ABB drives and motorsATEX compliant low voltage AC drives and motors for chemical, oil and gas

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2 3AUA0000037223 REV A EN 8.9.2008 ABB

Profi le

When an electric motor and an AC drive, together with the driven equipment, are installed in a potentially explosive atmosphere, there is an increased risk

of an explosion occurring.

To tackle this situation, European Union (EU) directives – known as ATEX – have been implemented covering the Essential Health and Safety Requirements (EHSRs) for products used in potentially explosive atmospheres.

ATEX is the French acronym for Atmosphères Explosibles (explosive atmospheres) and is used to describe the application of two directives, covering product safety and worker safety - see page 12 to 15.

The importance of ATEX

ATEX is not new: it is a group of EU directives to rationalize legislation and increase the harmonization of equipment sales across the EU so that a UK company, for example, can purchase equipment from Germany without worrying about standards in different countries.

The objective of Product Directive 94/9/EC (also known as ATEX 95) is to ensure that equipment

and protective systems function safely when used in potentially explosive atmospheres. ATEX 95 covers the minimum requirements applicable to mechanical and electrical equipment capable of causing an explosion through its own potential sources of ignition.

Directive 94/9/EC is made under Article 95 of the European Treaties and is referred to as ATEX 95. It is intended to allow the free movement, within the EU, of equipment and systems for use in a hazardous area without the need for separate testing and documentation.

The Worker Protection Directive 1992/92/EC (also known as ATEX 137) covers the minimum requirements for improving the health and safety protection of workers operating in potentially explosive atmospheres. ATEX 137 also defi nes the various Zones for gases, vapors and dusts.

ATEX 95 and ATEX 137 harmonize the standards and rules for designing, manufacturing, testing, using and maintaining products and equipment throughout the EU. They also establish a framework of certifi cation bodies - the Ex Notifi ed Bodies - who are able to undertake the supervision of products and quality systems.

Shared responsibility

The installation of electrical equipment in potentially explosive atmospheres used to be a straightforward procedure, requiring only the selection of equipment certifi ed for the appropriate area. However, the arrival of the ATEX directives from the EU changes all that.

While the end-user is responsible for installation of products and equipment, the electric motor manufacturer is responsible for safety of the motors and for delivering maintenance and installation instructions. The end-user must defi ne the Zone, the gas group, the temperature class and the preferred protection class. Based on this information, the manufacturer proposes the product/equipment to be used.

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Profi le

The impact on AC drives and motors

Electronic speed control of AC motors brings a range of benefi ts to processing industry applications including:

soft startprecise control of speed and torquesignifi cant energy savingsoptimal process control, removing bottlenecks in production

An ATEX approved AC motor and AC drive combination gives safe, economical power combined with effective control. Usually only the motor and driven load are installed in the potentially explosive atmosphere, with the drive being installed in a safe area.

By choosing an ABB ATEX package, end-users can be confi dent that the motor and drive combination is optimized for their application. The package can result in a cost benefi t: end-users that choose to match their own drive and motor combinations may be forced to select a larger motor than optimum because of the limited selections available from their chosen manufacturers.

Global impact

Although ATEX directives are only applicable within the EU, they are based on European standards which has lead to their principles being demanded by users throughout the world.

However, ATEX approval is generally not recognized outside Europe and industries with hazardous areas should investigate which approval schemes apply locally.

The Zone system divides hazardous areas into Zones, based on the presence of a potentially explosive atmosphere. The Zone system is used all over the world, except in North America. Here, a system of Classes and Divisions is used to denote hazardous locations. The Classes are based on the

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type of hazard, while the Divisions are based on the risk of explosion that the material presents (see Table 1 below). Both the EU and the US system provides effective solutions for managing electrical equipment (ATEX directives also apply to mechanical equipment) in hazardous areas and both systems have excellent safety records.

Some US companies have now established the use of Zoning in their coding to be compliant with ATEX directives and are therefore able to sell products and equipment to EU end-users.

Table 1: US system of Classes and Divisions compared to EU Zone system.

Hazardous material

US Class, Division system

EU Zone system

Gases or vapors

Class I, Div. 1 Class I, Div. 2

Zone 0 and Zone 1Zone 2

Dust Class II, Div. 1Class II, Div. 2

Zone 20, Zone 21,Zone 22

About this brochure

This brochure aims to give a practical overview of the requirements to be considered when selecting an AC drive and electric motor for use in hazardous environments within chemical, oil and gas.

The focus is on using ABB low voltage AC drives alongside an ABB AC motor. With this combination, users can rest assured that by following the advice contained herein, a safe and reliable ATEX approved installation will result.

4 3AUA0000037223 REV A EN 8.9.2008 ABB

Products

Main sources of ignition risk

The main sources of risk affecting AC drives and motors in hazardous environments are:

Sparks in the motor windings – due to insulation breakdown caused by steep voltage rises and refl ected voltages. Sparks in the motor bearings - due to common mode voltages caused by the AC drive. Increase in the motor surface temperature - resulting in reduced cooling capacity or overload of the motor. Reduced cooling capacity is caused by driving the motor outside its specifi ed speed range. Increased surface temperature can occur if the motor is incorrectly dimensioned for use with an AC drive.

Protection against ignition from sparks in the motor windings

The steep voltage rises in the output waveform of some AC drives can cause stator winding insulation breakdown. These voltage rises can also lead to another phenomenon called refl ected voltages, which can increase the motor terminal volts by as much as 2.5 times the nominal voltage. For nominal voltages between 500 V and 600 V, the motor needs either reinforced insulation or the drive requires du/dt fi lters. Above 600 V, both reinforced insulation and du/dt fi lters are needed. Please consult the motor manufacturers catalog for more detailed instructions. More information on pages 11 to 12.

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Factors affecting selection of Ex motor and AC drive

Figure 1. Refl ected voltages can cause sparks in motor windings.

When controlling motors in potentially explosive atmospheres, it is important to be aware of the effects an AC drive has on the motor.

The effect of an AC drive on the operating conditions of a motor changes, compared to Direct On Line (DOL) operation, due to:

Higher voltage stress due to steep voltage pulsesCommon mode voltages and currents Higher motor surface temperature rise due to non-sinusoidal supply

For these reasons ATEX directives call for extra attention to be given when an Ex motor is used with an AC drive.

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Effects of an AC drive on the motor

Total accumulated voltage

Original voltage pulse

Refl ected voltage pulse

Protection against ignition from sparks in the motor bearings

An AC drive can be a source of common mode voltages. Depending on the motor frame size, this source can induce voltages across the frame of a motor, which in turn can give rise to a current through the motor bearings. This can cause premature bearing failure with a risk of sparks, which could cause ignition.

For motors with frame size IEC 280 and above, insulated non-drive end bearings are critical to break the potential paths for circulating currents. In addition to insulated bearings, a common mode fi lter within the AC drive is required for motors with frame size IEC 344 and above.

The above measures will reduce the risk of ignition and prolong the bearing life.

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Products

Protection against excess motor surface temperature

High motor surface temperatures may be caused by running the motor at reduced speed without adequate cooling. With a shaft mounted cooling fan the reduced speed will reduce the air fl ow available to cool the motor.

For use in hazardous area locations, the motor surface temperature rise must be rigorously tested in accordance with the appropriate standards.

The methods for ensuring the correct motor surface temperature depends on the fl ammable material surrounding the motor. The key goal is to ensure that the surface temperature stays below the allowed limits. For some cases, only testing is allowed; while for others, direct measurement is possible; while some require calculations as a last option, if testing is not practical. Method 1:Use a direct temperature measurement signal from the motor and use this signal to initiate shut down when excess temperature is present. This is only valid for stator-critical motors.

How to obtain certifi cationThe motor, especially when used with a non-DTC drive, can be protected using direct thermal control. This can be achieved using thermal sensors in the motor windings that control either a certifi ed disconnection circuit or contactor. Method 2:To control and limit the power which is transferred to the motor and thus prevent excess temperature. To achieve adequate cooling of motors driven by AC drives, separate cooling is sometimes used as the fan speed of a self-cooled motor drops with the motor speed.

How to obtain certifi cationOption 1: When using an ABB industrial drive, its motor control platform - Direct Torque Control (DTC) - can help reduce the temperature. Using DTC control, along with ABB’s dimensioning and selection tool DriveSize, prevents overtemperature. The dimensioning is based on type tested load capacity curves. This also ensures the application is optimized for the load. Option 2: Combined test with motor and drive to ensure that the motor surface temperature does not exceed the limits.

Figure 2. Typical motor load capacity curves.

Motors with separate cooling

Self-cooled motors

Frequency (Hz)

T/T

N (%

)

6 3AUA0000037223 REV A EN 8.9.2008 ABB

ABB industrial drives, 0.55 to 5600 kW

ABB industrial drives are available as complete AC drives and as modules to meet the requirements of the chemical, oil and gas industries. These highly fl exible AC drives can be tailored to meet the precise needs of industrial applications and as such specifi c confi guration of the drives can be carried out during ordering.

The complete drives and modules cover a wide range of powers and voltages. ABB industrial drives come with a broad selection of inbuilt options. These drives can be easily programmed which makes adaptation to different applications easy.

Adaptive programming - like having a PLC (programmable logic controller) inside the driveDTC (Direct Torque Control) - well proven motor control platformAll major types of drive topology covered - 6-pulse, 12-pulse, 4-quadrant, low harmonic, air-cooled, water-cooled, etc.

Wall-mounted drives from 0.55 to 200 kW, (230 to 690 V)Free-standing drives from 45 to 560 kW, (230 to 690 V)Drive modules from 0.55 to 1900 kW (230 to 690 V)Cabinet-built drives from 45 to 2800 kW, (380 to 690 V)Multidrives from 1.1 to 5600 kW, (400 to 690 V)

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What is DTC?

Widely recognized as a major leap forward in motor control, DTC (Direct Torque Control) is an optimized AC drives control principle where inverter switching directly controls the motor variables i.e. fl ux and torque. The measured motor current and voltage are used as inputs to an adaptive motor model which produces an exact actual value of fl ux and torque every 25 microseconds. This is the motor control method used in the ABB industrial drive.

ABB drives

ABB drives is the generic name used to defi ne the portfolio of AC drives, from 0.18 to 5600 kW, manufactured by ABB.

ABB is a world leading brand that is recognized as the global number one supplier of low voltage AC

Products

drives, with the widest available range from any manufacturer.

ABB drives is a reference for drives users the world over signifi ng reliability, simplicity, fl exibility and ingenuity, throughout the lifecycle of an AC drive.

73AUA0000037223 REV A EN 8.9.2008ABB

ABB standard drives, 0.75 to 355 kW

ABB standard drives are simple to buy, install, confi gure and use, saving considerable time. They are widely available through ABB’s channel partners, hence the use of the term standard. The drives have common user and process interface with fi eldbus, common software tools for sizing, commissioning, maintenance and common spare parts.

Assistant control panel providing intuitive use of the drivePatent pending swinging choke for superior harmonic reductionSensorless vector and scalar control

Note: These drives DO NOT feature DTC

Wall-mounted drives from 0.75 to 110 kW, (380 to 480 V) (230 V also available)Free-standing drives from 110 to 355 kW, (380 to 480 V)

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ABB general machinery drives, 0.37 to 22 kW

ABB general machinery drives are specifi cally designed for use in machines. The drives are designed to be the fastest drives in terms of installation, setting parameters and commissioning. The basic products are as user-friendly as possible, yet providing high intelligence. The drives offer diverse functionality to cater for the most demanding needs.

IP20 as standard (UL type 1 as option)Advanced functionality with sequence programmingConfi guration of unpowered drive in 2 sec.

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Products

8 3AUA0000037223 REV A EN 8.9.2008 ABB

Products

ABB hazardous area low voltage motors

Flameproof motors, frame size 80 to 400, 0.55 to 630 kWIncreased safety motors, frame size 80 to 560, 0.25 to 1000 kWNon-sparking motors, frame size 71 to 560, 0.25 to 2000 kWEx tD/DIP motors, frame size 71 to 400, 0.25 to 630 kW (see below)

Terminal boxes of ABB low voltage Ex motors are designed for 240 V or higher and thus meet the requirements of AC drive use.

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ABB Ex tD/DIP motors

With Ex tD/DIP motors, any explosion transmission of dust is prevented. The following should be considered when using Ex tD/DIP motors.

The ingress of dust into the motor is prevented - IP55 or IP65 for non-conductive dust and IP65 for conductive dust.The maximum surface temperature outside the motor must not exceed the temperature class for which the motor is certifi ed.No sparks must occur outside the motor enclosure.

When using an AC drive:

Certifi cation can be based on type test results or calculation results - depends on agreement between the manufacturer and certifi cation authority.Certifi cate for Ex tD/DIP (in Zone 22 area with non-conductive dust) motors with AC drive can be announced by factory or authorized certifi cation body (third party certifi cation). Certifi cate can be machine specifi c or standard type.

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Products

Considerations when using an ABB drive with a non-ABB motor

This brochure aims to show the merits of using an ABB low voltage AC drive with an ABB motor and the benefi ts of this ATEX approved combination.

However, while ABB drives can be used with motors from other manufacturers it is important to consult the motor manufacturer. In particular, the following considerations need to be discussed:

Load capacity of the motor.Protection method - see page 5 for options.Peak voltage. du/dt limitation - needed to combat steep voltage rises in the output waveform. du/dt fi lters protect motor insulation and reduce bearing currents.Approval (test/calculation).

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10 3AUA0000037223 REV A EN 8.9.2008 ABB

Products

The route to EC Declaration of Conformity for ABB low voltage AC drives and motors

Important note: This fl owchart only applies to standard ABB motors

If the motor voltage is <500 VCheck the frame size:

Up to IEC 250...

IEC 280 to 315...

IEC 355 and above...

...a standard motor is ok

...insulated non-drive end bearings

...insulated non-drive end bearings

...common mode fi ltering installed

motor needs

motor needs

AC drive needs

If the motor voltage is 500 to 600 V

Motor needs reinforced winding insulation

AC drive needs du/dt fi ltering fi tted

In addition, check the frame size.

OR

Up to IEC 250...

IEC 280 to 315...

IEC 355 and above...

...if a du/dt fi lter is selected for

the drive (as above) a standard

motor is ok

...insulated non-drive end bearings

...insulated non-drive end bearings

...common mode fi ltering installed

motor needs

motor needs

AC drive needs

If the motor voltage is 600 to 600 V

Motor needs reinforced winding insulation

AC drive needs du/dt fi ltering fi ttedAND

In addition, check the frame size.

motor needs

motor needs

AC drive needs

Up to IEC 250...

IEC 280 to 315...

IEC 355 and above...

...no additional motor or drive

requirements other than those

above

...insulated non-drive end bearings

...insulated non-drive end bearings

...common mode fi ltering installed

Ex nA

Ex p

Ex dEx de

Ex tD/DIP

Ex nA

Ex p

Ex dEx de

Ex tD/DIP

ABB drive without DTC

ABB drive with DTC

113AUA0000037223 REV A EN 8.9.2008ABB

Figure 3. EC Declaration of Conformity for ABB low voltage AC drives and motors

Products

ABB industrial drive,

without DTC

ABB general machinery drive,

ACS350

ABB standard drive,

ACS550

Please check motor load capacity curves

to ensure correct dimensioning of the motor

Additional testing required to obtain EC Declaration

of Conformity

EC Declaration of Conformity

ABB industrial drive DriveSize - Using ABB’s DriveSize tool, users can select a suitable combination of motor and drive. The tool also shows combinations that have not been tested.

Web site - contains all relevant certifi cates for tested drive and motor combinations.www.abb.com/driveswww.abb.com/motors&genetartors

EC Declaration of Conformity

12 3AUA0000037223 REV A EN 8.9.2008 ABB

Expertise

What is a potentially explosive atmosphere?

The following constitutes a potentially explosive atmosphere:

The frequency with which a potentially explosive atmosphere may exist.The capability of a gas or dust laden atmosphere to ignite.

Explosive gases and dust are classifi ed according to the likelihood of their ignition, and other characteristics including:

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Table 2. Categorization of Zones

Minimum ignition energyMinimum ignition temperatureLayer ignition temperature

Because of the addition of dust within ATEX 95, the new directives will include a large number of industrial sites which were not regulated under the previous explosive atmosphere directives. These industrial sites include power plants using coal or organic material, timber industries, the food industry, etc.

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Connection between ATEX 95 and ATEX 137

ATEX 95 and ATEX 137 cover any electrical or mechanical product/

equipment that constitutes a potential source of ignition risk and which requires a special design or installation

procedure to prevent an explosion.

Safe operation of the product/equipment is the result of cooperation between the manufacturer, the end-user and, if involved, the contractor. However, the responsibility for explosion protection of the product/equipment can never be contracted out to a third party.

The manufacturer is responsible for ensuring that the product/equipment is safe when it leaves its

factory. The end-user is responsible for ensuring that the product/equipment is installed, maintained and operated so that it does not pose any danger of explosion.

ATEX 95The Product Directive

ATEX 95 concentrates on the manufacturer’s duties, giving the safety requirements for product/equipment – electrical and non-electrical – installed in hazardous areas within the European Union. The directive defi nes the Essential Health and Safety Requirements (EHSRs) of product/equipment for each Category of equipment (see Figure 5 and 6, page 14).

Atmosphere Zone Defi nition

Gas 0 Explosive atmosphere is present continuously, for long periods or frequently due to malfunctionsDust 20

Gas 1 Explosive atmosphere is likely to occur due to expected malfunctions in normal operationDust 21

Gas 2 Explosive atmosphere is unlikely to occur or, if occurring, is likely to only be of short duration and not in normal dutyDust 22

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Expertise

All product/equipment shall be delivered with instructions for safe:

assembling, installation and taking into service.operation, adjustment and maintenance.dismantling.

To fulfi l requirements from the end-user directive (ATEX 137), ATEX 95 guides manufacturers of product/equipment to:

prepare classifi cations of the product/equipment.prepare instruction for installation and use.certify the product/equipment and production.

To be certifi ed according to ATEX 95, the product/equipment must be classifi ed as belonging to one of the three Categories. Only Categories 2 and 3 apply to motors (see Figure 6, page 14). The notion of Zones does not exist in the Product Directive: it has been replaced by that of Categories.

This point is of particular importance, because all the inspection, maintenance and repair duties of the end-user will depend on the Category of the product/equipment and not on the Zone where it is installed.

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ATEX 137The Worker Protection Directive

The Worker Protection Directive, ATEX 137, concentrates on the duties of the end-user. The directive proposes a new system of risk identifi cation and requires a consistent assessment of all measures to prevent risks of explosions and injury to people both inside and outside of the plant.

ATEX 137 defi nes the Zones for gas (0, 1, 2) and for dust (20, 21, 22) and indicates which Category of product/equipment must be used in each Zone (see Figure 4, below). ATEX 137 then assigns to the end-user the duty of selecting the right product/equipment for the right Zone.

To reduce the risk of explosion and fl ash fi res, ATEX 137 guides end-users to use certifi ed product/equipment and to prepare:

a risk analysissafety instructions and trainingprocedures for operation and maintenance

Collecting all of the above documents as one fi le will form a part of the Explosive Protection Document (EPD).

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Figure 4. Permitted equipment categories, ABB recommends that this fi gure is consulted in conjunction with the detailed explanation on Categories and Zones which is given on page 14.

Zone 2 / 22Abnormal conditionPresence of explosive atmosphere only by accident, but not during normal duty (< 10 hours per year)

Zone 1 / 21OccasionallyIncidental presence of explosive atmosphere during normal duty (10 to 1000 hours per year)

Zone 0 / 20ContinuouslyPermanent presence of explosive atmosphere (> 1000 hours per year)

Combinations for G and D are possible

CE... II 2 G Ex d/Ex deCE... II 2 G Ex eCE... II 2 G Ex pCE... II 2 D Ex tD A21

CE... II 3 G Ex nACE... II 3 D Ex tD A22

Category 1

Categories 1 and 2

Categories 1, 2 and 3

14 3AUA0000037223 REV A EN 8.9.2008 ABB

Figure 5. Connection between ATEX 95 and ATEX 137

The Product Directive 94/9/EC (ATEX 95) concentrates on the responsibilities of the equipment manufacturer and defi nes the Essential Health and Safety Requirements (EHSRs) of equipment.

The directive makes a clear distinction between the duties of the end-user, which include the defi nition of the Zones, and those of the manufacturer, who will be concerned with meeting the Category requirements rather than the Zones. Based on the EHSRs, these Categories defi ne three safety levels:

Category 1 for Zones 0 and 20, where no motors can be installedCategory 2 for Zones 1 and 21, where motors must be “e”, “p”, “d”, or “tD A21” typesCategory 3 for Zones 2 and 22, where motors must be at least “nA” or “tD A22” types

The Worker Protection Directive 1999/92/EC (ATEX 137) concentrates on the responsibilities of the end-user. It classifi es the environment into Zones and states which Category of equipment must be used in each Zone.

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Expertise

Relationship between Categories and Zones

Figure 6. Categories of equipment

ATEX 95The Products Directive 94/9/EC

Defi nes the products/equipment and certifi cation requirements

EHSRsproducts

requirements

- Category 1

- Category 2

- Category 3

ATEX 137The Worker Protection Directive 1999/92/EC

Classifi es Zones and states the corresponding product Category

Zonesrisk analysis

- Zone 0/20

- Zone 1/21

- Zone 2/22

ATEX 95The Product

Directive

Mines

Group I

Category M1

Category M2

Surface industry

Group II

Category 1

(very high protection)

Category 2

(high protection)

Category 3

(normal protection)

No motors normally allowed

Profi tability, frequency, duration of occurrence of potentially explosive atmosphere

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Expertise

According to ATEX 95 - The Product Directive

● the product shall comply with following, so-called harmonized standards:

● EN 60079-0 General requirements ● EN 60079-2 Pressurized protection ● EN 60079-1 Flameproof protection ● EN 60079-7 Increased safety protection ● EN 60079-15 Non-sparking protection ● EN 61241-1 Protection by enclosure ‘tD’

According to ATEX 137 - The Worker Protection Directive

● the end-users must comply with the following standards:

● EN 60079-14 Installation rules of equipment in hazardous gas areas

● EN 60079-17 Inspection and maintenance rules for equipment in gas

● EN 60079-19 Repair and overhaul rules for equipment in gas

● EN 61241-14 Selection and installation of Ex tD equipment

Standards associated with ATEX directives

The equivalent EN standards, so-called harmonized standards, are commonly used for ATEX certifi cation to meet the Essential Health and Safety Requirements (EHSR) with respect to each category of equipment.

The EN standards introduced major

changes in the case of increased safety and non-sparking motors, as risks occurring in the starting of the motors must now be considered. The standard for Ex tD/DIP protection is totally new.

To meet the “minimum requirements“ of the Worker Protection Directive (ATEX 137), the end-user will fi nd that the standards EN 60079-14, EN 60079-17, and IEC 60079-19 contain all the necessary detail, as they describe, respectively, the installation, inspection and maintenance, repair and overhaul rules for equipment in areas where gas is present. EN 61241-14 provides the same information for Ex tD/DIP motors.

These standards are of particular importance for the installation of fl ameproof motors with an AC drive supply; the maintenance of Ex tD/DIP motors; and the repair of increased safety motors.

ABB will provide documentation, instructions and spare parts in conformity with the EN product standards.

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Expertise

Certifi cation procedure

Obtaining Declaration of Conformity certifi cation depends on the Category of the product or equipment. The procedure for mechanical equipment having no certifi cation “history” is different from that applying to electric motors, which were already subject to certifi cation.

For Category 3 motors (see Figure 5), typically non sparking “nA” or Ex tD/DIP, the directives accept Self Declaration of Conformity by the motor manufacturer. The Self Declaration of Conformity is based on internal quality control, checking that all the motors produced comply with the EHSRs as described in the EN 60079-15 standard. The CE marking appears on the motor nameplate (see page 17) with no further number or indication, and the complementary marking will not refer to a certifi cate number as there is no certifi cate.

For Category 2 motors, increased safety “e”, pressurized “p”, fl ameproof “d”, or Ex tD/DIP, certifi cation by a Notifi ed Body, is mandatory. Certifi cation includes the product tests for the “EC type examination” and a factory inspection for a “Product” or “Production” Quality Assurance Notifi cation. As a result, the identifying number of the Notifi ed Body appears near the CE mark on the nameplate and the certifi cate number is part of the complementary marking on the motor nameplate. The factory inspection is valid for three years only and is subject to a yearly audit. This audit can include suppliers or service providers who are part of the supply chain.

Even though the self-certifi cation associated with Category 3 motors may look straightforward and therefore attractive, it does not provide any real benefi ts.

This is because the motor manufacturer is nevertheless supposed to fulfi ll all the EHSRs described in the standards, including the new requirements intended to prevent the risk of explosion during the starting of the motor, and to produce the motors according to strict quality assurance procedures.

Ultimately the only difference when compared with Category 2 product/equipment is in the extra costs for assessment by a Notifi ed Body, which represent less than one per cent of the total costs.

For this reason - and because Category 3 product/equipment is governed by totally new standards – ABB has decided to follow the same certifi cation procedure as for Category 2 equipment, with the support of the relevant Notifi ed Bodies.

The marking of motors; the EC Declaration of Conformity; and the Production Quality Assurance Notifi cation will be identical to those for Category 2 and supported by the same documents confi rming motor safety issued by the competent body.

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Expertise

Figure 7. This is an example of ATEX labelling for a gas hazard which appears on the motor nameplate. It is important to note that it is mandatory that the motor is CE marked if it is operating in a hazardous area.

CE marking

Identifi cation of the notifi ed body responsible for the approval.0081 = LCIE

The European Community mark for products used in potentially explosive areas

Motor grouping: II for surface industry(I = mines)

Equipment category:2 allowed for Zone 1 or 21 or lower(1 for Zone 0 or 20, 3 for Zone 2 or 22)

Atmosphere surrounding the motor:G for explosive gas, (D for dust)

ProtectionEEx d =“Flameproof”

Gas groupII = atmospheresother than mines

Gas type(C = Hydrogen)

Temperature class(T4 = max permitted 135 °C)

CE conformity marking Complementary marking

In areas where an explosive gas presents a hazard, the motor protection is denoted by a sequence of letters detailing the type of protection. When the motor meets the appropriate harmonized standard/s in terms of electrical, mechanical and thermal requirements, this sequence commences Ex. This designation will appear on the motor nameplate.

In a dust hazard environment, motors are referred to as “Ex tD/DIP” types, but this designation may not appear on the nameplate.

To be sure that the motor is ATEX certifi ed and may be used in a potentially explosive atmosphere, the following markings must appear on the nameplate of the motor.

Labelling of motors in potentially explosive atmospheres

18 3AUA0000037223 REV A EN 8.9.2008 ABB

Expertise

Electric motors in potentially explosive atmospheres

In areas where an explosive gas presents a hazard, the motor protection is denoted by a sequence of letters detailing the type of protection. When the motor meets the appropriate harmonized standard/s(see following tables) in terms of electrical, mechanical and thermal requirements this sequence commences Ex.

Protection

Ex dfl ameproof

Ex e increased safety

Product requirements ATEX 95

EN/IEC 60079 –1:No specifi c requirementsNB Clarifi cation sheet 00/02/059/CSThe combination shall be designed and tested always as a unit with converter (AC drive) parameters listed, or direct thermal protection with suffi cient margin to protect bearings or rotor.

EN/IEC 60079 -7The combination shall be tested and certifi ed for this duty as a unit in association with converter (AC drive) specifi cations as detailed.

Installation requirements ATEX 137

EN/IEC 60079-14a) Either a direct temperature control by embedded

temperature sensors or other effective measures. The action of the protective device shall be to cause the motor to be disconnected. The motor and converter (AC drive) combination does not need to be tested together;

orb) the motor shall have been type-tested for this duty as a

unit in association with the converter (AC drive) and with the protective device provided.

EN/IEC 60079 -14The combination shall be type tested for this duty as a unit with the converter (AC drive) specifi ed and with the protective device provided.

This designation appears on the motor nameplate.

In a dust hazard environment, motors are referred to as tD/DIP types, but this designation may not appear on the motor nameplate.

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Expertise

Electric motors in potentially explosive atmospheres

Protection

Ex nA non sparking

Ex ppressurized

Ex tD protection by enclosures(former DIP)

Product requirements ATEX 95

EN/IEC 60079 -15

● Motors shall be tested with the specifi ed converter (AC drive) or with a comparable converter (AC drive) in reference to the output and current specifi cations, or

● Alternatively the temperature class may be determined by calculation.

IEC/EN 60079 -2:The safety of the combination shall be shown by calculations or other measures.

EN/IEC 61241-0 and 61241-1No specifi c requirements.

Installation requirements ATEX 137

EN/IEC 60079 -14a) Either the motor shall have been tested in accordance with

EN/IEC60079-15, with the specifi c converter (AC drive) or with a comparable converter (AC drive) in reference to the output voltage and current, or

b) the motor has its temperature class determined by calculation in accordance with EN/IEC60079-15.

EN/IEC 60079-14:a) Either a direct temperature control by embedded

temperature sensors or other effective measures. The action of the protective device shall be to cause the motor to be disconnected. The motor and converter (AC drive) combination does not need to be tested together; or

b) the motor shall have been type-tested for this duty as a unit in association with the converter (AC drive) and with the protective device provided.

EN/IEC 61241-14a) Either a direct temperature control by embedded

temperature sensors or other effective measures. The action of the protective device shall be to cause the motor to be disconnected. The motor and converter (AC drive) combination does not need to be tested together; or

b) the motor shall have been type-tested for this duty as a unit in association with the converter (AC drive) and with the protective device provided.

20 3AUA0000037223 REV A EN 8.9.2008 ABB

Figure 9. ABB drive lifecycle management model

Active Classic Limited Obsolete

■ The drive, with complete lifecycle services, is available for purchase.

■ The drive, with complete lifecycle services, is available for plant extensions and spare parts.

■ Spare parts, maintenance and repair services are available as long as materials can be obtained.

■ ABB cannot guarantee availability of lifecycle services for technical reasons or within reasonable cost.

Drive lifecycle phases:

Complete lifecycle services Limited lifecycle services

ABB follows a four-phase model for managing drive lifecycles, which brings enhanced customer support and improved effi ciency.

Lifecycle services are: selection and dimensioning, installation and commissioning, training and learning, technical support and remote services, maintenance, spare parts, repair, retrofi ts, replacement and recycling.

ABB has the largest service team of all variable speed drives suppliers. Field service engineers with experience throughout the chemical, oil and gas industries are located worldwide.

The service team works to the ABB drive lifecycle management model (see Figure 9 below). This model offers maximum profi t for any investment by maintaining high availability, eliminating unplanned repair costs and extending drive lifetime.

The lifecycle management model comprises a palette of dedicated services for the entire lifecycle of ABB low voltage AC drives. Services include:

Energy audit

The increasing interest in AC drives in the chemical, oil and gas industries is partly due to a greater awareness of energy issues and rising energy prices. In many countries, ABB offers energy audits that can rapidly determine just where and how much energy can be saved.

Power savings up to 50 per cent can be reached by reducing the motor speed by just 20 per cent, with payback as short as six months.

Harmonic survey

ABB collects data on harmonic currents and voltages interfering with the electricity supply network and details actions to minimize them.

Selection and dimensioning

Whatever the application, ABB’s vast experience will help in the correct selection and dimensioning of the drive. This ensures the correct drive installation, powerful enough for any motor requirements.

Services

213AUA0000037223 REV A EN 8.9.2008ABB

Services

Installation and commissioning

ABB’s professional start-up service uses certifi ed engineers to install and adjust the drive according to the application requirements, as well as to instruct the user on how to operate the drive. All start-up information and the production parameters are saved, should the engineer need to restore any information at a later date.

Training and e-learning

ABB offers dedicated drives training for serviceand operating personnel to acquire the skills to use ABB drives correctly and safely. The training is available via the internet and in local training centers.

Technical support

Technical support services provide accurate, consistent and responsive information and support to all ABB customers.

Maintenance and repair

ABB recommends regular preventive maintenance throughout the lifetime of its AC drives.

Maintaining drives in accordance with the maintenance schedules, ensures maximum availability, minimum repair costs, optimized performance and extended lifetime of the drive.

22 3AUA0000037223 REV A EN 8.9.2008 ABB

Services

Maintenance can be performed on a contract basis.

Preventive maintenance (PM) of drives consists of annual drive inspections and component replacements according to the product specifi c maintenance schedules using PM kits which contain all the service parts and materials defi ned for a certain preventive maintenance.

ABB’s certifi ed engineers provide maintenanceand repair services on site and in authorizedABB drive service workshops.

Drive service workshops

Maintenance and repair service - instead of performing maintenance or repair on site, drives or drive modules can be sent to an ABB drive service workshop. It is often practical to perform preventive maintenance at the same time.

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Exchange unit service - a convenient and fast way to fi x a problem with a drive is to order an exchange unit. A reconditioned drive is immediately shipped to the customer (subject to availability).

ABB Ex motor workshops

ABB is the world’s fi rst motor manufacturer to receive certifi cation for its own qualifi cation program for Ex service facilities. The certifi cate has been granted by BV-LCIE, a leading certifi cation body for the electrical and electronics sectors.

This recognition allows ABB to issue certifi cates of authorization to Ex workshops or repair facilities that comply with the ABB qualifi cation program which also includes the strict requirements of IEC/EN 60079-19 and ATEX directive 94/9/EC (ATEX 95).

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233AUA0000037223 REV A EN 8.9.2008ABB

Services

An ABB certifi cate of authorization confi rms that the workshop in question has been audited by ABB and it guarantees that ABB Ex motors repaired or overhauled there are safe and that their original ABB Declaration of Conformity remains valid. The certifi ed workshop, therefore, is qualifi ed to operate under ABB responsibility.

Spare part services

Genuine ABB factory-certifi ed drive parts are delivered quickly worldwide. They guarantee full compatibility and are available throughout the drive lifetime following the drive lifecycle model.

Spare part services include:

Parts OnLine - a web-based spare part information system. Address: www.abb.com/partsonlineConventional spare and maintenance part service - parts available through your local ABB representative.24-hour emergency spare part service - provides spare parts 365 days a year.

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Inventory Access - an ABB owned and maintained spare part inventory at the disposal of a customer. This spare part inventory is usually located at the customer’s site or at an ABB location. This service provides the customer with up-to-date spare parts with no capital investment for a fee that is based on the inventory value and duration of the contract commitment.

Upgrade and retrofi t

Drives upgrade and retrofi t offerings are designed for improved performance and extending the lifecycle, resulting in the best possible return on your drive assets.

Replacement and recycling

ABB’s replacement drive scheme provides a correctly dimensioned drive, while disposing of old equipment. The scheme covers any drive or motor, regardless of the original manufacturer.

More information of parts available via Parts OnLine.

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24 3AUA0000037223 REV A EN 8.9.2008 ABB

ABB in chemical, oil and gas

Unrivalled in its scope and applications expertise, ABB instrumentation is a global leader with solutions certifi ed to international standards, and a worldwide network of manufacturing plants and strategically situated calibration labs.

ABB instrumentation provides a wide variety of FOUNDATION Fieldbus, PROFIBUS and HART enabled instrumentation.

Analytical instrumentsFlow measurement productsTemperature measurement productsRecorders and controllersProcess analyticsPressure measurement productsDevice management and fi eldbus

Main Automation Vendor (MAV)

A MAV supplies the automation system and associated scope along with the engineering design and responsibility for ensuring compatibility and interfacing of the automation system with interconnected devices and intelligent systems.

ABB’s control systems and products portfolio ranges from Programmable Logic Controllers (PLCs), small to large Distributed Control Systems (DCS), and TÜV certifi ed Safety Instrumented Systems

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ABB in chemical, oil and gas

ABB provides a diverse range of products and solutions for the chemical, oil and gas sectors. ABB can take on different scopes to bear the overall responsibility as described below.

Main Automation/Electrical Contractor (MAC/MEC)

A MAC/MEC provides project management and the supply of a composite scope of expertise, products, systems and services. It also provides interface management of the engineering suppliers to ensure commonality of supply and takes responsibility for the data transmission between parties. Initial concept design and FEED (front-end engineering design) studies can be undertaken to rationalize process requirements with practical, optimal solutions, thereby reducing costs and changes during project implementation.

Main Instrument Vendor (MIV)

A MIV supplies the instrumentation, analyzers, valves and associated scope along with the engineering design. The MIV takes responsibility for the instrumentation, meeting the measurement and control needs of the process as well as being compatible with, and interfacing to, the control and safety systems.

253AUA0000037223 REV A EN 8.9.2008ABB

ABB in chemical, oil and gas

(SIS), to Collaborative Process Automation Systems (CPAS) for an extended automation scope, as well as a wide range of control products that can be used individually or in combination. ABB offers a complete set of Industrial IT automation solutions to meet the entire plant automation needs.

Extended Automation System 800xA - Scalable extended automation system for process and production control, safety and production monitoringFreelance 800F - Compact Distributed Control System (DCS) for small to medium size applicationsCompact products - A wide range of process PLC products for open automation solutions

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Main Electrical Vendor (MEV)

The supply and engineering of an integrated electrical scope and the automation centers /system as required to provide advanced operations.

Medium voltage power distributionCircuit breakers and contactorsFuses and cutoutsModular systemsProtection and controlTransformersSurge arrestersSwitchgear and motor controlVoltage indicatorsCurrent limiters and arc suppressorsInstrument transformers and sensorsSwitches and disconnectors

Low voltage power distributionCircuit breakersControl productsIndustrial plugs and socketsSwitchboardsIntelligent MCCs (Motor Control Centers)Power Distribution UnitsModular DIN rail productsWiring accessoriesConnection devicesEnclosuresSwitches and fusegearDrives and motors

Power Management System (PMS)

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26 3AUA0000037223 REV A EN 8.9.2008 ABB

ABB in chemical, oil and gas

Telecommunications

The supply and engineering of an integrated telecoms scope and the integration to the operational centers for integrated visibility within the automation system.

Networks for management and automation systemsInternal communication systems

PA systems etc.External communication systems

radio/satellite, WANSecurity - networks/IT infrastructure, CCTVAccess control

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Management

Lifecycle managementSupporting the entire instrumentation, automation and electrical installation throughout each phase of its use

Project managementProviding the best engineering resource to oversee all phases of the main automation design, installation and commissioning

Interface managementData fl ow management between client and package sub-suppliers

Full Service TM

Full outsourced maintenance management of the automation, electrical and telecoms assets

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273AUA0000037223 REV A EN 8.9.2008ABB

Contact and web informationwww.abb.com/drives www.abb.com/motors&generators

ABB’s worldwide presence is built on strong local companies working together with the channel partner network. By combining the experience and know-how gained in local and global markets, we ensure that our customers in all industries can gain the full benefi t from our products.

For further details about all our low voltage AC drives and services please contact your nearest ABB offi ceor ABB drives channel partner or visit the websiteswww.abb.com/drives and www.abb.com/drivespartners and www.abb.com/motors&generators and www.abb.com/partsonline

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Internet www.abb.com/drives www.abb.com/motors&generators

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