Motor Area Classifications - A Review and Comparison - North American & IECDefinitions & CertificationsBP ICE Conference 3E-3September 27, 2006Ron Busse BP Global Account ManagerRussell Almond Electrical Technical Authority CXHO

The Basics- Hazardous AreasHazardous Locations or Hazardous Areas are areas where concentrations of combustible gasses, vapors, dusts, fibers of flyings can be present some of the time.

Areas with these hazards present are classified as to the risk, based on how close you are to the source of release, and what that substance being released is.

Hazardous materials from an explosive standpoint typically have a temperature associated with their ignition. For Mining, it is 150C, for petrochemical, it varies with the gas/vapor or dust.

The Basics- Area ClassificationFor petrochemical, process and dust industries, the engineering operation designing the facility typically has the responsibility for classifying the area. The US typically classifies in Divisions, but some newer installations are Zone classified.Installations outside North America are typically classed in Zones

Area classification is a method of analyzing and classifying the environment where explosive gas atmospheres may occur to facilitate the proper selection and installation of apparatus to be used safely in that environment, taking into account gas groups and temperature classes.

The Basics- Area ClassificationClassification depends on Source of release (how far)Grade of release (how frequent)What is being released (thermal and ignition properties)Release rateVentilationInspection, maintenance and house keepingBoth Division and Zone classification use similar principlesWhen RequiredFor petrochemical, certified equipment is required in the US if the exposure is likely to occur in normal operation. Self declared equipment may be used if the exposure is not likely to occur. For the international community, certification is usually required in both cases.

The Basics- Certification BodiesIn the North American market for certification, Reliance deals with three certification bodies, Underwriters Laboratories Inc., Canadian Standards Association and FM Approvals.

For Europe, there is a CE Marking Directive, ATEX, which requires using specific certification bodies, called Notified Bodies for hazardous location equipment certification (ie: Sira Test and Certification). This ATEX Directive applies to both electrical and mechanical products.

For Australia, for petrochemical, IEC Certification (IECEx) is accepted.

The Basics- StandardsCertifications are conducted to standards.The standard used varies with the certification desired.UL has standards for Division based certificationFM also has standards for Division based certificationEurope has IEC based standards for ATEXUS and Canada have IEC based standards for certificationOther markets often use IEC based standardsIEC based certification can be either to the pure IEC standard, or for national certification, the IEC standard + national differences.

Overview of Divisions and Zones

Product UtilizationFor hazardous areas there are several protection concepts offered: Division 1 / Zone 1 If the risk of exposure is likely there are several options based on either containing the explosion, or eliminating the source. These protection concepts involve flameproof (special motor enclosures) or in the case of IEC based, Increased Safety which involves more robust electrical designsDivision 2 / Zone 2 If the risk of exposure is not likely, the design is close to an ordinary location motor, enclosed or open, using sealed thermostats, space heaters with known temperatures and constructions to minimize the risk of sparking.

North American Hazardous Duty StandardsNorth American System of Area Classification as defined in NEC (Classification NFPA 497, products NFPA 70, Article 500)Class (I, II, III) Class I is Gas, Class II is Dust, Class III is fibers/flyingsDivision (1, 2) Division 1 ignitable concentrations of gases, vapors, or liquids can exist all or some of the time under normal conditionsDivision 2 ignitable concentrations are not likely to exist under normal operating conditions. The US NEC excludes starting as a normal condition for motors.Note NEC not law, States & Municipalities adopt local code

Hazardous Duty EnvironmentsClassification

Class IClass IIClass III

Group AGroup BGroup C

Group D

Group E

Group FGroup G

Division 1

Division 2

Potentially explosive flammable gases or vapors in the airCombustable dust in the airIgnitable fibers or flyings (dust) in the air

AcetyleneHydrogen, gases or vapors of manufactured originEthyl-ether vapors, ethylene or cyclopropaneGasoline, hexane, naphtha, benzine, butane, propane, alcohol, acetone, benzol, laquer, solvent vapors, or natural gas (methane)Conductive dust and metal dust: aluminum, magnesium - their commercial alloys, etc.Carbon black, coal, or coke dustFlour, starch, grain dusts

Location where hazardous material exists (always or periodically) during operating conditionsLocation where hazardous material exists only in the case of fault situation (leaky valve, burst pipe, faulty equipment)

Division Gas GroupsGroup AAcetyleneGroup BGases or Vapors havingMESG < 0.45 mm or MIC ratio< 0.40

Group CGases or Vapors havingO.45 mm < MESG > 0.75 mm or 0.40 < MIC ratio> 0.80Group DGases or Vapors havingMESG > 0.75 mm or MIC ratio> 0.80.Note: MESG is maximum experimental safe gap. MIC ratio is minimum igniting current ratio (gas to methane). Courtesy of Underwriters Laboratories Inc. Issue Flame transmission , Risk of explosion

Hazardous EnvironmentsDivision 1 - Explosion-Proof - Dust Ignition-Proof Class I- (Gases) Group A, B, C & D

Design- Maximum Explosion PressureConsiderations - Maximum Safe Clearance of Fits - Minimum Ignition Temperature

Class II- (Dusts) Groups E, F & G

Design - Tightness of jointsConsiderations- Shaft Opening Clearance- Blanketing Effects of Dust- Electrical Conductivity of Dust- Ignition Temperature of Dust

Div 1 Design ConsiderationsMaximum Explosive PressureHeavier FrameLonger Rabbet Fits 3/4 vs 1/4Maximum Safe Clearance (Flamepath)Longer Rabbet FitsClose Machine ToleranceInner Cap & Shaft Clearance/SealsPotted Lead OutletMinimum Ignition TemperatureLow Rise DesignSpecial Insulation or Thermostats

NEC Temperature Codes

450 C300 C280 C260 C230 C215 C200 C180 C165 C160 C

(842 F)(572 F)(536 F)(500 F)(446 F)(419 F)(392 F)(356 F)(329 F)(320 F)

Class I, Gr D w/caution label

Class I, GR D w/ThermalsClass II, Groups E & F

Class II, Group GClass I, Group CT CodeT1T2T2AT2BT2CT2DT3T3AT3BT3C Max. Surface Temp. Min. UL XP Requirement for:Note Without thermostats, depend on insulation breakdown before explosion

Hazardous Duty Environments Division 1 Variable SpeedUL 674Motors used on Variable Frequency Drives (VFD) RequirementsTested with the specific type of VFDCSI Current SourceVVI Voltage SourcePWM Pulse Width Modulated ( Primary Technology Today) Marked for use with the specific VFDMarked with frequency range and load typeConstant TorqueVariable TorqueAn XP motor not marked for VFD duty will be in violation of its UL label if applied to a VFD

Reliance Motor Nameplate And UL Listed NameplateNote XP Motors have UL & standard NPsNote- IEC will have separate Certification plate

Hazardous EnvironmentsClass I- (Gases) Group A, B, C & DConsider- Minimum Ignition Temperature - Internal - External

Class II - (Dusts) Groups E, F & GConsider - Minimum Ignition Temperature - Conductivity of DustDivision 2

Hazardous Duty Environments Division 2-Fixed Speed (Sine Wave Power)NEC Article 501.125(B)Open or Non-explosion proof enclosed motors without arc producing devices are permitted

It is important to consider the temperature of internal and external surfaces that may be exposed to the flammable atmosphere Reliance Electric General PolicyUse of TEFC motors that are not UL listed Division 1 are permitted if both internal and external surfaces are considered as potential ignition sourcesWhen a Division 2 motor is requested, the rotor as well as the winding temperature will be reviewed by Engineering.The motor will be nameplated for Division 2 including the Class Group and Temperature CodeProper thermal protection will be supplied when necessaryCSA c-us Logo will be applied assuring compliance to US and Canadian Requirements

Note 841XL supplied with Max Surface Temperature N/P

Hazardous Duty Environments Division 2 Sine Wave BP/Reliance Div 2 General Policy

Unless otherwise specified on the data sheet, motors in frame sizes 180-449 will be suitable for operation in NEC code T3(200*C)Supplied without the CSA Div 2 label Supplied without ThermostatsAllows for a model number stock motor to be pulled from shelfCSA Logo will be applied when requested assuring compliance to standards set by CSA, and motor will be labeled with appropriate T code rating.May require hot-mod to stock motor. (3-10 day lead time)

CSA Div 2 Charts Sine Wave Duty FC-XE

Hazardous Duty Environments Division 2-Variable Speed BP/Reliance Div 2 General Policy

CSA Certified Motor Provided for Div 2 Variable Speed on a hot mod/production basisCertification Limited on VFD Division 2Variable Torque2:1 CT Speed Range (No fan change)> 2:1 Dependent on Application Detail (Usually Change out fan)The motor will be nameplated for Division 2 including the Class, Group and Temperature CodeCSA c-us Logo will be applied assuring compliance to standards for both the US and Canadian market.

CSA Div 2 Charts Inv. Duty FC-XE

Overview of Divisions and Zones

North American ZonesUS Standards and Certification for Hazardous Locations-Zone based certificationsEquivalent Zone Marked (ie. Class I, Zone 1, IIB T3)(supported by NEC, OKd by CSA) True Zone certified (IEC Based standards) Class I, Zone 1 AExd IIB T3)Certified to UL60079 / ISA SP12 Series

Canadian Standards and Certification for Hazardous Locations-Zone based certificationsEquivalent Zone Marked (Allowed on CSA c-us)True Zone certified (IEC Based standards) E79 Series Compliance with C22.1 Canadian Electric Code is required.

Both US standards and Canada E79 Zone standards lag the basic IEC standard due to the time required for National review

Division Zone ComparisonNote: Div/Zone dual marking supported by CSANote: T4 Reliance Capability Div 2 only

Sheet1

Motor Certification Capabilities - Div 2 , Zone 1 & 2Bill Casper/Joe Hillhouse - 1/1/05

CertificationRMMRAGRGGRSNRST

Div 2No CertCSA CertificationCSA CertificationCSA Certification

Presently pursuing

Div 2 -Inverter DutyUses Div 1 motorIn ProcessCSA labelSelf CertifySelf Certify

Investigating need for futureTarget completion 1st qtr 05Cl 1, Div 2,Grp A,B,C,D

Currently Self CertifyingCl 2, Div 2, Grp F,G

Zone 2 - Equivalent MarkingCan Dual MarkCan Dual MarkCan Dual MarkCan Dual Mark

( Dual labled with CSA Div 2)

(Must be Dual Marked -Note 1)

Zone 2 - ExnNew testing close to completePreliminary Planning for 2005

CSA to IEC StdsEstimate 2005 Availabilityinitiation of required RSN work

Example: Cl 1, Zone 2, Exn, ll (llA,llB,llC or ll), T3

Zone 2, EExnEuropean agency Cert toEuropean agency Cert to

Europe schemefollow "CSA to IEC" stdsfollow "CSA to IEC" stds

approvalapproval

Zone 1, Exd (flameproof)ATEX cert for EExd IIBATEX cert for EExd IIBATEX cert for EEx lATEX cert for EEx l

56-180 frames180-449T framesMining motorsMining motors

90-100 IEC frames112S-280M frames

T3, T4 Temp Codessine wave & Inverter

Exd 1or llB

Quoting in processT3,T4 ,T5 temp codes --

(D/S review suggested)

Orders in process

Note 1- Dual Marked: Cl 1, Div 2, Grp A,B,C,D T3C

: Cl1, Zone 2, llA, llB, llC, ll , T3Typical Motor Protection Methods

Typical Method CategoriesIEC StandardCEN Standard

Div/Zone ComparisonEx*Protection MethodIECExATEX

ConditionDIVZoneZone 0iIntrinsically Safe (2 faults)IEC 60079-11EN 50020

Ignitable concentrations normally all the timeDiv 1Zone 0used for components not

Ignitable concentrations normally some timeDiv 1Zone 1motors

Ignitable concentrations not normal conditionDiv 2Zone 2Zone 1dFlameproof, Similar to Div 1IEC 60079-1EN 50018

contains explosion

GroupsDivZonedependent on gas group

acetyleneAllCZone 1eIncreased Safety,standardIEC 60079-7EN 50019

hydrogenBllCenclosure,tighter constraints

ethyleneCllBon electrical design

propaneDllAZone 1pPurged, not dependent onIEC 60079-2EN 50016

gas groups

AIT - Max Surface TempDIV T CodeZone T CodeZone 2nNon sparking, similar to Div 2IEC 60079-15EN 50021

450 deg CT1T1

300 deg CT2T2

280 deg CT2ATypical Motor Markings

260 deg CT2BFlameproof motorEx d ll B T3

230 deg CT2CIncreased Safety MotorEx e ll B T3

215 deg CT2DNon Sparking MotorEx n ll B T3

200 deg CT3T3Mining Flameproof MotorEx d l

1800 deg CT3ANotes: Gas Group ll B includes ll B and ll A; ll is all groups , ll C, ll B, ll A

165 deg CT3BNotes: Regional Variations - Europe marks as EEx, USA as AEx

160 deg CT3C

135 deg CT4T4

Sheet1 (2)

Motor Certification Capabilities - Div 2 , Zone 1 & 2Bill Casper/Joe Hillhouse - 1/1/05

CertificationRMMRAGRGGRSNRST

Div 2No CertCSA CertificationCSA CertificationCSA Certification

Presently pursuing

Div 2 -Inverter DutyUses Div 1 motorIn ProcessCSA labelSelf CertifySelf Certify

Investigating need for futureTarget completion 1st qtr 05Cl 1, Div 2,Grp A,B,C,D

Currently Self CertifyingCl 2, Div 2, Grp F,G

Zone 2 - Equivalent MarkingCan Dual MarkCan Dual MarkCan Dual MarkCan Dual Mark

( Dual labled with CSA Div 2)

(Must be Dual Marked -Note 1)

Zone 2 - ExnNew testing close to completePreliminary Planning for 2005

CSA to IEC StdsEstimate 2005 Availabilityinitiation of required RSN work

Example: Cl 1, Zone 2, Exn, ll (llA,llB,llC or ll), T3

Zone 2, EExnEuropean agency Cert toEuropean agency Cert to

Europe schemefollow "CSA to IEC" stdsfollow "CSA to IEC" stds

approvalapproval

Zone 1, Exd (flameproof)ATEX cert for EExd IIBATEX cert for EExd IIBATEX cert for EEx lATEX cert for EEx l

56-180 frames180-449T framesMining motorsMining motors

90-100 IEC frames112S-280M frames

T3, T4 Temp Codessine wave & Inverter

Exd 1or llB

Quoting in processT3,T4 ,T5 temp codes --

(D/S review suggested)

Orders in process

Note 1- Dual Marked: Cl 1, Div 2, Grp A,B,C,D T3C

: Cl1, Zone 2, llA, llB, llC, ll , T3Typical Motor Protection Methods

Typical Method CategoriesIEC StandardCEN Standard

Div/Zone ComparisonEx*Protection MethodIECExATEX

ConditionDIVZoneZone 0iIntrinsically Safe (2 faults)IEC 60079-11EN 50020

Ignitable concentrations normally all the timeDiv 1Zone 0 (20-Dust)used for components not

Ignitable concentrations normally some timeDiv 1Zone 1 (21-Dust)motors

Ignitable concentrations not normal conditionDiv 2Zone 2 (22-Dust)Zone 1dFlameproof, Similar to Div 1IEC 60079-1EN 50018

contains explosion

GroupsDivZonedependent on gas group

acetyleneAllCZone 1eIncreased Safety,standardIEC 60079-7EN 50019

hydrogenBllCenclosure,tighter constraints

ethyleneCllBon electrical design

propaneDllAZone 1pPurged, not dependent onIEC 60079-2EN 50016

gas groups

AIT - Max Surface TempDIV T CodeZone T CodeZone 2nNon sparking, similar to Div 2IEC 60079-15EN 50021

450 deg CT1T1

300 deg CT2T2

280 deg CT2ATypical Motor Markings

260 deg CT2BFlameproof motorEx d ll B T3

230 deg CT2CIncreased Safety MotorEx e ll B T3

215 deg CT2DNon Sparking MotorEx n ll B T3

200 deg CT3T3Mining Flameproof MotorEx d l

180 deg CT3ANotes: Gas Group ll B includes ll B and ll A; ll is all groups , ll C, ll B, ll A

165 deg CT3BNotes: Regional Variations - Europe marks as EEx, USA as AEx

160 deg CT3C

135 deg CT4T4

Note - Can be Dual Marked: Cl 1, Div 2, Grp A,B,C,D T3C

: Cl1, Zone 2, llA, llB, llC, ll , T3

Sheet2

Sheet3

North American ZonesNorth American System of Zone Classification as defined in NEC (NFPA 70, Article 505) Being added to OSHA 29CFRClass (I, II, III) Class I is Gas, Class II is Dust, Class III is fibers/flyings(Class is not used with Zones in Canada)Zone (0, 1, 2) Zone 0- Ignitable concentrations of gases, vapors, or liquid are present continuously under normal operating conditionsZone 1- Ignitable concentrations of gases, vapors, or liquid are likely to exist under normal operating conditions.Zone 2- Ignitable concentrations of gases, vapors, or liquid are not likely to exist under normal operating conditions.Note- The US view is that Division 1 overlaps Zone 0 and Zone 1Note : In Code Since 1996

North American ZonesNorth American System of Zone Classification for dust as defined in NEC (NFPA 70, Article 506) was added in the most recent code cycle.(Class is not used with dust Zones)Zone (20, 21, 22) Zone 20- Ignitable concentrations of combustible dust or ignitable fibers and flyings are present continuously or for long periods of time.Zone 21- Ignitable concentrations of combustible dust or ignitable fibers and flyings are likely to exist occasionally under normal operating conditions of may exist frequently due to repair or maintenance.Zone 22- Ignitable concentrations of combustible dust or ignitable fibers and flyings are not likely to occur in normal operation.

Note- Class II Division 1 may be additionally marked either Zone 20 or 21, Class II Division 2 may be additionally marked Zone 22. In both cases the Temperature must be indicated

Note - US NEC, 2005, Article 506 introduces US to Zones for dust.

Refining Global ECoP Call for help

Franz Stolz BP Lingen RefineryEmail Network - Monday September 25, 2006 Lost a motor upon TAR start up500 KW2 Pole 6KV Machine500L frameClassification EEx de IICT4Who has a motor, and is it right?

IEC Zones

IEC System of Zone Classification as defined IEC60079-10Zone (0, 1, 2) Zone 0- Ignitable concentrations of gases, vapors, or liquid are present continuously or long periods ( >1000 hr/yr.)Zone 1- Ignitable concentrations of gases, vapors, or liquid are likely to occur in normal operation, occasionally (>10

IEC Zones - DustWhat does IEC do for dust?Zone Classifications (described in IEC61241-0)Zone 20 place in which an explosive atmosphere in the form of a cloud of combustible dust in air is present continuously, or for long periods or frequently.Zone 21 place in which an explosive atmosphere in the form of a cloud of combustible dust in air is likely to occur, occasionally, in normal operation.Zone 22 place in which an explosive atmosphere in the form of a cloud of combustible dust in air is not likely to occur in normal operation but, if it does occur, will persist for a short period only

IEC Zone Protection Concept

IEC StandardsIEC 60079-0 This standard contains the general requirements for hazardous locations. Typically IEC60079-0 is referenced in the front of a protection method standard. IEC has current work programs to shift general requirements from the protection method standards back to the general requirements. These general requirements include a requirement that manufacturers provide with the product, instructions for installation, repair, maintenance.IEC 60079-1 This standard contains the particular requirements for Exd flameproof products. IEC 60079-2 This standard contains the particular requirements for Exp purged products. Note, different from the US CSA purged , the IEC purged requirements require third party verification testing.Note: 60079 is Gas Series

IEC StandardsIEC60079-7 This standard is used for Increased Safety, Exe. The motor requirements vary with edition.IEC60079-10 This standard is used for Zone classification.IEC60079-11 This standard is used for Intrinsic Safety, Exi. This standard is quite complex, and is a full system certification based on limiting the energy level to components through isolators, barriers etc. to a level which will not create ignition.IEC60079-14 This standard is used for installation practicesIEC60079-15 This standard is used for Exn (formerly called non-sparking) devices. The motor requirements vary with edition.IEC60079-19 This standard is used for repair and overhaul.Note: IEC 60079 does not require IEC motor 60079-0 does imply metric fasteners

IEC Group l lGroup llCAtmospheres of Acetylene, Hydrogen or Gases or Vapors havingMESG < 0.50 mm or MIC ratio< 0.45

Group llBAtmospheres of Ethylene, Acetaldehyde or Gases or Vapors havingO.50 mm < MESG < 0.90 mm or 0.45 < MIC ratio< 0.80Group llAAtmospheres of Acetone, Ammonia, Ethyl, Alcohol, Gasoline, Methane, Propane or Gases or Vapors havingMESG > 0.90 mm or MIC ratio> 0.80.Note: MESG is maximum experimental safe gap. MIC ratio is minimum igniting current ratio (gas to methane). Courtesy of Underwriters Laboratories Inc. Note IEC is slightly different than NEC due to test equipment and process used

ATEXWhat is ATEXATEX is the European Potentially Explosive Atmospheres Directive (94/9/EC). This covers both electrical and mechanical equipment (NEMA and IEC frames) that may be used in potentially explosive atmospheres in addition to other European Directives such as the Electromagnetic Compatibility (EMC) (89/336/EEC) or Low Voltage (73/23/EEC) Directives.

ATEX comes from ATmospheres EXplosibles

Explosion Proof hazardous application for Zone 1 (similar to Div 1) and/or Zone 2 (similar to Div 2) motors were required to have the ATEX certification for import to Europe beginning July 1, 2003.Labeling vs IEC (Example) Protection Method Example : Non-sparking, Non-arcingEx n (IEC) and EEx n (European)

ATEX CategoriesATEX adds categories to the Zone conceptFor ATEX , products are identified as Category 2 for Zone 1

Equipment Protection LevelsPresently, Zones are not marked on international products, only in the US market. The concept of Equipment Protection Levels is being introduced (starting in the 2007 version of IEC60079-14):

Zone- Risk of flammable Release; EPL Risk of Equipment ignition sourceCome together in installation; Combination is potential consequence Optimize by reducing zone classification or increasing EPL Intent drive classification system to be more risk assessment based Notes:

Equipment protection level

Zone

Ga

0, 1, 2

Gb

1,2

Gc

2

Da

20, 21, 22

Db

21, 22

Dc

22

IEC Ex Testing CommentsTemperature TestingFor Flameproof (Exd), external temperature is a concernFor Exn and Exe, internal (rotor) temperature also is of a concernExe Requires design specific temperature testing For Flameproof Flame Transmission, Reference Pressure and Hydrostatic Testing Flame transmission defines whether fit keeps flames within motorReference Pressure Max pressure motor could see in explosionHydrostatic tests similar as UL but different gases When is Testing Required?For Initial product Line Certifications to Demonstrate Family ConformanceExe , as noted, Requires Each Specific Design to be TestedWith or Without Required Testing a Full Assessment is RequiredClause by Clause review of Standard vs Submitted Product.

ComponentsUsing IEC and cable gland as an example-For IEC certified motors, the component certification must be suitable for the same groups and environment as the motor.For instance, an IECEx motor using a suitably certified gland if marked for Zone 1 Group II would need a gland which is IECEx Certified for Zone 1 Group II.If the motor is Australian certified (to Australian standards) the gland must carry Australian certification.Product Manufacturer must verify the suitability of all components to the requirements of the motor group and environment.

Product Certification StrategiesATEX or IEC?ATEX certification does not assure IEC compliance.-mechanical products, declaration of conformity

IEC certification can be used for ATEX

ATEX has documentation and certification requirements beyond IECEx

To have validity IEC certification should be through the IECEx Scheme

ATEX Labeling ExamplesExamplesEEx d IIA T3 this is ATEX Certified EEx d, Gas Group IIA, T3 temp code for Zone 1 and is similar to U/L Div I, Class I, Group D, T3 temp code.

EEx d IIB T3 this is ATEX Certified EEx d, Gas Group IIA and IIB, T3 temp code for Zone 1 and is similar to U/L Div 1, Class I, Group C & D, T3 temp code.

EEx n II T3 this is EEx n, Gas Groups IIA, IIB and IIC, T3 temp code for Zone 2 and is similar to Div 2, Class I, Groups A,B,C and D, T3.Not available at this time can offer EEx d, IIA, IIB, T3 with Increased Safety c/box

EEx de IIB T3 this is ATEX Certified Ex d, Gas Group IIA and IIB, T3 temp code for Zone 1 and is similar to U/L Div 1, Class I, Group C & D, T3 temp code, with an EExe terminal box

Note: Reliance is certified to provide our EExd motor with any suitably certified EEx e box, and with the motor and box marked separately, EEx d on the motor, EEx e on box

Exe Increased Safety Terminal BoxThis is an EExe box, mounted on a Reliance EExd motor in a turbine starter motor application

CENELECCE is a product mark designating compliance to the European Directives, such as EMC and Low Voltage directives and ATEX. It is important to review a manufacturers declaration of conformity to determine what directives are met by the CE mark.

CENELEC is the European Committee for Electrotechnical Standardization

CEN is the European Committee for StandardizationTogether, these two committees prepare European Standards in specific sectors of activity.

ATEX motors are certified to the CENELEC standard series (the European Norms) but are Declared by the manufacturer as compliant with the Directive (self declaration).

Putting IEC and ATEX TogetherIECEx Product CertificationGoal - One Certificate, One Test, One Mark for the worldEX CB (Certified Body) maintains Conformity CertificateRequires factory Quality Assessment for Ex productsCertification requires full compliance with the IEC Ex series of standards.ATEX Mandatory Compliance within European Economic Area (EEA)Considers Electrical and non electrical productsImposes requirements for non electrical sources of ignition, such as bearingsType examination certificate (EC) and Quality Assessment Notification (QAN) issued by NBManufacturer alone is responsible for Declaration of Conformity

The Future - RAPS ViewThe future will rely on the IEC based standards

The US will gradually implement IEC requirementsBarriers to implementation: NEC, OSHA, Standards

Australia and Europe are strong players in the IEC SchemeLook for new requirements for Mechanical in IEC Look for new requirements for competency from AustraliaLook for new requirements for Repair and Overhaul, and certification of repair facilities

Rockwell Automation presently participates in standards writing for all of our core Ex standards, as well as the IECEx Certification process.

WelcomeStarting to lay a foundation here-

Whether it is a hazardous location in the US Division scheme, or a Hazardous Area in the global Zone scheme, the principles and concepts are similar. The areas are classified based on risk and exposure.

Typically, our customers tell us what their classification is for their area, or whether or not certification is required in the case of mining. Over the years there has been some confusion relative to certification needs for drives when outside of the hazardous areas, and powering motors inside the hazardous area. We will discuss this point more later in the presentation.Classifications are typically done by the engineer designing the facility in conjunction with local authorities or specialist consultants.More specific information on classification can be found in the National Electric Code, NFPA70 and in IEC60079-10General, EngineeringInformation on US certification bodies can be found on the OSHA site, under nrtl or nationally recognized testing laboratory http://www.osha.gov/dts/otpca/nrtl/ Information on ATEX Notified Bodies can be found at the Europa website:http://europa.eu.int/comm/enterprise/newapproach/legislation/nb/en94-9-ec.pdf

There are three Australian certifiers, TestSafe, Simtars and ITACSGeneral - EngineeringMore details on the specific standards will follow later in the presentation.

MSHA Requirements can be found on the internet, and are included in your reference material as 30CFR or at the following link: http://www.msha.gov/30CFR/CFRINTRO.HTMHow do Zones and Divisions Relate?This slide gives an overview of Divisions and Zones, used for non-mining, gas and dust classification.General, Marketing, Sales IndustryLater on in the presentation, I have some example photographs of typical products used in these areas.General Marketing, Sales, IndustryIt may be interesting to note here, that our National Electric Code is not law, instead, individual states and municipalities will adopt various versions of the NEC as their local code.

Also, if you were to look at the front of the NEC, several key areas are excluded, or as indicated in Article 90.2 Not Covered-Ships (except as indicated in Title 46 CFR, Parts 110-112), Underground mines, railways, communication utilities, and electric utilities* where the utility has exclusive control of the installation.

This is why, for instance, that coal fired power plants do not have to classify for dust.What does apply for mining? MSHA uses permitted equipment near the face and inby the first cross cut. Permitted means Approved. There really are not requirements for equivalent areas to Division 2, away from the face. Since there is a risk, the government, NIOSH (National Institute of Occupational Safety and Health) is researching these Div. 2 requirements for MSHA.2EngineeringThe next few inset slides came from a UL presentation by Ed Briesch to the Department of Energy 2002, Overview of Area Classifications. More presentations can be found at www.ul.com/hazloc sidebar Training and Education, papers and presentations. This UL Site also has a lot of information on global compliance. I have also included with UL permission several other good background papers, North America on the way to IEC Zone System esmg paper 2002 and NEC Group Classification Briesch paper for AICHE 2002,

MESG is determined experimentally as the maximum gap which will extinguish the flame. There are several recognized test methods in the world, each with slightly varying results. UL was a pioneer in this research.

MIC Ratio is the ratio of the igniting current of the candidate gas to methane.4679115131313How do Zones and Divisions Relate?This slide gives an overview of Divisions and Zones, used for non-mining, gas and dust classification.General, EngineeringYou may notice two standards for Division 1 certifications.In the US market, standards development organizations, or SDOs develop standards to address regulatory concerns such as the National Electric Code. In the US, we have two major certifiers for Hazardous Equipment, UL and FM Approvals. Each certifier has their own standard. Compliance with the UL requirements does not assure compliance with the FM requirements and compliance with the FM requirements does not assure compliance with the UL requirements.Two minor cases in point, last year we tested a UL Division 1 motor for a customer who desired FM Division 1 and found additional chemical resistance and flammability requirements at FM.Several years ago, we determined that an FM Division 1 RTD did not have sufficient wall thickness to meet the UL requirements for a sheet metal enclosure. EngineeringZones for gas have been in the NEC for several code cycles, since the fall of 1996.

EngineeringZones for dust were added to the 2005 version of the code. IEC based certification standards will be released for the next code cycle, and the code will be updated to add dust protection concepts.General Marketing, Sales, IndustryThe information on hours per year can be found in various certification bodies compliance posters, rather than the IEC60079-10 Classification standard. The hours used above are generally accepted, and come from the Sira Test & Certification poster. A copy of this poster in .PDF format is included in your reference material.General Marketing, Sales, IndustryThe information on hours per year can be found in various certification bodies compliance posters, rather than the IEC60079-10 Classification standard. The hours used above are generally accepted, and come from the Sira Test & Certification poster. A copy of this poster in .PDF format is included in your reference material.General, Marketing, Sales, IndustryIn this Zone classification, the first 2 indicates dust, the second number parallels the gas zones.This standard series also has protection methods and protection method standards. Protection by enclosures is covered by IEC61241-1 and is called Ex td. This protection method standard presently has two methods of certification, one Method A is based on ingress protection testing (IP classification to IEC 60529) and temperature testing, the other Method B is based somewhat on the UL testing where the product is operated in a dust cabinet with as much dust as will layer on top on the product, while temperatures are monitored, In either case a depth of dust can be specified as TL if requested.

The next version of IEC61241-1 is considering a new method, which combines A&B.

Slide 9 has a comparison table for Divisions and Zones.GeneralAs you can see from the table, there are several different protection concepts that can be used for Zone 1. There are other protection concepts which are not on the chart, such as encapsulation and oil immersion.

Not all of these methods can be used in mining. For instance Exn is not used in mining, however Exd, Exe, Exi, Exm (encapsulated) are used in mining equipment.

EngineeringA brief certification note at this point-

If IEC60079-0 is called up as being normative (required) for compliance with the protection concept standard, an IEC test report must consider all of the part 0 requirements. The maintenance recommendations in an instruction may include must only be repaired by manufacturer (but this may not be commercially feasible), or Reliance does not recommend reclamation of flameproof parts but this has a commercial impact as well on customers without adequate spare inventory.EngineeringTwo of these standards Exn and Exe have similar requirements, except Exn is for Zone 2 and Exe is for Zone 1. One of the right off the bat differences is that the Exe standard derated the allowable temperatures, increases internal electrical spacings and introduces rotor and stator incendivity requirements for larger motors. Starting is considered a normal condition for these motors, and typically manufacturers provide provisions for pre-purge and suggest soft start means for customers.

IEC60079-19 goes into repair and overhaul, and the general assumption is that manufactures will make available their schedule drawings for servicing. For flameproof motors simply restoring to the dimensions called out in the standard will not necessarily guarantee a safe product. We are working on guidelines of how much information to share to whom, under what conditions.EngineeringThe next few inset slides came from a UL presentation by Ed Briesch to the Department of Energy 2002, Overview of Area Classifications. More presentations can be found at www.ul.com/hazloc sidebar Training and Education, papers and presentations. This UL Site also has a lot of information on global compliance. I have also included with UL permission several other good background papers, North America on the way to IEC Zone System esmg paper 2002 and NEC Group Classification Briesch paper for AICHE 2002,

MESG is determined experimentally as the maximum gap which will extinguish the flame. There are several recognized test methods in the world, each with slightly varying results. UL was a pioneer in this research.

MIC Ratio is the ratio of the igniting current of the candidate gas to methane.GeneralSo, just when you had figured out Zones, ATEX adds Categories, and the categories do not align with the zones.

Equipment Categories describes the type of equipment which can be used in a particular zone classified area, and allows the user to apply risk assessment to his installation.

The Annexes for Compliance are Annexes of the ATEX Directive. This is where product inspection and quality certification is added to the ATEX directive.

While on this topic, quality and inspection, ATEX and IECEx share the same inspection criteria and require that we track by at least lots our critical dimensions and quality data, and require ongoing factory audits by the certifier. Our ATEX audits serve to support our IECEx certifications as well.[Pull up Sira Poster from Misc. Reference Material] This is an example of ATEX marking.

GeneralThis concept of Equipment Protection Levels parallels the ATEX Equipment Category concept.

Good point for a brief break.

After the break, we will view a brief presentation on IECEx, IECEx Intro.EngineeringRelative to temperature testing, some IEC standards such as IEC60079-1 directly point to standards such as IEC60034-1 for temperature testing, which allows a +/-5% tolerance for voltage, if the motor is marked with that range. IEC60079-0 clause 26.5.1 allows us to demonstrate that other standards prescribe other tolerances for equivalent industrial electrical apparatus. and argue for the IEC60034-1 tolerance band, as described in Figure 12 , pg. 70 applies. This is used in 79-1 Table 5 Note as reference.Relative to providing data, presently the IECEx Scheme is considering a document which will allow motor manufacturers to provide temperature test data as part of a witnessed program. This may open the door to annual audits and data submission in between.

We are in somewhat of a quandary in the US. As manufacturers and the USNC we support this, but OSHA will only accept witnessed data for national certifications, so we are asking the rest of the world to do something that we cannot yet do here.GeneralI have to reiterate- components are important, and can be show stoppers. Check the certificate for your components early on.

If your supplier does not have the required certification, the quickest solution will be to find someone who does.

A parallel to this, our motors are components to our customers. It is in our best interest to determine a strategic plan which will not require our customers to wait for certification.

As an example of a certificate, lets take a moment and look at one of our own, from Miscellaneous Reference Material the IECEx Certificate example.

This certificate has an X, conditions appear on page 3 (4: Cable Gland, 5: Cooling Water, 6: Thermal Protection) all of which the customer needs to be aware of before the product arrives.ATEX certification does not assure IEC compliance. ATEX declaration and EC Type Examination Certificate can be made by complying with the EHSR route rather than standards route. It may be possible to accomplish this without additional testing, if the ATEX Notified Body is also an IECEx TL, and the product fully complied with the EN standard to start with, but a clause by clause assessment must be done.

IEC certification can be used for ATEX. The newer EN60079 series is identical to the IEC standard series except for cover and Annex ZZ, so conversion to ATEX from IECEx is relatively easy,To have validity IEC certification should be through the IECEx Scheme(An IEC Product Conformity Certificate is of little commercial value.)Plan for an IECEx Certificate of Conformity.Presently in the US most installations are classified in Divisions, and our NEC allows for equivalent Zone marking, so there is not a major push in the US market for true IEC certifications..BUT we are finding much less acceptance internationally for Division certified product. At RAPS we are presently developing a strategy to transition to IEC certifications for global markets.

General General For the US, relative to gradual often times it takes retirements or a changing of the guard on code panels to bring about change. Many of the staunch supporters for status quo are retiring. There are cost advantages in IEC based construction and wiring methods, and these cost savings, together with platform standardization will drive users to in the future AEx in the US market.

Nationally, industry is working to drop barriers at OSHA relative to the IECEx Scheme and to reduce national differences in standards.

A summary of the hazardous location standards we participate on is attached in the reference material, EX Standards Participation.