§ 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 elec-

tric 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 ›noti-
fied body‹. Along with the formal require-
ments, the electrician working as an installer
must take into account a whole series of
conditions during the selection, adjustment Figure 1: Example rating plate on a motor with type of
and testing of such overload protective protection ›e‹ with the explosion-protected
devices. related marking
Temperature class T3
Starting current ration IA/IN = 8.1
Safe locked-rotor time tE = 12 s
Selection and adjustment

General requirements
Clause 7 and 11.2.1 of IEC/EN 60079 -14:
Electrical equipment for explosive gas at-
mospheres, 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 pro-
tective device (e. g. bi-metallic relay) for
monitoring all three phases is not permitted
to be set higher than the rated current (nomi-
nal 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.
Additional requirements for type of protec-
tion 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 deter-
mined 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 locked-
rotor 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 igni-
tion 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).
 Ex-Magazine 2007 26 | 27

40
s

20

10
8
6

tEmin
4

The installer must select a protective

2
switch with a characteristic that complies
with these shutdown conditions. In general,
this requirement is met because during
1
the type examination, attention is generally 2 3 4 5 6 7 8 9 10
only paid to approving combinations of IA / IN
IA/ IN and tE that are technically feasible for
the bi-relay manufacturers (Figure 2). How- Figure 2: Minimum tE - time as a function of the relative starting current IA/IN in accordance with Figure 3 in
ever, the equipment data and the documen- EN 60079-7 [4]. The characteristics from the individual manufacturers are not standardised, however in general
they meet this requirement
tation must be checked in each case.
The characteristic of the protective device
›must be available at the user’s operating
organisation‹ in accordance with IEC/EN 100
60079-14 – as a rule as documentation on s
paper in the form of operating instructions or
50
a manual.
An example for the label data in Figure 1 MR
is given in Figure 3.
20
tE
Certification as protective system nominal
Article 1 (2) of the directive 94/9/EC ad- 10
t

dresses the topic covered here:

›Safety devices, controlling devices and 5
regulating devices intended for use outside
t actual
potentially explosive atmospheres but
required for or contributing to the safe func- 2
tioning of equipment and protective systems
with respect to the risks of explosion are also
1
covered by the scope of this Directive.‹ 1 2 3 4 5 6 7 8 9 10
In the ATEX Guidelines dated July 2005 I / IE
[5], in section 3.10 on page 18, there are
examples of such safety devices, also specif- Figure 3: Checking the motor protection characteristic MR for a motor with relative starting current IA/IN = 8.1 as
ically including overload switches for elec- a multiple of the rated current IN or the current set IE · setpoint for the time tE = 12 s.
tric motors with type of protection increased Actual value for the tripping time t = 4.2 s i.e. relay is suitable (characteristic shown simplified)

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 manufacturer’s EC declaration of
conformity and the protective device is
described in the operating instructions. How-
ever, it is recommendable and, given corre-
sponding 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). Ë
Explosion protected electric motors
Figure 4: Marking on a motor protective relay
compliant with the directive for an explosion-
protected 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 sys-
tems in potentially explosive atmospheres,
this issue is addressed in general form in
clause 7.1: ›Precautions shall be taken to pre-
vent operation of multi-phase electrical
equipment (e. g. three-phase motors) where
the loss of one or more phases can cause
overheating to occur.‹
W2
L1
U1
U2
L2
V1
V2
L3
W1
Y ∆
W2 U2 V2
U1 V1 W1
MS
Figure 5: Circuit diagram for Y-Δ-switching with
arrangement and rating of the bi-metallic switch MS
for the phase current Iph = IN / 1.73
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 imbal-
ance 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 peri-
ods. Therefore, for delta wound machines,
phase imbalance protection shall be provid-
ed which will detect machine imbalances
before they can give rise to excessive heat-
ing effects‹.
It is positive to note that the current for-
mulation replaces the 1998 version: ›Pre-
cautions shall be taken to prevent the opera-
tion of a three-phase motor on the loss of a
phase.‹ Specifically, at partial load the single-
phase 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.
Connection of the trips
Y-Δ-starting and pole switching
In earlier PTB test certificates it was
defined that on windings in a delta configu-
ration, the bi-metallic relay or trip must
be connected in series with the phase wind-
ings 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 ap-
propriate:
> In the case of Y-Δ-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 inter-
locked. In general the currents in all three
lines are to be monitored.

Single-phase motors
As function-tested motor protective de-
vices 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 bi-
metallic elements present with a three-phase
connection (Figure 6).
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 manu-
facturer of the protective device.
It is sufficient both during the initial in-
spection and during subsequent periodic
inspections to check the values set. A mea-
surement of the tripping values (with pre-
heating 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 infor-
mation on the tasks and plans for periodic
inspections (for essential requirements see
the German national safety regulations (e. g.
L1 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.
Ex-Magazine 2007 28 | 29
K x IE
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
für Betriebssicherheit‹ (TRBS 2.1.5. – publi-
cation in ›Bundesarbeitsblatt‹) may be fol-
lowed. 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. Ë
Explosion protected electric motors
M M
3~
L1 L2 L3
Figure 8: Applying a current load to a bi-metallic relay
for checking the tripping characteristic on site.
Small motors 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).
Checks on site
This method can, of course, only be ap-
plied 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 motor’s 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.
3~
L1 L3
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.
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 opera-
tion 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.
References
[1] Directive 94/9/EC of the European Parlia-
ment 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: Electro-
mechanical 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 at-
mospheres; Part 17: Inspection and
maintenance of electrical installations in
hazardous areas (other than mines)
[10] Betriebssicherheitsverordnung
(BetrSichV): Verordnung über Sicherheit und
Gesundheitsschutz bei der Bereitstellung
von Arbeitsmitteln und deren Benutzung bei
der Arbeit, über Sicherheit beim Betrieb
überwachungsbedürftiger Anlagen und über
die Organisation des betrieblichen Arbeits-
schutzes vom 27.9.2002; BGBl. Teil 1 Nr. 70,
S3777-3816
[11] Greiner, H. u.a.: Elektroinstallation und Be-
triebsmittel in explosionsgefährdeten Bere-
ichen; Hüthig & Pflaum Verlag; München
Heidelberg (2006)