Functional safety and ATEX official presentation.pptx

ABB ATEX Safety presentation for VFDs.

1. Functional safety and ATEX Motors and drives for applications in potentially explosive atmospheres

2. Functional safety in ABB drives Safe torque off (STO) ACS880 – Advanced safety functions Support material Introduction – Ex Motors and drives for applications in explosive atmospheres ACS880 drives and ATEX certified protection functions January 14, 2021 Slide 2 Contents

3. Functional safety in ABB drives

4. ABB drives functional safety management January 14, 2021 Slide 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 “

5. Drive-based functional safety Prices are based on single component orders January 14, 2021 Slide 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

6. Safe torque off (STO)

7. Safe torque off January 14, 2021 Slide 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

8. Functional safety January 14, 2021 Channel separation Slide 8 Typical safety functions with STO Prevention of unexpected start-up Emergency Stop Safe stopping STO

9. Functional 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

10. Safe torque off (STO) – details January 14, 2021 Slide 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.!

11. ACS880 – Advanced safety functions

12. ACS880 drives and integrated safety January 14, 2021 Slide 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

13. ACS880 drives and integrated safety January 14, 2021 Slide 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

14. ACS880 drives and integrated safety January 14, 2021 Slide 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

15. Provide PROFIsafe over PROFINET connection between the Safety PLC and the drive Works only with safety PLC Safely stop the drive via PROFIsafe STO & SS1-t safe stopping function TÜV-certified, PL e & cat.3 / SIL 3 Supported 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 ms Other PROFINET features: Shared device Media Ring protocol (MRP) Tool network (One wire) Drive-based functional safety January 14, 2021 Slide 15 PROFIsafe safety functions module, FSPS-21 Product overview

16. Compact and cost-effective solutions One Integrated package reducing component cost, engineering and required space Better cost efficiency and reliability with safe speed detection even without motor encoder Flexibility and Ease of use Integrated 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 Slide 16 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 situations Maximize productivity by keeping the process running by Safely Limited Speed (SLS) instead of stopping it

17. Speed 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 Slide 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~

18. Support material

19. Drive-based functional safety web site January 14, 2021 Slide 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…

20. ABB’s drive-based f unctional s afety January 14, 2021 Slide 20 youtube.com Video of an elephant moving smoothly and safely in a porcelain shop Elephant is controlled by ACS880 with FSO

21. Introduction - Ex

22. January 14, 2021 Slide 22 Examples of industries Where do the potentially explosive atmospheres exist? Oil and gas Chemical Mining Wastewater treatment Food and beverage Sawmills Pharmaceutical Textile

23. What does ATEX mean? January 14, 2021 Slide 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)

24. Global effect January 14, 2021 Slide 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

25. CEC, 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

26. Motors and drives for applications in potentially explosive atmospheres January 14, 2021 Slide 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

27. Motors and drives for applications in explosive atmospheres

28. Motors and drives for applications in explosive atmospheres January 14, 2021 Slide 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 needed In ATEX, protection devices shall be certified Note: With Ex eb (former Ex e) and ec (former Ex nA ) motors, protection with temperature measurement is not possible

29. Motors and drives for applications in explosive atmospheres January 14, 2021 Slide 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

30. Note! 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 Slide 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…

31. Motors 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 Slide 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

32. Motors and drives for applications in explosive atmospheres January 14, 2021 Slide 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

33. Motors and drives for applications in explosive atmospheres January 14, 2021 Slide 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

34. ACS880 drives and ATEX certified protection functions

35. ACS880-01, -x4, -104 (+Q971) January 14, 2021 Slide 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.

36. ACS880 industrial drives January 14, 2021 Slide 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

37. ACS880 industrial drives January 14, 2021 Slide 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)

38. ACS880 cabinet-built drives January 14, 2021 Slide 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

39. Using motors with drives in potentially explosive atmospheres - website January 14, 2021 Slide 39 https://new.abb.com/drives/segments/motors-and-drives-in-potentially-explosive-atmospheres

40. January 14, 2021 Slide 40