protection of workers. Until today they differ partially from country to country, obstruct the flow of goods in spite of the mutually agreed free movement of goods within the EU (EU agreement, article 28), and do not include all theoretically potentially explosive equipment and systems.
Regulations for equipment and systems
Uniform European solution
The new Directive 94/9/EC on the design and structure of equipment which can be used in potentially explosive atmospheres was enacted with the goal of reaching a uniform solution for the entire European Union (EU) and increasing the safety of personnel and systems. It was adopted as law by individual states on September 1, 1995, and is established law since March 1, 1996, parallel to existing applicable individual regulations during a transition period. In the meantime, it was amended by EU Directive 1999/92/ EC for the installation and operation of explosion-proof systems. The acronym ATEX (Atmosphres Explosibles) has established itself as a designation for the new guidelines. The EU Directive 94/9/EC (ATEX 100a) governs all regulations concerning the design and structure of explosion-proof devices, the EU Directive 1999/ 92/EC (ATEX 137) governs the safety of personnel during installation, operation and maintenance of potentially explosive systems. Starting July 1, 2003, only the Directives 94/9/EC and 19999/92/EC will be in force in the EC. This comprehensive harmonization of explosion protection in the EU permanently removes all existing trade barriers in this area among the European countries. A transitional period is in effect until June 30, 2006 for all systems that were put to use prior to June 30, 2003, and did not meet the new regulation 1999/92/EC.
Designations
Transitional periods
Transitional periods of EU directives 94/9/EC and 1999/92/EC

Introduction of 94/9/EC 3/1/1996 Introduction of 1999/92/EC 1/28/2000 Legal validity of 94/9/EC and 1999/ 92/EC 7/1/2003 End of transitional period for 1999/92/ EC 7/1/2006
Putting equipment into circulation Based on "old" regulations Based on 94/9/EC Construction of systems Based on "old" regulations Based on 1999/92/EC Converting existing systems to minimum requirements of 1999/92/ EC
Of course, the Directive 94/9/EC also applies to all products manufactured outside the EC and imported into the EC. To provide an outside indication of conformity with Directive 94/9/EC, explosion-proof equipment now carries the CE marking on the nameplate. In contrast to the regulations that are in effect during the transitional period, explosion protection in accordance with 94/9/EC covers electrical as well as mechanical equipment and defines equipment categories for the first time. The assignment of equipment categories to the new danger zones is newly regulated in Directive 1999/92/EC.
3.1
Useful Internet addresses

Additional information about explosion protection can be found at the following Internet addresses: European Union online: http://europa.eu.int/comm/enterprise/atex/index.htm Physikalisch-Technische Bundesanstalt (PTB), Braunschweig: http://www.explosionsschutz.ptb.de Deutsche Montan Technologie GmbH: http://www.dmt.de/gf/gf%5Fsa%5F02.html Federal Ministry of Labor and Social Affairs: http://www.bam.de/index4.htm Main Association of Industrial Social Insurance against Occupational Accidents: http://www.hvbg.de Federal Office for Material Research and Testing: http://www.bma.bund.de/index.cfm?F0D98AC704AB7AB1BD5BCCCE467E1 Laboratoire Central des Industries Electriques (LCIE): http://www.lcie.fr/FR/home.cfm SEW-EURODRIVE GmbH & Co KG: http://www.sew-eurodrive.de/deutsch05_dokumentation/index_doku.htm
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The New Protection Concept

The EU Directives 94/9/EC and 1999/92/EC form the basis of the new concept. EU Directive 94/9/EC is the harmonized European regulation for the design and structure of explosion-proof equipment; 1999/92/EC regulates the safe operation of this equipment with respect to personnel. This volume deals primarily with the design of the equipment, but it also addresses the use of such equipment to facilitate understanding.
4.1
Overview of EU Directive 94/9/EC

EU Directive 94/9/EC is primarily intended for manufacturers of equipment and protective systems. One of the fundamental changes in 94/9/EC compared to previous regulations is the fact that 94/9/EC does not directly refer to European standards.
Minimum requirements
The Directive 94/9/EC defines minimum requirements for equipment and protective systems for use in potentially explosive atmospheres. This makes it possible to build and certify equipment and protective systems for the first time that do not, or only partially, meet a valid explosion protection standard as long as they meet the requirements of 94/9/EC. This is an important aspect when it comes to enabling solutions in the future that are not yet defined in a standard.
Mechanical equipment
Yet another profound change in the course of the introduction of 94/9/EC is the integration of mechanical (non-electrical) equipment in the explosion protection. However, the practical implementation faces special difficulties since the respective standards of the EN 13 463 series (non-electrical equipment) are currently being created. According to 94/9/EC, the equipment is newly classified in groups, categories and protection types. Group I, categories M1 and M2 for underground mines and Group II, category 1 for particularly high safety requirements (zones 0 and 20) are special areas and, therefore, not discussed in any detail. This volume focuses on the equipment groups, categories and protection types (highlighted in gray in the tables) that apply to gear units, motors, electrical and electronic installations and sensors.
Categorization
Categories
According to EU Directive 94/9/EC (also referred to as ATEX 100a), explosion-proof equipment is divided into categories. The category indicates the level of protection of the equipment as well as the operating conditions. In addition, equipment must be identified for use in areas with explosive gas-air mixtures with the letter G with explosive dust-air mixtures with the letter D.
Category1) M1
Level of protection Very high
Guarantee of protection through two independent protective measures, two errors may occur independent of each other through two independent protective measures, two errors may occur independent of each other suitable for normal operation and heavy conditions Through a protective measure, suitable for normal operation and frequently anticipated malfunctions, a fault may occur Suitable for normal operation
Operating conditions Equipment remains in operation with existing explosive atmosphere Equipment remains in operation with existing explosive atmosphere Equipment is switched off with existing explosive atmosphere Equipment remains in operation with existing explosive atmosphere
Very high
M2 2
High High
Normal
Equipment remains in operation with existing explosive atmosphere
1) Only the gray boxes are relevant to drives from SEW-EURODRIVE.
Protection types
The protection type indicates the method used to implement the explosion protection.
Protection type1) d e i n / nA m o q
2)
Type of equipment Motors (electrical equipment)
Standard EN 50014 + EN 50018 EN 50014 + EN 50019 EN 50014 + EN 50020 EN 50014 + EN 50021 EN 50014 + EN 50028 EN 50014 + EN 50015 EN 50014 + EN 50017 EN 50014 + EN 50281 EN 13463 P. 1 and 6 EN 13463 P. 1 and 5 EN 13463 P. 1 and 3 EN 13463 P. 1 and 2 EN 13463 P. 1 and 4 EN 13463 P. 1 and 8
Description Flameproof enclosure Increased safety Intrinsic safety Non-sparking Encapsulation Oil immersion Sand filling Dust explosion protection Protection by control of ignition sources Design safety Flameproof enclosure Restricted breathing Inherent safety Liquid immersion
Gear units (mechanical equipment)3)
b c d fr g k
1) Only the gray boxes are relevant to drives from SEW-EURODRIVE. 2) No explicit protection types are specified for dust explosion protection. 3) The standardization of protection types for gear units (mechanical equipment) has not been finalized yet.
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4.2
Overview of EU Directive 1999/92/EC

In contrast to EU Directive 94/9/EC, which specifies the equipment properties for the manufacturer, the EU Directive 1999/92/EC is directed at system operators. Besides various requirements for the installation and operation of systems, it also defines the classification of the equipment category to the different danger areas (zones),
System safety
EU Directive 1999/92/EC deals with Minimum regulations to improve protection of health and safety of workers at possible risk through explosive atmospheres. The system operator is required to: guarantee the safety of the system during the operating time, either prevent the formation of explosive mixtures in the system or prevent the ignition of explosive mixtures and at worst, reduce the harmful effects of an explosion to the extent that health and safety of workers is guaranteed. create an explosion protection document and keep it current:
excerpt from the Operational Reliability Regulation (BetrSichV, effective starting 10-03-2002) Explosion protection document (1) Independent of the number of employees, the employer must ensure as part of his duties according to 3 that a document (explosion protection document) is created and kept up-to-date. (2) In particular, the explosion protection document must show that the danger of explosion was determined and evaluated that appropriate measures were taken to achieve the objectives of the explosion protection which areas were divided into zones in accordance with appendix 3, and to which areas the minimum requirements in accordance with appendix 4 apply (3) The explosion protection document must be created before work is taken up. It must be updated if the tools and fixtures or the sequence of operations is changed, expanded or redesigned.
Risk assessment
Within a general and special assessment of explosion risks, the responsible operator divides the production facilities into zones that reflect the degree of danger in the frequency and duration of occurrences of explosive atmospheres. The most important criteria for the zone classification are: probability and duration of occurrence of explosive atmospheres, possible ignition sources, interactions between facility, procedure and product scope of expected effects
Supplementary to the classification of zones, the ignition temperature for gas and dust atmospheres and for dust as well as the smoldering temperature are important for risk assessment.
Zone1) Gas 02) 1 2 Dust 202) 21 22 Probability of a potentially explosive atmosphere occurring Constant, long-time, often, the majority of times Occasionally, during normal operation Seldom, short-term
1) Only the gray boxes are relevant to drives from SEW-EURODRIVE. 2) Not relevant for electrical drives
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Classification of category - zone
The following overview shows the use of equipment of certain categories in the respective zones:
Gas (G) explosion atmosphere Category1) 1G 2G 3G For use in zones 0, 1 and 2 1 and 2 2 Dust (D) explosion atmosphere Category 1) 1D 2D 3D For use in zones 20, 21 and 22 21 and 22 22 + conductive dust 22
1) Only the gray boxes are relevant to drives from SEW-EURODRIVE.
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Drives to EU Directive 94/9/EC

For explosion-proof equipment, the EU directive 94/9/EC defines which equipment falls under the directive the requirements for the equipment and its assignment to categories the certification of equipment and manufacturing site the responsibility of the manufacturer or the person putting it into circulation
5.1
Conformity evaluation
To assess the conformity, the manufacturer must first decide to which group and category his products belong. This volume deals exclusively with equipment of Group II for the use in areas that do not belong to underground mining. As a further limitation, only categories 2 and 3 that are customary for drives are taken into account.
Category Type Electrical units 2 Non-electrical units 3 All Conformity through EG prototype test and Conformity based on type of construction or Production quality assurance Technical documentation to designated authority and internal production control Internal production control
5.2
EC-type examination
Electrical equipment of category 2 which also includes motors, motors with frequency inverters and sensors of drive engineering must pass through an EC-type examination at a notified body. If the submitted type meets the provisions of the Directive, the notified body issues an EC-type-examination certificate. The certificate contains the name and address of the manufacturer, conclusions of the examination and the necessary dataf for identification of the approved type. A list of the relevant parts of the technical documentation shall be annexed to the certificate and a copy kept by the notified body. Each notified body shall communicate to the other notified bodies the relevant information concerning the EC-type-examination certificate. The manufacturer shall keep copies of EC-type examination certificates and their additions for a period ending at least 10 years after the last equipment was manufactured.
Electrical equipment
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5.3
Production quality assurance

In addition to the EC-type-examination certificate, a requirement for the approval of explosion-proof electrical equipment of category 2 is that the production quality assurance is certified by a notified body und monitored permanently.
5.4
Internal control of production

Mechanical equipment of category 2 and all equipment of category 3 are subject to internal production control. This means that the manufacturer shall establish a designated selection of documentation to cover the design, manufacture and operation of the product and keep it for a period ending at least 10 years after the last piece of equipment was manufactured. The manufacturer shall take all measures necessary to ensure that the manufacturing process guarantees compliance of the manufacture equipment with the technical documentation referred to above.
Mechanical equipment
5.5
Declaration of conformity and CE marking

In all cases, the manufacturer draws up a declaration of conformity that certifies the conformity of the equipment with the corresponding standards and regulations. The equipment receives a CE marking to provide an external indicator of the conformity with European directives. The marking indicates not only conformity with 94/9/EC, but also conformity to all concurrently applicable directives, such as Directive 89/336/EEC (Electromagnetic Compatibility).
The low-voltage directive does not apply to equipment according to 94/9/EC
The Low-Voltage Directive 73/23/EEC, on the other hand, explicitly does not apply to equipment that is subject to the EU Directive 94/9/EC. However, all electrical equipment operated with explosion-proof equipment outside the potentially explosive atmosphere, is subject to the low-voltage directive. The same applies to protection, control and monitoring equipment installed in switch cabinets and, of course, to separate frequency inverters for speed control of motors.
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5.6
Designation key for explosion-proof equipment

All explosion-proof electrical equipment continues to be designated with a uniform key. The complete designation became longer due to the addition of equipment group, category, distinguishing feature for gas or dust, and the listing of the designated authority responsible for certification. For example, an explosion-proof AC motor designated for use in zone 1 with protection type Increased Safety now carries the following identification next to the type designation: EEx e II T3 According to EU Directive 94/9/EC, the new designation is: 0102 II 2G EEx e II T3
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EU Directive 94/9/EC links the protection types to the equipment groups, categories, explosion atmospheres, minimum protection types and temperature classes. The CE marking may be listed. Example: Equipment in "flameproof enclosure" protection type.
0102 CE marking Code number of the notified body 0102: PTB (Physikalisch-Technische Bundesanstalt, Braunschweig) Marking of explosion protection (according to 94/9/EC) Unit group II: Use above ground Category 2: for zones 1, 2, 21, 22 3: for zones 2, 22 Potentially explosive atmosphere G: Gas D: Combustible dust European standards EN II 2 G E Ex d II C T3
Explosion protection Protection type d: Flameproof enclosure e: Increased safety nA: Protection type n; A: Nonsparking equipment c: Mechanical safety k: Liquid immersion Explosion group II Maximum width of gap A: d 0.9 mm B: 0.9 mm > d 0.5 mm C: 0.5 mm > d Surface temperature (C with dust) Temperature class (for gas) Limit temperature T1: max. 450 C T2: max. 300 C T3: max. 200 C T4: max. 135 C T5: max. 100 C T6: max. 85 C
The designation IIA, IIB and IIC applies in connection with protection type "d." For all other protection types, only II is listed here.
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5.7
Mechanical equipment according to EU Directive 94/9/EC

In contrast to electrical equipment, mechanical equipment exhibits important differences for use in potentially explosive atmospheres. In contrast to electrical equipment, the gas and dust explosion protection is covered by the same standard series.
Responsibility of the manufacturer
After the standard series EN 13463 is available in the future, every manufacturer will be able to declare the mechanical equipment for use as equipment category 2 or 3 in direct responsibility as explosion-proof equipment for gas and dust atmospheres. In this context it is also important that the manufacturer approves the equipment of category 2 in direct responsibility for use in zones 1 or 21. For electrical equipment, an EC-type examination is required. The same standard also defines new protection types. In the future, different protection types for mechanical equipment will be applicable. To be able to designate gear units as equipment of category 3, the manufacturer must demonstrate fulfillment of EN 13463-1 Basic Methodology and Requirements. The designation for this category does not contain any protection type. If gear units must now be designated as equipment of category 2, two sections of the standard series EN 13463 must be met. It is left to the manufacturer to decide which part ( 2 8 ) will be met in addition to Part 1. The protection type is defined depending upon the selected part. Of highest importance for gear unit engineering are the standards EN13463-5 and EN13463-8. EN13463-5 is entitled Protection by constructional safety and corresponds to protection type c. EN13463-8 is entitled Liquid immersion and corresponds to protection type k.
New protection types Category 3
Category 2
Protection type c Constructonal safety according to EN134635
Description An explosion protection type which uses structural measures to ensure protection against possible ignition through moving components, generated hot surfaces, sparks and adiabatic compressions.
Application For all non-electrical equipment of category 2G and 2D, provided that they do not have any ignition sources that can be created through anticipated faults.
ok!
k Liquid immersion according to EN134638 A protection type in which potential ignition sources cannot become active or are separated from the ignitable atmosphere, either through complete immersion in a protective liquid or through partial immersion and continuous wetting of its active surface with a protective liquid, so that a potentially explosive atmosphere that can be located above the liquid or outside the equipment housing cannot be ignited. For all non-electrical equipment of categories 2G, 2D, 3G and 3D.
Since the standards series EN 13463 is still under development, no detailed information concerning the contents of protection types or the characteristic properties of these protection types can be given here. The explosion-proof gear units from SEW-EURODRIVE are always designed for applications in categories II2G/II2D. They automatically meet the requirements of categories II3G/II3D, which means explosion-proof gear units of categories II2G/II2D can also be used in applications for categories II3G/II3D.
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5.8
Required accompanying documentation

Each equipment must be accompanied by operating instructions including at least the following particulars: general and specific safety instructions, definite information for the identification of the unit, analogous to the nameplate, definite information on the intended use, warning about the consequences on non-intended use which occurs empirically, important technical data and drawings / diagrams for assembly, installation, startup and maintenance detailed instructions for safe assembly and dismantling (if required), installation, startup and operation, detailed information for safe removal of malfunctions and maintenance,
Operating instructions
including all required diagrams and drawings for this purpose.
Language of country of use Availability at installation site
The operating instructions must be available in the language of the country in which the equipment is to be used and in the original language. The operating instructions is an important document that accompanies the installation, startup and maintenance or troubleshooting or repair with binding and safety-relevant instructions and information. It is part of the equipment and must always be available for work with and on the equipment. The equipment supplier provides the operating instructions together with the equipment upon delivery of the drive to the mechanical and systems engineer. The systems engineer is responsible for forwarding the instructions to the operator of the system.
Declaration of conformity
In addition, every equipment must be provided with the conformity declaration of the manufacturer and, if necessary, a copy of the EC-type examination certificate.
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Figure 4: Operating instructions as mandatory accompanying documentation
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Gas Explosion Protection
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6.1

Categorization
The EU Directive 94/9/EC adopts essentially the existing statutes for electrical equipment and supplements them by the classification into categories.
Ignition temperature Temperature class / explosion group
After determining the danger level and subsequently the zone through the systems operator, the systems operator determines the ignition temperature for the possible gas mixture. The temperature class T.. is derived from the ignition temperature. Yet another characteristic of the gas-air-mixture is the explosion group, i.e., the ability for transmission of internal ignition (relevant for protection type d). Here, the dangerous nature increases from explosion group IIA to IIC. Gases of explosion group IIC are the most dangerous ones.
Temperature class1) Explosion group1) T5 [C] T6 [C] IIA IIB IIC
Gases and vapors Ethanal Acetone Acetylene Ammonia Benzine Benzene (pure) Cyclohexanone Diesel fuels Ethanoic acid Acetic anhydride Ethane Ethyl acetate Ethyl alcohol Ethyl chloride Ethylene Ethyl ether Ethyl glycol Heating oils Carbon oxide Methane Methanol Methyl chloride Naphthalene n-butane n-butyl alcohol n-hexane Phenol Propane Carbon bisulphide Hydrogen sulphide City gas Toluol Hydrogen
Ignition temperature C1) 140 540 305 630 220 - 300 555 430 220 - 300 485 330 515 460 425 510 425 170 235 220 - 300 605 595 455 625 540 365 340 240 595 470 95 270 560 535 560
T1 [C] > 450
T2 [C]
T3 [C]
T4 [C]
300 ... 450 200 ... 300 135 ... 200 100 ... 135 85 ... 100
1) No responsibility is accepted for the accuracy of this information; please verify in particular cases at appropriate authority!
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Unit category
The next step consists of determining the equipment category. Essential criteria for this purpose include: the zone conditions at the site that could make a uniform equipment outfit necessary
6.2
Protection types
In the case of several possibilities, the specification of the protection type is influenced by the following aspects: the costs typical country-specific practices conditions at the site that could make a uniform equipment outfit necessary the operating mode
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Figure 5: Motor with protection type "Increased Safety," II2GEExe design
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Protection type d Flameproof enclosure in accordance with EN 50018
Description Potential ignition sources are enclosed in a flameproof housing in such a way that the explosive gas mixture may enter and possibly ignite, but the mixture burnt inside is forced to cool off on its way to the outside by means of ignition gaps. The temperature which is now lower and not dangerous prevents an ignition of the external atmosphere. The gas-air-mixtures are classified into explosion groups depending upon their ignitability and explosive force. The construction of flameproof housings is dependent upon the maximum experimental safe gap of the ignition gap. In principle, the designation of the flameproof equipment includes the explosion group. To reduce the risk of sparking during operation, special construction measures are taken, such as: maintaining minimum safe gaps, observing creepage clearances and distances, special selection of enameled wires, careful selection of utilized plastics and insulating materials. To prevent excessive surface temperatures, the critical components are taken into consideration in the electrical specification. The verification of maintaining permitted surface temperatures must be carried out through complicated measurements. An error must be observed in the specification of the equipment and the subsequent test. The sum of these measures practically rules out the ignition of air-gas-mixtures. Special monitoring of potential ignition sources with motor protection switch or PTC thermistors ensures that a temperature rise to ignitable temperatures does not occur. With a stalling of the motor at operating temperature condition, the motor protection switch must switch off the motor at the specified Ia/In within the tE time. If PTC thermistors (TF) are used as the only monitoring device, a tA time is determined and specified. With a stalling of the rotor, the TF must trip in cold condition within this time period.
Application Within the scope of electrical drive engineering primarily for equipment where its operation may create sparks: collector, commutator, and slip ring units, mechanical brakes. Also used for squirrel-cage motors if very high danger potentials are present, if the chopping operation changes the motor from thermally critical stator to thermally critical rotor that can no longer be protected via PTC thermistor, or if electronic speed control is required for application in zone 1. This protection type is applicable only for equipment for which sparking is typically not expected. Within the scope of electrical drive engineering, protection type e in the power range up to approx. 50 kW is applied primarily for continuous duty squirrel-cage motors in zone 1 with fixed supply voltage and frequency. In exceptional cases (single certification), electronically speed-controlled squirrel-cage motors can also be designed as e. Single certifications for operating modes S2, S3 and S4 are also possible up to certain limits. In addition, e is frequently used in combinations such as with d: e.g., explosion-proof motors with terminal box in e.
e Increased safety in accordance with EN 50019
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Protection type i Intrinsic safety in accordance with EN 50020
Description Intrinsically safe electric circuits are defined by the fact that a power limitation in the case of a malfunction ensures that neither a spark nor a thermal effect are capable of causing an ignition of explosive atmospheres.
Application Intrinsically safe equipment within the scope of electrical drive engineering are, for example, all types of sensors.
Protection type nA is used primarily nA The construction and specification requirements of Non-sparking in accor- protection type nA correspond largely to those of pro- for equipment of category 3G. dance with EN 50021 tection type e. The major difference lies in the fact that only undisturbed operation (no faults) must be taken into account for protection type nA.
nA
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6.3
Protection type e standard for AC motors in zone 1

The protection type e was developed in Germany several decades ago and has proven itself in practical applications. This protection type made its way into international standards by means of IEC 60079-7 and was subsequently accepted into the series of harmonized European standards as EN 50019.
"e": extremely economical
In contrast to protection type d, increased safety is a very economical and space- and time-saving protection type that is now widely used in Europe. The use of protection type e in zone 1 for squirrel-cage motors in the range up to approximately 50 kW is now given priority in Europe. In Germany, 75 to 80% of the motors in zone 1 are protected in accordance with e.
Principle
The principle of protection type e lies in avoiding ignition sources. The operating principle of the asynchronous motor does not allow any sparking during operation. Constructive measures ensure that any possible risk factors due to breakdowns and equipment failures are reduced to a minimum. For all motors that are used primarily as continuous duty, the remaining main risk, overload and therefore increased surface temperature, is controlled by proven monitors. Motor protection switches approved by a notifed body must be set to the rated current of the motor. The tripping time of the protection switch can be determined by means of the characteristic curve of the protection switch and the starting current ratio IA/IN of the motor. It must be shorter than the tE time of the motor. PTC thermistors are built into the motor winding. They are connected to an approved PTC thermistor trip switch. If the motor, starting in cold condition, is connected to the power supply system in stalled condition, the time tA passes until the PTC thermistor trip switch responds. As a prerequisite, the motor must be a stator-critical motor, i.e., the highest temperature increase occurs in the stator. Here, the starting current ratio IA/IN has the same significance as with a motor protected by a motor protection switch. The safety is increased significantly. Only the monitoring principle with motor protection switch is certified.
Continuous duty
Sole protection through motor protection switch
Sole protection through PTC thermistor
Protection through motor protection switch and PTC thermistor
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Type examination certificate Limitations for "e"
The demonstrated properties of the motors under specified voltage and frequency conditions within the scope of the EC-type examination in connection with the monitoring system are recorded on the examination certificate of the notified body. With the exception of complicated single certifications, protection type e is not possible in the following cases: AC squirrel-cage motors for intermittent operation, switching operation, short-term operation and others that cannot be reliably protected against overload, electrical machines with sliprings, commutators, and collectors (sparking), operation with frequency inverter.
In these cases, the usual protection type is flameproof enclosure "d". The following diagram shows the sample temperature variation on a motor with blocked shaft. Due to the fault, the motor heats up rapidly and can reach critical temperatures within a short period of time. The temperature climbs from the rated temperature N during the heating period tE to the maximum permitted surface temperature T3 = 200 C.
[C] W
200 175 150 T3
N
125 100 75 50 amb 25 0 tE
t
51015AXX
W = Maximum permitted winding temperature N = Steady-state temperature of the motor in operation without malfunctions amb = Ambient temperature
To effectively protect the motor against inadmissibly high temperatures, the disconnection of the motor from the power supply system must be carried out in a time that is shorter than the heating time tE.
24
For this purpose, special motor protection switches with a trip characteristic according to EN50019 were used ( following chart). In practice, this means for motors with protection type "e" that the heating time tE dependent upon the ratio of starting current to rated current (IA/IN) must fall above the trip characteristic (M). The switch-off time of the motor protection switch must fall below the trip characteristic (S).
Example
Drive in accordance with II 2G EEx e II T3: eDT80N4 / tE = 22 s / IA/IN = 4.4
tE [s] 120 60 40 20
10
S
5
EN 50019
1.5
9 10 IA/IN
51016AXX
S = Range of protection device M = Range of motors
25
6
6.4
Special features of speed-controlled AC motors

With the exception of mechanical variable speed gear units, todays squirrel-cage motors in connection with frequency inverters are typically speed-controlled. The explosion protection of such drives must be solved differently than that for equipment linked directly to the power supply system because voltage and frequency are variable, the variable speed also influences the thermal development due to the different cooling effect of the fans.
A distinction is made between explosion-proof motors with inverters outside of the danger zones and motors with integrated frequency inverters.
Use of category 2G in zone 1
The inverter-supplied drives listed first of category 2G for zone 1 can be designed as protection type d or e. The design in e is complicated, generally too expensive for individual drives, and due to the mandatory conformity declaration of every combination of inverter, motor, and monitoring system with the intended function often also unacceptable with respect to the delivery time. However, the flameproof motor can be tested as type independent of the individual inverter make, taking into account the maximum speed setting range for the inverter operation. Thermal monitoring of the flameproof motor is carried out through PTC thermistors as sole protection. The inverter current must be limited to a maximum value of 2 x IN. The frequency may not exceed 110% of the tested frequency. Explosion-proof inverter motors for zone 1 are delivered exclusively in flameproof enclosure.
Use of category 3 in zone 2 or 22
Speed-controlled applications in zone 2 and 22 are designed preferentially with AC squirrel-cage motors of category 3 and frequency inverters approved according to technical specifications in the switch cabinet outside the potentially explosive zone. This requires that the motor is operated with limited torque. The thermal monitoring is carried out exclusively with PTC thermistors and approved tripping unit.
26
MOVIMOT inverter motors of category 3D are also recommended for operation in zone 22.
Figure 6: Geared motor with integrated MOVIMOT frequency inverter in II3D design
51283AXX
27
7
7
Dust Explosion Protection

Today, the dust explosion protection receives a more appropriate significance with the new zone classification according to EU directive 1999/92/EC. Dust explosions occur more frequently than expected. Here, dusts from food and feed are prominent. Until now, the dust explosion protection was regulated imperfectly. A majority of the electrical equipment used in zone 11 was not certified until now.
51284AXX
Figure 7: Brake motor in II3D design (dust explosion protection)
28
Difference compared to gas
In contrast to explosion protection with gas atmospheres, the following must be observed for dust: dust does not evaporate but deposits itself in an increasingly thicker layer the dust explosion protection is highly dependent upon the operating conditions.
An ignitable gas atmosphere can be diluted through strong venting to the point that no danger of explosion exists any longer. If the same procedure is used for dust accumulations, they are whirled up, distributed and form additional sources of danger. The dust layers obstruct the cooling of the equipment and, thereby form an additional ignition risk. This means that periodic cleaning of the respective equipment is absolutely mandatory for the dust explosion protection. For this reason, three characteristic values are used for the atmosphere of ignitable dusts: Ignition temperature Smoldering temperature Maximum surfacetemperature
7.1
Characteristic values for dust explosion protection in accordance with EN50281-1-1:1998

The lowest temperature of a hot surface at which a deposited layer of flammable dust with a thickness of 5 mm barely ignites is referred to as smoldering temperature T5 mm. The lowest temperature at which a dust cloud (dust-air-mixture) with flammable dust of a particle size between approx. 0.02 and 0.4 mm and a concentration between 20 g/m3 and 2 kg/m3 barely ignites is referred to as ignition temperature TCI. The maximum surface temperature that a unit reaches during rated operation and malfunctioning operation is referred to as maximum surface temperature Tmax and is part of the equipment designation. Unless otherwise indicated, this temperature information refers to a maximum ambient temperature of 40 C.
Smoldering temperature Ignition temperature Maximum surface temperature Reference temperature
29
Interaction
The possible change between whirled-up and deposited dust is treacherous: the increased dust concentration in the dust cloud tends to reduce the danger of explosion, the larger thickness of the deposited layer increases it. For this reason, a sufficient safety range must be maintained between the permitted surface temperature of the equipment and the ignition and smoldering temperature of the dust. Interrelationships between the maximum surface temperature and the smoldering or ignition temperature: Tmax = T5 mm - 75 K Tmax = 2/3 TCI
For the specification of the maximum permitted surface temperature of the equipment, the smaller of the two values Tmax must be taken into account.
Example
A grain silo is to be equipped with drives. The values for Tmax from the table "Temperature characteristic of selected dust types" amount to 215 C from the smoldering temperature table and 280 C from the ignition temperature table. The maximum permitted surface temperature may not exceed 215 C. If dust deposits above 5 mm can be expected, the maximum permitted surface temperature of the equipment must be reduced accordingly. The following group of curves furnishes reference values:
400 Tmax [C] 300
200 T5mm 400C T5mm 100 320C T5mm 400C 250C T5mm 320C
10
20
30
40
a [mm]
50
50267AXX
Figure 8: Smoldering temperature in reference to layer thickness
30
The following table contains an overview of solid matters that may cause danger of explosion in dust form as clouds or deposits:
Dust cloud Material designation Ignition Temperature1) [C] 530 560 380 310 420 400 580 460 470 610 440 540 500 530 620 280 500 440 590 450 510 360 480 570 Tmax1) [C] 353 373 253 207 280 267 387 307 313 407 293 360 333 353 413 187 333 293 393 300 340 240 320 380
Dust deposit Smoldering temperature1) [C] 280 350 225 300 290 300 460 220 300 410 340 300 340 380 385 280 245 290 245 300 300 295 450 440 Tmax1) [C] 205 275 150 225 215 225 385 145 225 335 265 225 265 305 310 205 170 215 170 225 225 220 375 365
Aluminum Cotton Brown coal Iron Grain Wood dust Cocoa Rubber Cork Magnesium Milk powder Paper Polyvinyl acetate PVC Soot Sulphur Soya Starch Hard coal Tobacco Tea Peat Wheat flour Zinc
1) No responsibility is accepted for the accuracy of this information; please verify in particular cases at appropriate authority!
31
7
7.2
New zone classification according to EC Directive 1999/92/EC

The introduction of Directive 1999/92/EC results in fundamental changes for the atmosphere of flammable dust. The adoption of the IEC classification of potentially explosive atmospheres with ignitable dust-air-mixtures in 3 zones is new (Figure 9): Zone 20 (zone 10 until now), Zone 21 (zone 10 or 11 until now), and Zone 22 (zone 11 until now).
05992AEN
Figure 9: Change in zone classification
Comparison: "old" and "new" zones
It must be observed here that areas of the old zones 10 and 11 do not automatically change over to zones 20, 21 or 22. The zone classification must be verified in accordance with the new requirements. This situation will intensify after 1 July 2003 (end of transitional period), because only equipment approved for the new zone classification may be sold as of that date. For this reason, system operators should inform themselves early about the new zone classification.
Help
It is highly recommended that the system operator consult the proper monitoring authority (e.g. UL) or employers liability insurance association if any uncertainties exist.
32
7.3
Standards / design regulations for dust explosion protection

The requirements of EU Directive 1999/92/EC for electrical equipment were implemented with the introduction of EN60079-14 (installation regulations) and EN50281-1-2 (equipment regulations). In contrast to gas explosion protection for electrical equipment with several protection types, there are no different protection types for gas explosion protection.
IP enclosures
One of the decisive design criteria for equipment used in potentially explosive dust atmospheres is the fulfillment of certain IP enclosures (protection from foreign matter entering the equipment in accordance with EN 60529). Electrical equipment of category 3 is required to meet at least IP54, for category 2 at least IP6X is required. Figure 10 shows a test object in the dust protection test chamber.
IP Enclosure IP65 Dust-proof housings according to EN50281-1-1
Description The housing is designed so that dust cannot enter the housing. For this reason, ignition sources inside the housing no longer need to be considered. Only the housing itself can represent an ignition source (surface temperature). Constant temperature monitoring of the housing allows for implementing an effective protection.
Application For all electrical equipment with enclosed housing and monitoring of surface temperature.
IP65
IP54 Dust-proof housings according to EN50281-1-1
IP54
The housing is designed so that dust cannot enter the housing in dangerous quantities. For this reason, ignition sources inside the housing no longer need to be considered. Only the housing itself can represent an ignition source (surface temperature). Constant temperature monitoring of the housing allows for implementing an effective protection.
For all electrical equipment of category 3D with enclosed housing and monitoring of surface temperature.
51293AXX
Figure 10: Variable speed geared motor in dust protection testing chamber
33
8
8
8.1
Pusher
Application Examples
Transportation of sacks / standard operating conditions
A pusher at the end of the belt moves the sacks into the palletizer. The pusher is switched 900 times / h and powered with a 4-pole helical-bevel geared motor with brake via a gear rack. The brake stops the pusher at the end positions.
50194AXX
Figure 11: Pusher drive
Based on friction forces, mass moments of inertia and pinion diameter at the output shaft, the following data can be calculated: Mos = 70 Nm nos = 130 min-1 For this reason, a helical-bevel geared motor KA37 DT90S4/BMG
with the following data is used:
51285AXX
Pmot = 1.1 kW Mos = 0 79 Nm SEW operating factor -fB = 2 nos = 133 min1 i = 10.49
34
Palletizers
The palletizer works as a hoist without counterweight and is powered by an 8/2-pole geared motor with brake.
50223AXX
Figure 12: Palletizer drive
Hoist data vhub = 0.6 ms-1 mmax = 400 kg 50 cycles / hour Results in the following calculation: Pmax = approx. 2.7 kW Mstat = ca. 200 Nm A parallel shaft helical geared motor FA57 SDV112M8/2/BMG with the following data is selected: P = 0.8 / 3 kW nos = 32 /129 min-1 i = 21.17 Wbr_max= 55.81 Ws
35
8
8.2
Transportation of sacks / zone 22

The same machine combination is to be delivered for a palletizer to push off flour sacks. The operator prescribes explosion hazard in accordance with zone 22 for this area. Any occurrence of explosive flour dust is expected to be rare and only short-term. The equipment of category 3D approved for operation in zone 22 must fall below the following temperature limit values with their maximum surface temperature: from ignition temperature: 480 C temperature limit = 2/3 480 C = 320 C from smoldering temperature: 450 C temperature limit = 450 C - 75 K = 375 C
Pusher
The following applies to the pusher: it must be guaranteed that the maximum permitted single-shot braking work for the respective brake is not exceeded. Since the maximum braking work of the BMG brake is not reduced in category 3D, it is possible to fall back on the calculation of the output drive. The thermal utilization of the motor by the switching operation may not exceed the thermal classification range B. It is not possible to use a motor protection switch for monitoring purposes. The bimetal has a small time constant and tends to trip after only a few switchings. With the required 900 switchings/h, the drive can be meaningfully protected with PTC thermistors TF only. The calculation for this drive example is: Zperm = Z0 KJ KM KP 900 switchings/h Zperm = 2200 0.8 1 0.6 = 1050 switchings/h The drive in use is a helical-bevel geared motor KA37 DT90S4/BMG/II 3D 120 in II3D 120 design.
51287AXX
36
Palletizers
Explosion-proof pole-changing drives are limited in their adaptability to changing operating conditions. For this reason, we decided to drive the palletizer with a certified inverter drive consisting of a 4-pole geared motor and MOVITRAC 31C frequency inverter also with respect to future adaptation to other procedures. The calculation results in a parallel shaft helical geared motor type FA57 DV112M4/BMG/II3D T120 which is powered by the MOVITRAC 31C frequency inverter of type MC31C 030-503-4-00.
51317AXX
Parallel shaft helical geared motor in shaft-mounted version, dust explosion protection design II3D 120 and MOVITRAC 31C frequency inverter
37
8
8.3
Transportation of sacks / zone 1

The operating range is defined as zone 1 for the use in a chemical plant. Explosive gas may occur occasionally during normal operation.
Pusher
A brake motor of II2G Eex ed IIB T3 design is selected for the clocked pusher, type eDT90S4/BC2/HR/TF with 1.1 kW. The starting frequency test is identical with that listed under 8.2.: Zperm = 2200 0.8 1 0.6 = 1050 switchings/h 900 switchings/h The designation for the complete geared motor is KA37 eDT90S4/BC2/HR/TF with i = 10.49. In addition, it must be checked whether the single-shot maximum braking work for the BC2 brake is not exceeded. The calculation results in a braking work of 70 Ws. The maximum braking work of the BC2 brake with approx. 500 Ws for 900 switchings/h is much higher.
Palletizers
If a frequency inverter is used for exact positioning of the hoist drive of the palletizer, a flameproof brake motor is required that is powered by a MOVITRAC or MOVIDRIVE frequency inverter. Explosion-proof motors are approved for inverter operation with a certain maximum speed setting range based on their type examination. Unlike protection type Increased Safety, they are not tied to certain frequency inverters. Thermal monitoring of the flameproof motor is carried out through PTC thermistors as sole protection. The inverter current must be limited to a maximum value of 2 x IN. The frequency may not exceed 110% of the tested frequency.
38
Service and Maintenance

All service and maintenance work must be performed by qualified personnel according to EU Directive 1999/92/EC. It must be guaranteed that no additional explosion risk exists during service and maintenance work.
Applicable Directive of the European Union 94/9/EC: Distribution (production) of explosion-proof equipment 1999/92/EC: Operation (maintenance) of explosion-proof equipment Corresponding German law Equipment safety law Explosion protection regulation Labor protection law Equipment safety regulation
In Germany, the EU Directive 1999/92/EC was converted to become national law through the new Operational Reliability Regulation (Betriebssicherheitsverordnung, BetrSichV) dated October 3, 2002. The new operational reliability regulation invalidates a number of German regulations effective until June 30, 2003, the end of the transitional period for the introduction of EU Directive 1999/92/EC, such as: ElexV Acetylene regulation
Operational reliability regulation

Qualification of personnel
Original text of operational reliability regulation (7) Qualified personnel as defined by this regulation are those individuals who possess the necessary technical knowledge for testing tools and fixtures based on their technical training and current work experience. (3) The employer must ensure that tools and fixtures are tested for safe operation by qualified personnel following repair work that may impact the safety of tools and fixtures. The employer must document the test results according to 10. The appropriate authority can demand that these documents are also made available at the operating location. The documents must be kept for a reasonable time, but at least until the next test. If tools and fixtures subject to 10 section 1 and 2 are used outside the company, they have to be accompanied by a proof of the performance of the last test.
Testing after repair
Documentation of test results
Extreme care
All work performed in this context must be carefully documented. A provisional maintenance due to time constraints for the purpose of maintaining production contradicts the notion of protection and is not allowed. For all assembly and disassembly work, the respective documentation of the manufacturer must be followed in any case. For service and maintenance, a distinction must be made with respect to general maintenance and special maintenance.
39
9
9.1
General maintenance
General maintenance includes all work that does not deal with explosion protection. This includes, for example, replacing bearings, replacing gaskets, etc. In performing this work, only genuine spare parts from the manufacturer or spare parts approved by the manufacturer may be used.
Qualification of personnel
The work is performed by qualified personnel according to the operational reliability regulation. This includes work for which the explosion-proof housing of an equipment must be opened. For this type of work, special care should be paid to the ignition gap. If the damaged parts are replaced by genuine spare parts from the manufacturer, it is not necessary to consult an expert. The following applies to general maintenance: It is not necessary to obtain a certificate about the continued suitability with respect to explosion protection. It is nevertheless advisable to document the work performed.
9.2
Special maintenance
Special maintenance includes all work that concerns the explosion protection of the equipment. This includes the maintenance of the winding of a motor of protection type Increased Safety or work on the ignition gaps of a flameproof equipment. To perform this type of work, an appropriate technical equipment of the repair facility and qualification of the repair personnel is required.
Individual test
The equipment must be tested after maintenance. These tests encompass, for example, the test of the motors temperature rise with locked rotor for the rewinding of a motor of protection type e. For example, if the ignition gaps of flameproof equipment are damaged by scratches, these components must be replaced with genuine spare parts from the manufacturer. However, qualified personnel can check the components for continued usability and issue an appropriate certificate if the test is positive. A test must also be performed by qualified personnel if the damaged parts are replaced with appropriate components that are not from the manufacturer. This includes parts such as those made by the repair facility. The following applies to special maintenance: Only qualified personnel may perform maintenance work. The measures taken must be documented. In addition, the work performed is noted on the equipment. If an equipment is repaired by the manufacturer or tested by the manufacturer following a repair, an examination is not necessary. In this case, the manufacturer certifies that the equipment meets the requirements of the explosion protection.
Certificate
40
A Comparison of Foreign Regulations
10
10

Most international rules and regulations concerning explosion protection are similar in so far as they are all based on the central regulation body of the IEC (International Electrotechnical Commission). It defines the fundamental principles of explosion protection, zone classification, and design requirements although at present only for electrical equipment. All Asian, African, Central and South American countries as well as Australia and New Zealand are also influenced by the IEC, as are the countries of the European Union and all other European countries. Only the North American continent with the US and Canada represents an exception, but one which affects all others as entry restrictions to this market. At a closer look, certain countries in Asia and Central and South America that are heavily influenced by American companies feature particular regulations that are derived from American rules and mostly in the form of factory regulations. In principle, orders from non-EU countries should be checked with respect to the rules that are in force for applications in potentially explosive atmospheres.
IEC vs. North American regulations
10.1 North American regulations

Traditional class and division
In the US and Canada, potentially explosive atmospheres are defined as Class I for flammable gases, vapors, mists, Class II for flammable dusts, and Class III for fibers and lint from textiles.
Depending on the frequency and duration of dangerous concentrations, the atmospheres are divided further into Division I and Division II.
This is the traditional classification until now.
IEC influence
The zone classification according to IEC has been effective in Canada since 1988 and in the US since 1996 for all areas of Class I. In Canada, the zone classification is since mandatory for all newly constructed systems; in the US, the user can decide on the system that is best suited for his purpose. In addition, explosive gases, vapors and mists of Class I are divided into groups A, B, C and D. Flammable dusts of Class II are differentiated according to groups E, F and G.
41
10
In contrast to the European regulations based on the IEC, group A is the most dangerous gas group, with decreasing danger to group D. Confusing is the fact that Canada, in connection with the compulsory introduction of zone classification in accordance with IEC, also performs a classification of the explosiveness of gases in accordance with the IEC for all new systems effective 1988; here, group C is the most dangerous one. The surface temperatures of the equipment are classified into temperature classes T1 ( 450 C) through T6 ( 85 C) in accordance with the IEC. Fine intermediate levels exist for the (older) classification into divisions, e.g., T2A, T2B, T2C, T2D, etc., while the zone classification utilizes the grading in accordance with the IEC. Temperature classes are also used with the classification into divisions for dust protection.
Standards and regulations for explosion-proof systems
The classification of potentially explosive atmospheres, the installation of electrical systems in these areas, and the design requirements for appropriate electrical equipment is regulated with the National Electrical Code (NEC) for the US and the Canadian Electrical Code (CEC) for Canada. Additional regulations of various testing authorities, especially Underwriters Laboratories (UL) and Factory Mutual (FM), apply to the construction and testing of explosionproof systems and equipment in the US. Without test certificates from these authorities, the operation of explosion-proof systems in the US is traditionally not approved by the approval authority. In Canada, the Canadian Standards Association (CSA) is responsible for testing and certification. The licensing procedures for the operation of explosion-proof electrical systems is similar to that in the US.
42
Overview of Standards
11
11
Overview of Standards
EN 60079-10 Electrical apparatus for explosive gas atmospheres (Part 10: Classification of hazardous areas) EN 60079-14 Electrical apparatus for explosive gas atmospheres (Part 14: Electrical installations in hazardous areas [other than mines]) EN 50014 Electrical apparatus for potentially explosive atmospheres (General requirements) EN 50018 Electrical apparatus for potentially explosive atmospheres: Flameproof enclosures "d" EN 50019 Electrical apparatus for potentially explosive atmospheres: Increased safety "e" EN 50020 Electrical apparatus for potentially explosive atmospheres: Intrinsic safety "i" EN 50021 Electrical apparatus for potentially explosive atmospheres: Protection type "n" EN 50281-1-1 Electrical apparatus for use in the presence of combustible dust (Part 1-1: Electrical apparatus protected by enclosures construction and testing) EN 50281-1-2 Electrical apparatus for use in the presence of combustible dust (Part 1-2: Selection, installation and maintenance) EN 13237-1 Potentially explosive atmospheres: Explosion prevention and protection (Part 1: Terms and definitions for equipment and protective systems intended for use in potentially explosive atmospheres) EN 13463-1 Non-electrical equipment for potentially explosive atmospheres Basic method and requirements. EN 13463-5 Non-electrical equipment for potentially explosive atmospheres Basic method and requirements. (Part 5: Protection type "Protection by constructional safety" EN 13463-8 Non-electrical equipment for potentially explosive atmospheres Basic method and requirements. (Part 8: Protection type "Protection by liquid immersion"
11.1
Figures
[1] Figure 1: Berufsgenossenschaftliches Institut fr Arbeitsschutz - BIA (part of the Hauptverband der gewerblichen Berufsgenossenschaften HVBG), St. Augustin [2] Figure 2: Ex magazine, Issue no. 7 of 09-27-1995; published by: R. Stahl Schaltgerte GmbH, Knzelsau
43
12
12
List of References
List of References
Brenn- und Explosionsgren von Stuben (BIA-Report), Hauptverband der gewerblichen Berufsgenossenschaften, 12/97 Elektrischer Explosionsschutz nach DIN VDE 0165 (a praxis-oriented introduction to applicable guidelines, standards and regulations), E. Linienklaus, VDE-Verlag Explosionsgeschtzte Elektromotoren (Explanations for DIN VDE 0165, 0170/1 and 0530 as well as relevant standards with notes on technical-economical drive optimization), K. Falk, VDE-Verlag Sicherheitstechnische Kennzahlen brennbarer Gase und Dmpfe; K. Nabert, G. Schn; Deutscher Eichverlag; 2. exp. Edition. Braunschweig 1963, with 5th Addendum 1980 Explosionsschutz, Explosionsschutzverordnung (ExVO), Verordnung ber elektrische Anlagen in explosionsgefhrdeten Rumen (ElexV) (Commentary and documentation list); W. Jeiter, M. Nthlichs; Erich Schmidt Verlag, Bielefeld 1968 Explosionsgeschtzte Maschinen der Schutzart "Erhhte Sicherheit" (Ex)e (Volume 3 of PTB testing rules); H. Dreier, H. Stadler, U. Engel, H. Wickboldt; Deutscher Eichverlag; Braunschweig 1969, reprint 1978 Umrichtergespeiste Drehstromantriebe; U. Engel, H. Wickboldt; PTB Information 98, Number 1; 1988 Explosionsgeschtzte Drehstrommotoren und die neuen Normspannungen; U. Engel, H. Wickboldt; ETZ Volume 112, Number 20; 1991 Grundsatzuntersuchungen fr explosionsgeschtzte elektrische Betriebsmittel zum Einsatz in Zone 2 (PTB final report) Explosionsgeschtzte Drehstrommotoren in Zndschutzart "Druckfeste Kapselung" / Sichere Komponenten auch im Umrichterbetrieb; H. Grass Installationstechnik in der Zone 2; K. de Haas; 11. Ex Experts Seminar; 1991 Explosionsschutz bei Umrichterantrieben; U. Engel, H. Wickboldt; Conference documentations on ZVEI/FV1 Exchange of Experiences on Inverter Supply; 1993 Neue Normspannung 400 V nach IEC38: Weiterbetrieb oder Umwicklung von Drehstrommotoren; H. Greiner; ema, Elektrische Maschinen, Number 4; 1993 Explosionsgeschtzte Industriemotoren entsprechend Europanorm; H. Grass; Technische Information der Firma Felten & Guillaume Explosionsgeschtzte Elektromotoren; K. Falk; VDE Documentation Series 64; VDE-Verlag; Berlin 1997 Vernderungen in den Rechtsgrundlagen des Explosionsschutzes; H. Wehinger; STAHL-Ex-Journal; 1996 Elektrische Betriebsmittel der Zndschutzart "n" fr explosionsgefhrdete Bereiche der Zone 2; B. Limbacher, W. Berner; STAHL-Ex-Journal; 1998 Elektroinstallation und Betriebsmittel in explosionsgefhrdeten Bereichen; H. Olenik, H. Greiner u. A.; Verlag Hthig & Pflaum; Munich 1999 Normung im Bereich des nichtelektrischen Explosionsschutzes; M. Kloska; STAHL-Ex-Journal; 1999 Explosionsschutz bei Getriebemotoren; H. Greiner; Danfoss Bauer SD 300
44
Glossary
13
13
Glossary
The certificate of a notified body for the successful explosion protection examination of a specimen representative of the production. A specified qualitative value, usually supplied by the manufacturer, for a specified operating condition of an equipment, protective system or component. Legally authorized entity that performs expert explosion protection tests and issues appropriate certificates. Use of equipment, protective systems and devices in accordance with the equipment group and category and taking all manufacturers data into account that are required for the safe operation of the equipment. The specified devices are: Safety and control devices for use outside of potentially explosive atmospheres that are, however, required for or contributing to the safe operation of equipment and protective systems with respect to explosion risks. Required trade symbol in the European Union that indicates the conformity of the designated product with the applicable directives of the EU council. A protection type where all components that could ignite a potentially explosive atmosphere are placed in an enclosure that withstands the pressure developed during an internal explosion of an explosive mixture and prevents the transmission of the explosion to the explosive atmosphere surrounding the housing. The principle of protection type "e" lies in avoiding ignition sources. Constructive measures ensure that any possible risk factors due to breakdowns and equipment failures are reduced to a minimum. Combustion process which releases dangerously high energy for a short time. Mixture of atmospheric oxygen and flammable gas or dust. Degree of ignitability (dangerousness) of explosive gases. Measure to prevent an explosion source or avoid harmful consequences. The equipment is classified according to the potentially explosive atmosphere in which it will be used. Within an equipment group, the equipment is classified into categories according to the protection level.
EC-type examination certificate Rated value
Notified body Intended use
CE marking
Flameproof enclosure
Increased safety
Explosion Potentially explosive atmosphere Explosion group Explosion protection Unit group Unit category
Smoldering temperature (of a dust layer) The lowest temperature of a hot surface at which a dust layer with a specified thickness ignites on this hot surface (EN 50281-2-1). IP enclosure Declaration of conformity Protection type defined in EN 60529 of an electrical equipment to prevent solids and water from entering. Written explanation from the manufacturer or the person putting the product into circulation about the conformity of the product with the applicable EU Directives. The highest temperature reached if an equipment or a protection system is operated under its anticipated operating conditions. The highest temperature that is reached in operation under most adverse conditions (but within the established tolerances) by a part or the surface of an equipment, protective system or component. The smallest energy determined under specified testing conditions that is capable of barely igniting the easily ignitable mixture. The situation in which the equipment, protective systems and components meet the intended function within their construction parameters. A housing that prevents dust particles from entering in visible amounts.
Maximum operating temperature Maximum surface temperature
Minimum ignition energy Normal operation Dust-proof housing
45
13
Glossary
Dust-protected housing
A housing where the entry of dust is not completely blocked, but where dust is not entering in sufficiently high amounts that would have an adverse affect on the safe operation of the equipment. Dust may not collect at locations inside the housing where it could create an explosion risk. Trip time = warming time of motor winding with locked rotor until response of PTC thermistor, based on the winding temperatur of 20 C. Classification of equipment, protective systems or components for use in explosive atmospheres according to their maximum surface temperature. Warming time that passes at stalling until the motor winding has warmed up from operating temperature to lower temperature limit of the temperature class (for protection with motor protection switch in protection type EEx e). If two housing sections are connected to each other such that the transmission of an igniting flame is barely prevented by the length and width of the resulting gap, this gap is referred to as flameproof joint. Any spark (mechanical, electrical or electrostatic) that can act as ignition source for igniting a given explosive atmosphere. The special measures applied to equipment to prevent the ignition of a surrounding explosive atmosphere. The lowest temperature of the hot inside wall of an oven at which a dust cloud in the air of the oven ignites (EN 50281-2-1).
tA time Temperature class tE time
Flameproof joint
Ignitable spark Protection type Ignition temperature (of a dust cloud)
46
Getriebemotoren \ Antriebselektronik \ Antriebsautomatisierung \ Services
SEW-EURODRIVE GmbH & Co KG P.O.Box 30 23 D-76642 Bruchsal/Germany Phone +49 7251 75-0 Fax +49 7251 75-1970 http://www.sew-eurodrive.com sew@sew-eurodrive.com

Explosion-Proof Drives

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Explosion-Proof Drives to EU Directive 94/9/EC

Drive Engineering Practical Implementation

Practical Engineering - Explosion-Proof Drives to EU Directive 94/9/EG

Purpose of Explosion Protection

Purpose of Explosion Protection

Figure 1: Serious damages caused by an aluminum dust explosion [1]

Figure 2: Gas explosion in a silo [2]

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Purpose of this Documentation

Purpose of this Documentation

Figure 3: "Explosion-Proof Drives" catalog

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Explosion Protection in Europe Today and Tomorrow

Explosion Protection in Europe Today and Tomorrow

Regulations for equipment and systems

Uniform European solution

Transitional periods of EU directives 94/9/EC and 1999/92/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Explosion Protection in Europe Today and Tomorrow

Useful Internet addresses

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

The New Protection Concept

The New Protection Concept

Overview of EU Directive 94/9/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

The New Protection Concept

Level of protection Very high

Equipment remains in operation with existing explosive atmosphere

1) Only the gray boxes are relevant to drives from SEW-EURODRIVE.

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

The New Protection Concept

Type of equipment Motors (electrical equipment)

Gear units (mechanical equipment)3)

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

The New Protection Concept

Overview of EU Directive 1999/92/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

The New Protection Concept

Classification of category - zone

1) Only the gray boxes are relevant to drives from SEW-EURODRIVE.

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Production quality assurance

Internal control of production

Declaration of conformity and CE marking

The low-voltage directive does not apply to equipment according to 94/9/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Designation key for explosion-proof equipment

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC

Mechanical equipment according to EU Directive 94/9/EC

Responsibility of the manufacturer

New protection types Category 3

Protection type c Constructonal safety according to EN134635

Drive Engineering - Practical Implementation Explosion-Proof Drives to EU Directive 94/9/EC

Drives to EU Directive 94/9/EC