Motors and drives for applications in potentially explosive atmospheres Functional safety in ABB drives Safe torque off STO ACS880 Advanced safety functions Support material Introduction Ex ID: 931353
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Slide1
Functional safety and ATEX
Motors and drives for applications in potentially explosive atmospheres
Slide2Functional safety in ABB drives
Safe torque off (STO)ACS880 – Advanced safety functionsSupport materialIntroduction – ExMotors and drives for applications in explosive atmospheres
ACS880 drives and ATEX certified protection functions
January 14, 2021
Slide
2
Contents
Slide3Functional safety in ABB drives
Slide4ABB drives functional safety management
January 14, 2021
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4
Vision
→ Product compliance through managed FS life cycle
(FSM System, FS awareness, competencies, expertise, tools)
→ Customer focused FS solutions and support
(Customer FS life cycle and application knowledge)
Be the preferred supplier
of drive products
and systems with professional
functional
safety solutions
and competent support
“
Slide5Drive-based functional safety
Prices are based on single component orders
January 14, 2021
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5
PROFIsafe
safety functions module
Thermistor protection modules
Tools
Products and tools
Safety option modules
For ACS880 industrial drives
Functional safety design tool, FSDT-01
Drive composer pro with
graphical user interface for safety
FSO-12
FSO-2
1
FSE-31
For ACS380 machinery drives,
ACS580 General purpose drives,
ACS880 industrial drives
FSPS-21
For ACS580 General purpose drives,
ACS880 industrial drives
CPTC-02
FPTC-01
FPTC-02
Slide6Safe torque off (STO)
Slide7Safe torque off
January 14, 2021
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7
Safe torque off (STO, EN/IEC 61800-5-2)
is a standard safety function in all ACS880 drives and inverters
Redundant structure: two independent
channels (Category 3)
SIL 3, PL e
Safe torque off
can be used as actuator in various
purposes such as:
To prevent an unexpected start-up
In emergency stop
In overspeed protection
In
overtemperature protection
Slide8Functional safety
January 14, 2021
Channel separation
Slide
8
Typical safety functions with STO
Prevention of unexpected
start-up
Emergency Stop
Safe stopping
STO
Slide9Functional safety and drive
s
January 14, 2021
IGBT
=
insulated-gate bipolar transistor
Slide 9
Safe torque off (STO) – functionality and benefits
STO is a safety rated circuit in the drive
Removes motor torque by shutting down the power
electronics (IGBTs)
Eliminates the need for two motor contactors
Benefits compared to using motor contactors
Lower cost
No space required
Faster reaction time
No wearing parts
Redundancy - STO replaces two contactors in a safety circuit
1
Feedback
2
Safe torque-off (STO) circuit
3
IGBTs
STO
VS
Integrated
STO
Motor
contactors
Drive
Control
1
2
3
+
+
+
-
-
-
STO1
STO2
Slide10Safe torque off (STO) – details
January 14, 2021
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10
Can be used for Emergency Stop (Stop Cat. 0 per EN 60204-1)
Can be used for Prevention of Unexpected Start-Up according to EN ISO 14118
Requires a lockable switch, resettable relay or similar solution
STO does not disconnect the machine from power supply
When STO is active, high voltage levels remain present in the motor cables
Additional main switch is required for disconnecting and isolating the drive from mains power supply
for maintenance work etc.!
Slide11ACS880 – Advanced safety functions
Slide12ACS880 drives and integrated safety
January 14, 2021
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12
Advanced safety functions
Safe torque off (STO)
is a standard safety function
in ACS880 drives
Safety performance (for STO)
SIL 3, SIL CL 3
(IEC 61508, EN 62061)
PL e
(EN ISO 13849-1)
Additional safety functions can be commissioned using
the optional safety functions modules
FSO-12, FSO-21, FSE-31 and FSPS-21
Safety performance:
SIL 3, SIL CL 3
(IEC 61508,
EN 62061)PL e (EN ISO 13849-1)
SIL levels: SIL 1 lowest ...
SIL3
highest safety
PL levels: PL a lowest ...
PL e
highest safety
Slide13ACS880 drives and integrated safety
January 14, 2021
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13
Advanced safety functions
Safety functions for industrial applications (EN/IEC 61800-5-2):
Safe torque off (STO)
Safe stop 1 (SS1): SS1-t, SS1-r
Safe stop emergency (SSE)
Safe brake control (SBC)
Safely-limited speed (SLS)
Safe maximum speed (SMS)
Safe direction (SDI)
Safe
speed monitor (SSM)
Prevention of unexpected start-up (POUS)
,
EN ISO 14118
Slide14ACS880 drives and integrated safety
January 14, 2021
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14
Safety functions module FSO
Quick to commission
Pre-programmed functions (logic)
Parameter configuration with Drive composer pro PC –
tool
Compatible with ACS880 single- and
multidrives
, drive modules
Robust
aluminium
construction
vibration, heat, EMC control
Slide15Provide
PROFIsafe over PROFINET connection between the Safety PLC and the driveWorks only with safety PLC
Safely stop the drive via PROFIsafeSTO & SS1-t safe stopping functionTÜV-certified, PL e & cat.3 / SIL 3Supported drives: ACS380, ACS580 & ACS880
Get (STO) status of the drive via the PROFINET connection
Control the drive through PROFINET same way as with standard PROFINET
IO module
PROFINET cycle time 4 msOther PROFINET features:
Shared device Media Ring protocol (MRP) Tool network (One wire)
Drive-based functional safety
January 14, 2021
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15
PROFIsafe
safety functions module, FSPS-21
Product overview
Slide16Compact and cost-effective solutions
One Integrated package reducing component cost, engineering and required spaceBetter cost efficiency and reliability
with safe speed detection even without motor encoderFlexibility and Ease of useIntegrated safety I/O and safe communication (PROFIsafe) to meet the needs of all applications
Easy to use safety engineering tools
with graphical user interface
Drive-based functional safety
January 14, 2021
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Value proposition
Maximized safety and conformity
Fulfilling the highest performance requirements in machinery safety –
up to SIL3/
PLe
Quality and Conformity with TÜV-certified components, tools and functional safety management system
Increased productivity by doing
things smarter
Minimize downtime and waste by keeping
the application in control
in all situationsMaximize productivity by keeping the process running by Safely Limited Speed (SLS) instead of stopping it
Slide17Speed
SLS function activated
SS1 function
activated
Limit switch 1
Limit switch 2
Stop
Time
Safety limit switch 1
Safety limit switch 2
Stop
Safely limited speed example
January 14, 2021
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17
+
+
+
-
-
-
24
VDC
24
V
DC
Moving
FSO
Safety-limited speed
Safe stop 1
STO path
STO
STO 1
STO 2
Slow
Stop
Drive
ACS880
M
3~
Slide18Support material
Slide19Drive-based functional safety
web
site
January 14, 2021
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19
new.abb.com/drives/functional-safety/
Articles, white paper
Technical guides and descriptions
FSDT-01 safety component libraries
EU Declarations of Conformity
Certificates
and a lot more…
Slide20ABB’s drive-based
functional safety
January 14, 2021
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20
youtube.com
Video of an elephant moving smoothly and safely
in a porcelain shop
Elephant is controlled by ACS880 with FSO
Slide21Introduction - Ex
Slide22January 14, 2021
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22
Examples
of
industries
Where do the potentially explosive atmospheres exist?
Oil
and
gas
Chemical
Mining
Wastewater
treatment
Food and
beverage
Sawmills
Pharmaceutical
Textile
Slide23What does ATEX mean?
January 14, 2021
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23
ATEX (
AT
mosphères
EX
plosifs
) is a set of EU directives concerned with all
equipment installed in potentially explosive atmospheres
(both gas and dust),
working in them
, and
used protective devices
(also ones installed outside the explosive atmosphere)ATEX 2014/34/EU: Duties of the manufacturer (Product safety)
ATEX 1999/92/EC: End user’s obligations (Worker safety)
Slide24Global effect
January 14, 2021
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24
Although ATEX directives are only applicable within EU, they are based on IEC (
→
EN)
standards which has led to their principles being demanded by users throughout the world
ATEX approval is generally not recognized outside Europe and industries with hazardous areas should investigate which approval schemes apply locally
In addition to EN standards (ATEX directives), a number of other standards are used in the world
Slide25CEC, CSA
NEC® CSA/US/UL
Inmetro
ZA certif
EAC
EAC
CNEx / CCC
EAC
PESO
TIIS
ANZEx / IECEx
Korean Std
ANZEx / IECEx
ITRI
ATEX
IECEx
A number of admissible standards
(IEC, ATEX, NEC, etc.)
UkrSepro
World of standards and directives
ECASEx
Slide26Motors and drives for applications in potentially explosive atmospheres
January 14, 2021
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26
Legislation & standards – Zone classification
First define the area based on risk analysis!
Zone, gas group, temperature class
…and what level of protection is required
from the device
Then you can install the devices with required protection level
Slide27Motors and drives for applications in explosive atmospheres
Slide28Motors and drives for applications in explosive atmospheres
January 14, 2021
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28
When an Ex Motor is controlled by variable speed drive (VSD),
the motor shall be protected against becoming a potential
ignition source
1. By testing the VSD-Motor pair
2. By safety devices
1.
A tested package typically needs no additional protection
(e.g. PTC/Pt100)
However, it is always recommended to consider protection
as “additional protection”
2.
If the Ex motor – VSD package is not tested,
temperature protection
is neededIn ATEX, protection devices shall be certifiedNote: With Ex eb (former Ex e) and ec (former Ex
nA) motors, protection with temperature measurement is not possible
Slide29Motors and drives for applications in explosive atmospheres
January 14, 2021
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29
Tested VSD – Ex motor packages
Note! It cannot be seen from the VSD markings whether the VSD is tested and certified with an Ex Motor(s)
(Drive’s ATEX marking is related to safety device certification)!
ABB Ex motors are certified with ABB drives (VSD), as packages:
ACS800, ACS880 with DTC
ACS880 scalar
ACS550, ACS580, ACH580, ACH580
ACS600, ACS800 and ACS880 (DTC) are comparable VSDs from the ABB motor perspective
For type tested & certified Ex motor – 800 packages, ACS600 or ACS800 can be replaced
by ACS880 without are-testing or re-certification
Same applies with ACS550
→
ACS580
Ex
motor’s rating plates (and EU Declaration)
show that the VSD is tested
and certified with the motor. The plate also shows conditions for using other VSDs
Slide30Note! It cannot be seen from the VSD markings whether the VSD is tested and certified with some Ex Motor(s) or not
Ex
motor’s
rating plates (and Declaration) show which VSDs are tested and certified with the motor.
The plate also shows conditions for using other VSDs
Motors and drives for applications in explosive atmospheres
January 14, 2021
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30
How safe operation is ensured– When drive is connected to Ex motor
Though
drive is being installed always in safe area
, certain criteria must be taken into account when drive is connected to Ex motor
Drive manufacturer has to meet the requirements of motor manufacturer
The requirements depend on the protection type in use and the Zone
ABB offers motors for explosive atmospheres for use with variable speed drives with the following protection types:
Flameproof, increased safety (on request), pressurized, non-sparking, and dust ignition protection
These motors are designed and certified for operation with frequency converters…
Slide31Motors for explosive atmospheres
56
63
71
80
90
100
112
132
160
180
200
225
250
280
315
355
400
450
Low-voltage motors for explosive atmospheres
January 14, 2021
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31
Product portfolio
Sizes 56–450
56
63
71
80
90
100
112
132
160
180
200
225
250
280
315
355
400
450
Flameproof motors
Increased safety Ex eb motors
Increased safety Ex
ec
aluminum motors
Increased safety Ex
ec
cast-iron motors
Dust ignition-proof aluminum motors
Dust ignition-proof cast iron motors
Slide32Motors and drives for applications in explosive atmospheres
January 14, 2021
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32
Benefits
ABB have motors that are tested and certified together with frequency converters
If bought separately from different suppliers, customer needs to ensure the compatibility of motor and drive by performing a combined test,
or by using thermistor protection
Dimensioning for combined solution makes optimization possible
e.g. bigger loads and increases output power
It’s a working combination
No extra margins since the performance of ABB motor and drive is known
Selection is easy with common tools and instructions
(
DriveSize
, Selection tool)
Total cost of ownership:
With optimized solution you can also optimize your costs
No need to oversize the motor
Benefits of the speed control
No costs from motor + drive combined tests
Temperature protection not required
ACS800 and ACS880 are comparable devices from the motor perspective
Slide33Motors and drives for applications in explosive atmospheres
January 14, 2021
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33
ATEX and safety devices
In ATEX, protective devices shall be certified and marked similarly
as the Ex motors
Marking can be found from the drive Marking does not mean the drive
is certified with same motor, it only indicates that the protective device integrated into drive is certified!
Drive must be always installed in safe area
Example of VSD labelled with ATEX marking
Slide34ACS880 drives and ATEX certified protection functions
Slide35ACS880-01, -x4, -104 (+Q971)
January 14, 2021
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35
ATEX-certified safe disconnection function, Ex II (2) GD
The safe torque off (STO) function of the ACS880 drive module is certified
as a protective device (component) within the scope of the ATEX Equipment Directive 2014/34/EU
The ATEX certificate enables using the ACS880 module’s STO as actuator
in the temperature protection function of Ex motors
Eliminates the need for external contactor(s) in temperature protection
System integrator can build the temperature protection function
from safety devices, using the ATEX-certified ACS880 STO
as a component in the Ex protection function.
Slide36ACS880 industrial drives
January 14, 2021
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36
FPTC-02 (+L537 +Q971)
ATEX-certified thermistor (PTC) protection module for ACS880 drives:
FPTC-02 (+L537 +Q971)
Eliminates the need for external PTC relay(s)
Two PTC interfaces (DIN 44081, DIN 44082):
One input for safety function (
certified
), activates STO
One input for monitoring (warning,
non-safety
)
Both input support a loop of 1…6 PTC sensors
PTC loop length: 700m + 700m (= distance 700m)
Short circuit detection guaranteed in cable length <100m + 100m
Reinforced insulation between inputs and drive control board
Certificate allows installing FPTC-02 to an existing drive
Slide37ACS880 industrial drives
January 14, 2021
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37
FPTC-02 (+L537 +Q971)
Certificates:
1. TÜV Nord (Functional Safety):
SIL 2, PL c
Applicable for all areas of industry (SIL)
IEC 61508; IEC 61800-5-2; IEC 62061; ISO 13849 (IEC 61511-compliant)
2. ATEX Type examination
, Eurofins Expert Services (Notified Body):
Ex II (2) GD
EN 50495
3. EU Declaration of Conformity as a safety device according to
ATEX product directive
and
Machinery Directive
FPTC-02 with the ACS880 internal STO complies with requirements
for standardized safety function (EN/IEC 61800-5-2)Safe Motor Temperature (SMT)
Slide38ACS880 cabinet-built drives
January 14, 2021
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38
ATEX certified protective functions
+L513 ATEX-certified motor thermal protection with PTC relay
+L514 ATEX-certified motor thermal protection with Pt100 relay
This option provides an Ex
i
interface for the motor
+L537 ATEX-certified thermistor protection function with integrated
FPTC-02 module
+L513/+L514/+L537 selects the code +Q971: ATEX-certified safe disconnection function, Ex II (2) GD
All ATEX certified safety functions are certified to be used with safety functions modules FSO-12 or FSO-21
Slide39Using motors with drives in potentially explosive atmospheres - website
January 14, 2021
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39
https://new.abb.com/drives/segments/motors-and-drives-in-potentially-explosive-atmospheres
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