Legislation, Standards and Technology

Explosion protected
electric motors
Selection, adjustment and testing of current-dependent overload protective devices
by Helmut Greiner
For the types of protection used for electric motors, particularly for increased safety
e, the overload protective device has the
important function of a protective system in
the protection against explosions. Since July
1, 2003 it has only been permitted to place on
the market devices and protective systems
that comply with EC Directive 94/9/EC [1]
ATEX 95 for short. On usage in category 2,
this compliance must be demonstrated by the
EC type examination certificate from a notified body. Along with the formal requirements, the electrician working as an installer
must take into account a whole series of
conditions during the selection, adjustment
and testing of such overload protective
devices.

Selection and adjustment

General requirements
Clause 7 and 11.2.1 of IEC/EN 60079 -14:
Electrical equipment for explosive gas atmospheres, part 14: Electrical installations in
hazardous areas [2] must be followed for
the thermal overload protection of rotating
electrical machines.
The current-dependent, time-delayed protective device (e. g. bi-metallic relay) for
monitoring all three phases is not permitted
to be set higher than the rated current (nominal current) of the motor. At 1.2 times the
set current, the device must trigger within
2 hours and at 1.05 times the current set,
the device must not trigger within 2 hours.
These figures are met automatically if the
device complies with the standard IEC/EN
60947- 4-1: Low-voltage switchgear part 4-1
[3] or if it is subjected to a function test by
a notified body, as has been stipulated for
placing on the market since July 1, 2003 by
the directive 94/9/EC.

Figure 1: Example rating plate on a motor with type of

protection e with the explosion-protected
related marking
Temperature class
T3
Starting current ration
IA/IN = 8.1
Safe locked-rotor time
tE = 12 s

Additional requirements for type of protection increased safety e

On motors with type of protection increased
safety e, the protection of the motor must
cover, along with continuous operation, also
the foreseeable locked rotor fault.
During the type examination by a notified
body (i.e. test centre such as PTB or other
authorized test house) the time after which
the protective switch must trigger is determined such that the temperature in the stator
winding and the rotor cage remains below
the ignition temperature of the explosive
mixture by a safe margin. The safe lockedrotor time tE determined in this manner is
categorised for the temperature classes
T1/ T2 / T3/T4, i. e. it is stated in the EC type
examination certificate categorised for ignition temperatures 450 / 300 / 200 /135 C. Only
the T. and tE values required in the specific
case are stated on the rating plate (Figure 1).

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Ex-Magazine 2007

40
s
20

10
8

tEmin

Certification as protective system

Article 1 (2) of the directive 94/9/EC addresses the topic covered here:
Safety devices, controlling devices and
regulating devices intended for use outside
potentially explosive atmospheres but
required for or contributing to the safe functioning of equipment and protective systems
with respect to the risks of explosion are also
covered by the scope of this Directive.
In the ATEX Guidelines dated July 2005
[5], in section 3.10 on page 18, there are
examples of such safety devices, also specifically including overload switches for electric motors with type of protection increased
safety e (Figure 4).
It is generally considered that an EC type
examination certificate from a notified body
is not mandatory for such a device if it is
used in addition to another protective device
or if it is protecting a motor in Zone 2 or 22
that has a manufacturers EC declaration of
conformity and the protective device is
described in the operating instructions. How-

1
2

10

IA / IN
Figure 2: Minimum tE - time as a function of the relative starting current IA/IN in accordance with Figure 3 in
EN 60079-7 [4]. The characteristics from the individual manufacturers are not standardised, however in general
they meet this requirement

100
s
50

MR
20

tE
nominal

10

The installer must select a protective

switch with a characteristic that complies
with these shutdown conditions. In general,
this requirement is met because during
the type examination, attention is generally
only paid to approving combinations of
IA/ IN and tE that are technically feasible for
the bi-relay manufacturers (Figure 2). However, the equipment data and the documentation must be checked in each case.
The characteristic of the protective device
must be available at the users operating
organisation in accordance with IEC/EN
60079-14 as a rule as documentation on
paper in the form of operating instructions or
a manual.
An example for the label data in Figure 1
is given in Figure 3.

t actual
2

1
1

10

I / IE
Figure 3: Checking the motor protection characteristic MR for a motor with relative starting current IA/IN = 8.1 as
a multiple of the rated current IN or the current set IE setpoint for the time tE = 12 s.
Actual value for the tripping time t = 4.2 s i.e. relay is suitable (characteristic shown simplified)

ever, it is recommendable and, given corresponding market development, also to be

expected that certified devices will also be
used in Zone 2 or 22, and for the protection
of motors with type of protection flameproof
enclosures d (not expressly stated in the
ATEX Guidelines).

Explosion protected electric motors

W2
L1
U1
U2
L2
V1
V2
L3
W1

Y
W2

U2

V2

U1

V1

W1

cautions shall be taken to prevent the operation of a three-phase motor on the loss of a
phase. Specifically, at partial load the singlephase operation of a three-phase motor does
not represent an acute thermal hazard it is
therefore not necessary to isolate the system
from the mains immediately upon failure of a
phase.
Even though not expressly stipulated in
the standard, the simple action sensitivity to
phase failure available on the market is also
recommended for the protection of windings
in a star configuration.

MS

Connection of the trips

Figure 5: Circuit diagram for Y--switching with
arrangement and rating of the bi-metallic switch MS
for the phase current Iph = IN / 1.73

Figure 4: Marking on a motor protective relay

compliant with the directive for an explosionprotected motor with type of protection e.
Device is allowed to have an effect in Zone 1
(category 2). Installation of the device in
the safe area (source: MOELLER GmbH)

Sensitivity to phase failure

The hazard from three-phase cage motors
in case of two lines operation on mains
with a fault is described in detail in [6]. In the
latest draft standard IEC 60079-14 [7], which
regulates the installation of electrical systems in potentially explosive atmospheres,
this issue is addressed in general form in
clause 7.1: Precautions shall be taken to prevent operation of multi-phase electrical
equipment (e. g. three-phase motors) where
the loss of one or more phases can cause
overheating to occur.

In clause 11. 2.1, for motors of the type of

protection increased safety e are defined in
more detail:
The properties of delta wound machines
in the case of the loss of one phase should
be specifically addressed. Unlike star wound
machines, the loss of one phase may not
be detected, particularly if it occurs during
operation. The effect will be current imbalance in the lines feeding the machine and
increased heating of the motor. A delta
wound motor with a low torque load during
start-up might also be able to start under
this winding failure condition and therefore
the fault may exist undetected for long periods. Therefore, for delta wound machines,
phase imbalance protection shall be provided which will detect machine imbalances
before they can give rise to excessive heating effects.
It is positive to note that the current formulation replaces the 1998 version: Pre-

Y--starting and pole switching

In earlier PTB test certificates it was
defined that on windings in a delta configuration, the bi-metallic relay or trip must
be connected in series with the phase windings and set to the phase current, that is
1/1.73 = 0.58 times the motor rated current
(Figure 5). Although this requirement has
disappeared, the recommendation is still appropriate:
> In the case of Y--starting the winding
is protected if not switched from star to
delta.
> In the event of the failure of a phase, the
protective effect for the winding is better.
In the case of pole switching motors,
a separate relay is to be provided for each
speed stage; these relays are to be interlocked. In general the currents in all three
lines are to be monitored.

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Ex-Magazine 2007

K x IE

Single-phase motors
As function-tested motor protective devices for single-phase motors are uncommon
on the market, it is mostly recommended
to use three-phase devices with the line
looped through. This action is necessary to
simulate the mutual heating of the three bimetallic elements present with a three-phase
connection (Figure 6).
L1

Inspections
The installer can assume that the two
standard points of the trigger characteristic
(for 1.05 and 1.2 times the set current) and
also the trigger point for starting current
IA (current with locked rotor) are met within
the tolerances allowed and are assured
by the quality assurance system at the manufacturer of the protective device.
It is sufficient both during the initial inspection and during subsequent periodic
inspections to check the values set. A measurement of the tripping values (with preheating or test current injection applied
during test) is not necessary unless there
are doubts as to the function of the relay
(e. g. due to damage visible from the exterior
caused during transport or prior use).
On this issue EN 60079 -17: Inspection and
maintenance [9], section 5.2.1 states:
Depending on experience, it may or may not
be necessary to measure the tripping times
by current injection at the initial inspection
and/or periodic inspection. The tripping time
in real operation shall be the same as the
time taken from the delay characteristic with
a maximum tolerance of + 20 %.
This standard also includes detailed information on the tasks and plans for periodic
inspections (for essential requirements see
the German national safety regulations (e. g.

L1

Figure 6: Looping through the current carrying line

L1 for a single-phase motor on the use of a motor
protective device intended for three-phase power as
standard (Source: Moeller book Switchgear for the
Protection of Electric Motors [8])

BetrSichV) [10]). In accordance with table 1,

the inspection plan for motors with types of
protection d and e are to include a detailed
check that, among other aspects:
> B9
The automatic electric protective devices
operate within the permitted limits
> B10
The automatic electric protective
devices are set correctly (auto-reset is
not possible)
Clause 5.2.1 as quoted above leaves it up
to experience and the local conditions for the
related system as to whether a test on the
tripping times must be incorporated.

L1

L3

Figure 7: Applying a current load to a bi-metallic relay

for checking the trigger characteristic in the laboratory
K-factor as multiple of the value set

The standard EN 60079 -17 is not specific

on the inspection intervals. In the absence
of national regulations, here the information
defined in the German safety regulations
and in their future form Technische Regeln
fr Betriebssicherheit (TRBS 2.1.5. publication in Bundesarbeitsblatt) may be followed. In accordance with 15 (1) and (15) of
the German safety regulations (BetrSichV),
the user must define the inspection interval
based on a safety assessment; the interval
must not be longer than three years.
Function tests
If, based on the criteria stated above,
a function test on the overcurrent protective
device should be necessary, the following
test methods have proven effective. In these
cases the related tripping characteristic
from the manufacturer is definitive for the
assessment.

Explosion protected electric motors

References

M
3~

L1

L2

L3

M
3~

L1

L3

Figure 8: Applying a current load to a bi-metallic relay

for checking the tripping characteristic on site.
Small motors without a gearbox.

Figure 9: Applying a current load to a bi-metallic relay

for checking the tripping characteristic on site.
Medium-sized motors with or without a gearbox.

Checks in the laboratory

The tripping characteristic for the specific
relay is checked under laboratory conditions
(e. g. using variable transformer or variable
resistors) (Figure 7). The variation is allowed
to be up to +20 % (IEC/EN 60079-17, 5.2.1).

Medium-sized and large motors are also

to be locked if starting with the wrong
direction of rotation would cause damage.
The test is to be performed in single-phasing
operation, that is with two lines (Figure 9).
Relays with sensitivity to phase failure trip
somewhat earlier with this method of operation than with a normal 3-line connection.
Relays without sensitivity to phase failure trip
after around 1.3 1.5 tE in a star configuration.
The test is to be stopped at the latest after
2 tE. At tripping times > 1.5 tE there is reason
to suspect that the tripping characteristic
has changed excessively.

Checks on site
This method can, of course, only be applied if the risk of explosion is excluded.
Smaller drives that can be safely locked are
checked under normal mains and adjustment
conditions with the rotor locked (Figure 8).
On setting to the rated current IN, the relay
must trip at the latest after the time tE stated
on the motors rating plate with a tolerance
of +20 %. The test is to be stopped at the
latest after 1.5 tE to prevent damaging heating
of the winding.

[1] Directive 94/9/EC of the European Parliament and the Council; Approximation of
the laws of the Member States concerning
equipment and protective systems intended
for use in potentially explosive atmospheres
[2] IEC/EN 60079-14
Electrical apparatus for explosive gas
atmospheres; Part 14: Electrical installations
design, selection and erection in
hazardous areas (other than mines)
[3] IEC/EN 60947-4-1
Low-voltage Switchgear; Part 4-1: Electromechanical Contactors and Motor Starters
[4] IEC 60079-7 (2006-07)
Explosive atmospheres; Part 7: Equipment
protection by increased safety e
[5] Guidelines on the Application of Council
Directive 94/9/EC of March 1994 on the
Approximation of the Laws of the Member
States concerning Equipment and Protective
Systems intended for Use in potentially
explosive Atmospheres; 2. Edition 2005
[6] Greiner, H.: Phasenausfallschutz von
Motoren; ep, 1996 Heft 3
[7] IEC 60079-14 (IEC 31J / 120 / CDV) 2006-06
Explosive atmospheres Part 14 Electrical
installation design, selection and erection
[8] Esser, H.-W.: Switchgear for the Protection
of Electric Motors;
Moeller Guide by Fa. Moeller, Bonn (1999)
[9] IEC/EN 60079-17
Electrical apparatus for explosive gas atmospheres; Part 17: Inspection and
maintenance of electrical installations in
hazardous areas (other than mines)
[10] Betriebssicherheitsverordnung
(BetrSichV): Verordnung ber Sicherheit und
Gesundheitsschutz bei der Bereitstellung
von Arbeitsmitteln und deren Benutzung bei
der Arbeit, ber Sicherheit beim Betrieb
berwachungsbedrftiger Anlagen und ber
die Organisation des betrieblichen Arbeitsschutzes vom 27.9.2002; BGBl. Teil 1 Nr. 70,
S3777-3816
[11] Greiner, H. u.a.: Elektroinstallation und Betriebsmittel in explosionsgefhrdeten Bereichen; Hthig & Pflaum Verlag; Mnchen
Heidelberg (2006)