Schneider ATV650U30N4, ATV650U15N4, ATV650U07N4 User Manual

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ltivar Process ATV600, ATV900

NVE42416 06/2016

Altivar Process ATV600, ATV900

Variable Speed Drives For Asynchronous and Synchronous motors

ATEX manual

for applications in explosive gas atmosphere or in the presence of combustible dust

06/2016

NVE42416.02

www.schneider-electric.com

The information provided in this documentation contains general descriptions and/or technical characteristics of the performance of the products contained herein. This documentation is not intended as a substitute for and is not to be used for determining suitability or reliability of these products for specific user applications. It is the duty of any such user or integrator to perform the appropriate and complete risk analysis, evaluation and testing of the products with respect to the relevant specific application or use thereof. Neither Schneider Electric nor any of its affiliates or subsidiaries shall be responsible or liable for misuse of the information contained herein. If you have any suggestions for improvements or amendments or have found errors in this publication, please notify us.

No part of this document may be reproduced in any form or by any means, electronic or mechanical, including photocopying, without express written permission of Schneider Electric.

All pertinent state, regional, and local safety regulations must be observed when installing and using this product. For reasons of safety and to help ensure compliance with documented system data, only the manufacturer should perform repairs to components.

When devices are used for applications with technical safety requirements, the relevant instructions must be followed.

Failure to use Schneider Electric software or approved software with our hardware products may result in injury, harm, or improper operating results.

Failure to observe this information can result in injury or equipment damage.

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Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

About the Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Functional Safety and ATEX applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 Applications for explosive atmosphere (ATEX) . . . . . . . . . . . . . . . . . . . . . 15

ATEX zones. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATEX Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 Wiring Diagrams For ATEX Applications . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 1: Single drive with PTC and control unit. . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 2: Single drive with PTC and control unit and with Safety Module

Type Preventa XPS-AF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 3: Drive Systems with PTC schematic 1 . . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 4: Drive Systems with PTC schematic 2 . . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 5: Drive Systems with PTC schematic 3 . . . . . . . . . . . . . . . . . . . . .

ATEX Installation Case 6: Drive Systems with PTC schematic 4 . . . . . . . . . . . . . . . . . . . . .

16 17

20 21

22 23 24 25 26

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Safety Information

Important Information

NOTICE

Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, service, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.

PLEASE NOTE

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.

A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation, and has received safety training to recognize and avoid the hazards involved.

Qualification Of Personnel

Only appropriately trained persons who are familiar with and understand the contents of this manual and all other pertinent product documentation are authorized to work on and with this product. In addition, these persons must have received safety training to recognize and avoid hazards involved. These persons must have sufficient technical training, knowledge and experience and be able to foresee and detect potential hazards that may be caused by using the product, by changing the settings and by the mechanical, electrical and electronic equipment of the entire system in which the product is used. All persons working on and with the product must be fully familiar with all applicable standards, directives, and accident prevention regulations when performing such work.

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Intended Use

This product is a drive for three-phase synchronous and asynchronous motors and intended for industrial use according to this manual.The product may only be used in compliance with all applicable safety standard and local regulations and directives, the specified requirements and the technical data. The product must be installed outside the hazardous ATEX zone. Prior to using the product, you must perform a risk assessment in view of the planned application. Based on the results, the appropriate safety measures must be implemented.Since the product is used as a component in an entire system, you must ensure the safety of persons by means of the design of this entire system (for example, machine design). Any use other than the use explicitly permitted is prohibited and can result in hazards. Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel.

Product Related Information

Read and understand these instructions before performing any procedure with this drive.

HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH

 Only appropriately trained persons who are familiar with and understand the contents of this manual

and all other pertinent product documentation and who have received safety training to recognize and avoid hazards involved are authorized to work on and with this drive system. Installation, adjustment, repair and maintenance must be performed by qualified personnel.

 The system integrator is responsible for compliance with all local and national electrical code

requirements as well as all other applicable regulations with respect to grounding of all equipment.

 Many components of the product, including the printed circuit boards, operate with mains voltage. Do

not touch. Use only electrically insulated tools.

 Do not touch unshielded components or terminals with voltage present.  Motors can generate voltage when the shaft is rotated. Prior to performing any type of work on the

drive system, block the motor shaft to prevent rotation.

 AC voltage can couple voltage to unused conductors in the motor cable. Insulate both ends of unused

conductors of the motor cable.

 Do not short across the DC bus terminals or the DC bus capacitors or the braking resistor terminals.  Before performing work on the drive system:

 Disconnect all power, including external control power that may be present.  Place a Do Not Turn On label on all power switches.  Lock all power switches in the open position.  Wait 15 minutes to allow the DC bus capacitors to discharge. The DC bus LED is not an indicator

 If the DC bus capacitors do not discharge properly, contact your local Schneider Electric represen-

 Install and close all covers before applying voltage.

Failure to follow these instructions will result in death or serious injury.

DANGER

of the absence of DC bus voltage that can exceed 800 Vdc. Measure the voltage on the DC bus between the DC bus terminals (PA/+, PC/-) using a properly rated voltmeter to verify that the voltage is <42 Vdc

tative. Do not repair or operate the product.

Drive systems may perform unexpected movements because of incorrect wiring, incorrect settings, incorrect data or other errors.

WARNING

UNANTICIPATED EQUIPMENT OPERATION

 Carefully install the wiring in accordance with the EMC requirements.  Do not operate the product with unknown or unsuitable settings or data.  Perform a comprehensive commissioning test.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

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Damaged products or accessories may cause electric shock or unanticipated equipment operation.

DANGER

ELECTRIC SHOCK OR UNANTICIPATED EQUIPMENT OPERATION

Do not use damaged products or accessories.

Failure to follow these instructions will result in death or serious injury.

Contact your local Schneider Electric sales office if you detect any damage whatsoever.

WARNING

LOSS OF CONTROL

 The designer of any control scheme must consider the potential failure modes of control paths and,

for critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop, overtravel stop, power outage and restart.

 Separate or redundant control paths must be provided for critical control functions.  System control paths may include communication links. Consideration must be given to the

implications of unanticipated transmission delays or failures of the link.

 Observe all accident prevention regulations and local safety guidelines (1).  Each implementation of the product must be individually and thoroughly tested for proper operation

before being placed into service.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

(1) For USA: Additional information, refer to NEMA ICS 1.1 (latest edition), Safety Guidelines for the Application, Installation, and Maintenance of Solid State Control and to NEMA ICS 7.1 (latest edition), Safety Standards for Construction and Guide for Selection, Installation and Operation of Adjustable-Speed Drive Systems.

NOTICE

DESTRUCTION DUE TO INCORRECT MAINS VOLTAGE

Before switching on and configuring the product, verify that it is approved for the mains voltage

Failure to follow these instructions can result in equipment damage.

The temperature of the products described in this manual may exceed 80 °C (176 °F) during operation.

WARNING

HOT SURFACES

 Ensure that any contact with hot surfaces is avoided.  Do not allow flammable or heat-sensitive parts in the immediate vicinity of hot surfaces.  Verify that the product has sufficiently cooled down before handling it.  Verify that the heat dissipation is sufficient by performing a test run under maximum load conditions.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

This equipment has been designed to operate outside of any hazardous location. Only install this equipment in zones known to be free of a hazardous atmosphere.

DANGER

POTENTIAL FOR EXPLOSION

Install and use this equipment in non-hazardous locations only.

Failure to follow these instructions will result in death or serious injury.

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At a Glance

Document Scope

Validity Note

About the Book

The purpose of this document is to explain how the STO (Safe Torque Off) safety function allows the ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 variable speed drives to control and command motors installed in explosive atmospheres (ATEX)

Original instructions and information given in this manual have been written in English (before optional translation).

This documentation is valid for the Altivar Process drives described in the Installation manual.

The technical characteristics of the devices described in this document also appear online. To access this information online:

Step Action

1 Go to the Schneider Electric home page

2 In the Search box type the reference of a product or the name of a product range.

 Do not include blank spaces in the reference or product range.  To get information on grouping similar modules, use asterisks (

3 If you entered a reference, go to the Product Datasheets search results and click on the reference that

interests you. If you entered the name of a product range, go to the Product Ranges search results and click on the product range that interests you.

4 If more than one reference appears in the Products search results, click on the reference that interests

you.

5 Depending on the size of your screen, you may need to scroll down to see the data sheet.

6 To save or print a data sheet as a .pdf file, click Download XXX product datasheet.

www.schneider-electric.com

Introduction

Chapter 1

Introduction

Functional Safety and ATEX applications

General

The variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 integrates the STO (Safe Torque Off) safety function which shuts off the motor torque safely. The use of the STO safety function allows the drive to be installed as a part of the safety-related electrical, electronic and programmable electronic control systems, dedicated to the safety of a machine or an industrial process.

The integrated safety function is compatible and certified following the information given in the Certification for Functional Safety section required for the safe functioning of equipment with respect to explosion risks.

The use of the STO safety function is required for the variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 to control and command motors installed in explosive atmospheres (ATEX).

The STO safety function is an ATEX certified function, according ATEX 94/9/EC directive and forthcoming 2014/34/EU directive.

(see page 11)

. It complies also with the EN 50495 (2010): Safety devices

Monitoring Of the ATEX Motor

The STO input(s) is (are) connected to the switching system which is embedded in the thermal sensor of the ATEX motor (or connected to the switching system of the control system if ATEX sensors of PTC type are used).

The variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 intended to be used to command and control asynchronous motors shall be installed only outside potentially explosive atmospheres for the protection of explosion-protected motors.

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ltivar Process ATV600, ATV900

NVE42416 06/2016

Applications for explosive atmosphere (ATEX)

Chapter 2

Applications for explosive atmosphere (ATEX)

What Is in This Chapter?

This chapter contains the following topics:

ATEX zones 16

ATEX Marking 17

Topic Page

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ATEX zones

Classification

The European directive 1999/92/EC (also called ATEX 137, or directive for protection of workers) classifies the ATEX zones and the type of products that they are compatible with. The user should define the ATEX zone in which the ATEX motor will be installed.

This equipment has been designed to operate outside of any hazardous location. Only install this equipment in zones known to be free of a hazardous atmosphere.

Different wiring diagrams for installation are suggested in this document. They are compatible with the use of motors in ATEX zones 1/21 or 2/22

The following table summarizes characteristics related to each ATEX zone

Atmosphere Zone Definition Presence of

explosive atmosphere per year

Gas 0 Explosive atmosphere is present continuously, for long periods or frequently

Dust 20

Gas 1 Explosive atmosphere is likely to occur due to expected malfunctions 10...1000 h

Dust 21

Gas 2 Explosive atmosphere is unlikely to occur or, if occurring, is likely to only be

Dust 22

due to malfunctions

of short duration and not in normal duty

> 1000 h

< 10 h

General

NOTE: Neither electrical equipment nor motors can be installed in ATEX zone 0 or 20.

The European directive 94/9/EC and forthcoming 2014/34/UE (also called ATEX 95, or product directive) defines applicable requirements for ATEX products and requirements for procedure of certification.

OEMs, installers, users are responsible for the choice and the commissioning of the products they use in order to realize the ATEX protection of systems that they design or systems that they implement.

 The motor needs to be ATEX certified EX “d” and compatible for use in zone 1/21 or 2/22.  The motor shall be equipped with thermal sensor(s) with embedded switching system ATEX certified,

or shall be equipped with thermal sensor(s) ATEX certified, associated to a control unit (Level of protection intrinsic safety "i"), which is to be also ATEX certified.

NOTE: Usually, the control unit is designed to be used outside the hazardous ATEX zone. Then it is possible to install the control unit near the variable speed drive, outside the hazardous ATEX zone.

The switching system, embedded into the thermal sensor, or included into the control unit of the thermal protection of the ATEX motor, shall be connected to the STO input of the variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980. When the excessive temperature of the ATEX motor is reached, the control system triggers the STO safety function. The electrical power of the motor is removed to help to ensure a temperature of the motor frame below the maximum temperature depending on the gas or the dust atmosphere in which the ATEX motor is installed.

When the ATEX application needs to apply the STO safety function, and prevent automatic restart, then a safety module (type Preventa) is to be used. The suggested wiring diagrams describe how the switching system, embedded into the thermal sensor or included into the control unit, is connected to the safety module. The output of the safety module must be connected to the STO input of the variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980.

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ATEX Marking

Identification

The variable speed drive Altivar ATV630, 650, 660 & 680, ATV930, 950, 960 & 980, ATEX certified, can be recognized by the specific marking reproduced hereafter:

1 0080 is the identification number of the notified body INERIS, which has delivered the notifications for systems of

production quality assurance of production lines for drives, in compliance with the standard EN 13980.

2 INERIS xxATEXxxxxx is the identification code of the EC Type examination certificate issued by the notified body

INERIS to demonstrate the compliance of the variable speed drive with the requirements of the ATEX 94/9/EC

directive. 3 Logo related to the identification of an ATEX product. 4 II relates to the use of products for ATEX application in surface industries. (ATEX applications for mines industries

are prohibited) 5 (2) Parenthesis identifies the variable speed drive ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 as a product

associated with the control & command of an ATEX motor installed in a hazardous zone. The number 2 identifies

the ATEX motor as a product of category 2 for use in ATEX zones 1 or 21. Motors of category 3 for use in ATEX

zones 2 or 22 are also covered by this marking. 6 G for Gas, is related to ATEX applications in atmospheres with explosive gas. D for Dust, is related to ATEX

applications in atmospheres with a mixture of explosive dust.

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ltivar Process ATV600, ATV900

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Wiring Diagrams For ATEX Applications

Chapter 3

Wiring Diagrams For ATEX Applications

What Is in This Chapter?

This chapter contains the following topics:

General 20

ATEX Installation Case 1: Single drive with PTC and control unit 21

ATEX Installation Case 2: Single drive with PTC and control unit and with Safety Module Type Preventa XPS-AF

ATEX Installation Case 3: Drive Systems with PTC schematic 1 23

ATEX Installation Case 4: Drive Systems with PTC schematic 2 24

ATEX Installation Case 5: Drive Systems with PTC schematic 3 25

ATEX Installation Case 6: Drive Systems with PTC schematic 4 26

Topic Page

NVE42416 06/2016 19

General

Requirements

Requirements provided by the ATEX standards for installation should be fulfilled. Also follow the requirements below:

 IEC 60079-14 Electrical installations design, selection and erection, for applications in atmospheres

with explosive gas,

 local regulation, cabling rules for applications in atmospheres with presence of gas or dust.

Wiring Diagrams Presentation

Schemes suggested in this document for installation and commissioning of variable speed drives ATV630, 650, 660 & 680, ATV930, 950, 960 & 980 for ATEX applications are based on thermal sensors (for example a PTC sensor) embedded in the ATEX motor and an intrinsic safety "i" control unit. The control unit is a device which converts in a switching function the variation of the characteristic of a thermal sensor.

ATEX Periodic test

The complete functional safety loop (which starts from the ATEX motor thermal sensor up to the STO safety function embedded in the drive), shall be activated at least once a year for preventive maintenance purposes, in order to check that the electrical power is always automatically removed from the motor in case of excessive temperature.

Shielded Cables on I/O

UNEXPECTED EQUIPMENT OPERATION

 Use shielded cables for all digital and analog I/O and communication signals  Ground cable shields at a single point.  Route communication and I/O cables separately from power cables.

Failure to follow these instructions can result in death, serious injury, or equipment damage.

WARNING

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ATEX Installation Case 1: Single drive with PTC and control unit

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO inputs used for protection of the ATEX motor sensor only, SIL1 capability according to IEC 61508,

stop category 0 according to IEC 60204-1without protection against supply interruption or voltage reduction and subsequent rotation.

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system.

Wiring Diagram

(1) ATEX Zone 1 or 21 or 2 or 22 with at least 1 thermal sensor PTC type (2) ATEX certified Control unit conversion / insulation / switching system with Level of protection intrinsic safety "i". (K72) ATEX certified PTC relay

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ATEX Installation Case 2: Single drive with PTC and control unit and with Safety Module Type Preventa XPS-AF

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO input used for protection of the ATEX motor, SIL 1 capability according to IEC 61508 and for

functional safety SIL3 capability according to IEC61508, stop category 0 according to IEC 60204-1, and category 3 PL e according to ISO 13849-1.

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system

Wiring Diagram

(1) ATEX Zone 1 or 21 or 2 or 22 with at least 1 thermal sensor PTC type (2) ATEX certified Control unit conversion / insulation / switching system (K72) ATEX certified PTC relay

22 NVE42416 06/2016

ATEX Installation Case 3: Drive Systems with PTC schematic 1

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO input used for protection of the ATEX motor, SIL 1 capability according to IEC61508 and for

functional safety SIL3 capability according to IEC61508 and stop category 0 according to IEC 60204-1.

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system

Wiring Diagram

(1) ATEX Zone 1 or 21 or 2 or 22 with at least 1 thermal sensor PTC type (2) ATEX certified Control unit conversion / insulation / switching system (3) (DIx) Internal I/O can be used for PTC monitoring. (K72) ATEX certified PTC relay (DIx) Internal I/O set to thermal management (S62) External emergency stop button.

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ATEX Installation Case 4: Drive Systems with PTC schematic 2

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO input used for protection of the ATEX motor, SIL 1 capability according to IEC61508 and for

functional safety SIL3 capability according to IEC61508 and stop category 0 according to IEC 60204-1.

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system

Wiring Diagram

(1) ATEX Zone 1 or 21 or 2 or 22 with at least 1 thermal sensor PTC type (2) ATEX certified Control unit conversion / insulation / switching system (K72) ATEX certified PTC relay (DIx) Internal I/O set to thermal management (Kx) Optional additional contacts within the safety path (S61) Emergency Stop button mounted in the enclosure door. (S62) External emergency stop button.

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ATEX Installation Case 5: Drive Systems with PTC schematic 3

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO input used for protection of the ATEX motor, SIL 1 capability according to IEC61508 and for

functional safety SIL3 capability according to IEC61508, stop category 1 according to IEC 60204-1 and category 3 PL e according to ISO 13849-1.

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system

Wiring Diagram

(1) ATEX Zone 1 or 21 or 2 or 22 with at least 1 thermal sensor PTC type (2) ATEX certified Control unit conversion / insulation / switching system (K72) ATEX certified PTC relay (DIx) Internal I/O set to thermal management (DIy) Internal I/O set to fast stop (Kx) Optional additional contacts within the safety path (K61) Safety relay for monitoring the Emergency Stop circuit Preventa XPS-ATR (S61) Emergency Stop button mounted in the enclosure door (S62) External emergency stop button (S63) Manual reset button

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ATEX Installation Case 6: Drive Systems with PTC schematic 4

Description

 ATEX motor in Zone 1 or 21 or 2 or 22  STO input used for protection of the ATEX motor and for the functional safety of Category 3 (ISO 13849-

1) and for SIL 1 (IEC/EN 61508 or IEC/EN 61800-5-2) in stopping category 0 according to IEC/EN 60204-1,

 Thermal protection of the ATEX motor by using an ATEX thermal sensor (PTC type, without embedded

switching system), and a control unit for the PTC conversion, including the switching system

 Embedded switching system protected against the failures of the installation.

Wiring Diagram

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ATV600_900_ATEX_manual_NVE42416_02

06/2016

Schneider ATV650U30N4, ATV650U15N4, ATV650U07N4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Altivar Process ATV600, ATV900

Table of Contents

Safety Information

About the Book

Introduction

Functional Safety and ATEX applications

Applications for explosive atmosphere (ATEX)

ATEX zones

ATEX Marking

Wiring Diagrams For ATEX Applications

General

ATEX Installation Case 1: Single drive with PTC and control unit

ATEX Installation Case 2: Single drive with PTC and control unit and with Safety Module Type Preventa XPS-AF

ATEX Installation Case 3: Drive Systems with PTC schematic 1

ATEX Installation Case 4: Drive Systems with PTC schematic 2

ATEX Installation Case 5: Drive Systems with PTC schematic 3

ATEX Installation Case 6: Drive Systems with PTC schematic 4