Explosion-Proof Drives to ATEX 100a

Explosion-Proof Drives to ATEX 100a Edition 12/2002 1056 2117 / EN

SEW-EURODRIVE

Content 1 Standards... 4 1.1 European Directives 94/9/EC and 1999/92/EC... 4 1.2 ATEX 137... 5 1.3 ATEX 100a... 6 1.4 Electrical explosion protection... 7 1.5 Mechanical explosion protection... 9 2 The Product... 13 2.1 ATEX 100a motor... 13 2.2 Gear units to ATEX 100a... 17 2.3 Identification key according to EC directive 94/9/EC... 20 2.4 Declaration of conformity... 21 3 Documentation... 22 4 Contact... 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Latest News Explosion-Proof Drives to ATEX 100a 3

1 Standards 1 Standards 1.1 European Directives 94/9/EC and 1999/92/EC As part of the standardization of European standards, the European Directive 94/9/EC is used to specify the explosion protection of technical equipment. The EC Directive 94/9/EC was adopted as early as March 1994 and must be transferred to national law by the EC member states by July 1, 2003. In December 1996, the EC Directive 94/9/EC was transferred to German law (Explosion protection regulation, ExVO). The supplement EC Directive 1999/92/EC is directed at the operator of systems and regulates the safety of personnel during installation, operation and maintenance of potentially explosive systems. Designations The designation ATEX (Atmosphères Explosibles) has established itself for the new guidelines. ATEX 100a controls all regulations for the condition of explosion-proof equipment, ATEX 137 governs the safety of personnel during installation, operation and maintenance of potentially explosive systems. Transitional periods Starting July 1, 2003, Directives 94/9/EC and 1999/92/EC will be in force in the EU only. This comprehensive harmonization of explosion protection in the EU permanently removes all existing trade barriers in this area among the European countries. A transitional period is in effect until June 30, 2006, for all systems that were put to use prior to June 30, 2003, and did not meet the new regulation 1999/92/EC. Transitional periods of ATEX 100a and ATEX 137 Introduction of ATEX 100a Introduction of ATEX 137 Legal validity of ATEX 100 a / 137 End of transitional period for ATEX 137 3/1/1996 1/28/2000 7/1/2003 7/1/2006 Putting equipment into circulation Based on "old" regulations In accordance with ATEX 100a Construction of systems Based on "old" regulations Based on ATEX 137 Converting existing systems To minimum requirements of ATEX 137 4 Latest News Explosion-Proof Drives to ATEX 100a

Standards 1 1.2 ATEX 137 The EC explosion protection safety-at-work directive ATEX 137 (predecessor ATEX 118a) controls the protective measures for employees in the working environment of potentially explosive areas. This safety-at-work directive is based on EC Directive 1999/ 92/EC and is primarily intended for operators of potentially explosive systems. This regulation describes the minimum requirements for improving the safety and health protection of workers potentially at risk from explosive atmospheres. In addition, it specifies various requirements for the installation and operation of potentially explosive systems, as well as the applicability of the equipment category in the different hazardous areas (zones). The plant operator is required to: guarantee the safety of the plant during the operating time, either prevent the formation of explosive mixtures in the plant or prevent the ignition of explosive mixtures and at worst, reduce the harmful effects of an explosion to the extent that health and safety of workers is guaranteed. Zone distribution The classification of a potentially explosive system is carried out exclusively by the plant operator. As part of a general and specific evaluation of the explosion criteria, the responsible operator divides the production plant into zones that reflect the hazard potential. The following factors must be evaluated: Probability and duration of occurrence of explosive atmospheres, Possible ignition sources, Interaction between facility, procedure and product, and Scope of expected effects. The hazard zones are defined according to the following classification: Gas 0 2) Zone 1) Dust Probability of a potentially explosive atmosphere occurring 20 2) Constant, long-time, often, the majority of times 1 21 Occasionally, during normal operation 2 22 Seldom, short-term 1) Only the gray boxes are relevant to drives from SEW-EURODRIVE. 2) Not relevant for electrical drives The decision, which hazard class applies to a given plant, must be made exclusively by the plant operator. Latest News Explosion-Proof Drives to ATEX 100a 5

1 Standards 1.3 ATEX 100a The directive 94/9/EC (ATEX 100a) specifies minimum requirements for the condition and distribution of equipment and protective systems for usage to the intended purpose in potentially explosive areas. It defines equipment categories, describes the conformity evaluation methods to be applied and specifies the basic safety requirements. This directive is primarily intended for manufacturers of explosion-proof equipment and protective systems. For the first time, the EC directive 94/9/EC (ATEX 100a) covers electrical as well as nonelectrical equipment. With respect to geared motors, this means that an assessment of the gear units is required in addition to the certification of the motor (with integrated frequency inverter, if necessary). For this reason, the complete drive unit consisting of motor and gear unit must meet the requirements of ATEX 100a. ATEX 100a Gear units non-electrical equipment Motor electrical equipment 05844AEN According to ATEX 100a, the equipment is newly classified in groups, categories and protection types. Unit group I Mines, firedamp Unit group II Other gas or dust potentially explosive areas Category M1 M2 1 2 1) Explosive atmosphere 2) G D G D G D Zone 0 20 1 21 2 22 Protection type Motor Gear units 3) d, e, i, p... (c, k...) (c, k...) 1) Only the gray boxes are relevant to drives from SEW-EURODRIVE 2) G = gas atmosphere, D = dust atmosphere 3) The standardization of protection types for gear units has not been finalized yet. 3 1) n(a) (c, k...) (c, k...) 6 Latest News Explosion-Proof Drives to ATEX 100a

Standards 1 Geared motors from SEW-EURODRIVE are suitable for operation in categories 2 and 3. The category indicates the degree of protection, the measures ensuring this protection and the operating conditions. Category Degree of protection Guarantee of protection 2 High Through a protective measure, suitable for normal operation and frequently anticipated malfunctions, a fault may occur Operating conditions Equipment remains in operation with existing explosive atmosphere 3 Standard Suitable for standard operation Equipment remains in operation with existing explosive atmosphere 1.4 Electrical explosion protection The equipment manufacturer must verify conformity with ATEX 100a. The following evidence or proofs of conformity must be established for electrical equipment: Category Type Conformity through 2 Electrical equipment 3 Electrical equipment EG prototype test and Conformity based on type of construction or Production quality assurance Internal production control The EG prototype test must be performed by a designated authority (e.g. PTB or TÜV). The conformity in accordance with ATEX 100a is confirmed by means of an EG prototype test certificate. In addition, quality assurance of the production must be certified and permanently monitored by a designated authority (e.g. TÜV). The conformity with ATEX 100a for electrical equipment in category 3 can be independently identified by the manufacturer. This requires that the internal production is documented by a specified selection of engineering, manufacturing and testing records and available for at least 10 years. Protection type for gas protection In addition to information about ATEX 100a, the equipment manufacturer is required to provide information about the protection type. The information about the protection type describes how explosion protection is implemented inside the unit. The following protection types together with the appropriate standards are listed for electrical equipment: Type of equipment Protection type Standard Description Electrical equipment d EN50014 + EN50018 Flameproof enclosure e EN50014 + EN50019 Increased safety i EN50014 + EN50020 Intrinsic safety n/na EN50014 + EN50021 Non-arcing m EN50014 + EN50028 Encapsulation o EN50014 + EN50015 Oil immersion p EN50014 + EN50016 Pressurized enclosure q EN50014 + EN50017 Sand filling The protection types listed in gray boxes apply to the electrical products from SEW- EURODRIVE. Additional information about protection types can be found in the publication "Drive Engineering Practical Implementation Explosion-Proof Drives to ATEX 100a." Latest News Explosion-Proof Drives to ATEX 100a 7

1 Standards Temperature classes for gas protection A temperature class is defined as additional characteristic value to the ATEX 100a conformity for electrical equipment. The temperature class defines the maximum permitted surface temperature of the electrical equipment. The ignition temperature of potentially explosive atmospheres must always be higher than the set temperature class. The temperature classes are specified with respect to the following maximum surface temperature values: Temperature class Maximum permitted surface temperature 1) T1 450 C T2 300 C T3 200 C T4 135 C T5 100 C T6 85 C 1) The surface of a unit also includes those parts that may come into contact with a potentially explosive atmosphere. Dust protection Compared to the explosion protection with gaseous atmospheres, the following items must be observed for dust explosion protection: Dust does not volatilize; instead, it settles as an increasingly thicker layer Dust explosion protection is highly dependent upon the operating conditions An ignitable gas atmosphere can be diluted through strong venting to the point that no danger of explosion exists any longer. If the same procedure is used for dust accumulations, they are whirled up, distributed and form additional "gaseous" sources of danger. The settled dust layers obstruct the cooling of the equipment and are therefore an additional ignition risk. This means that periodic cleaning of the respective equipment is absolutely mandatory for dust explosion protection. Surface temperature in dust protection The following characteristic values are defined for dust explosion protection of electrical equipment (EN50182-1-1): Smouldering temperature: The lowest temperature of a hot surface at which a deposited layer of flammable dust with a thickness of 5 mm barely ignites is referred to as smouldering temperature T 5 mm. Ignition Temperature: The lowest temperature at which a dust cloud (dust-air-mixture) with flammable dust of a particle size between approx. 0.02 and 0.04 mm and a concentration between 20 g/m 3 and 2 kg/m 3 barely ignites is referred to as ignition temperature T CI. Maximum surface temperature: The maximum surface temperature that a unit reaches during rated operation and malfunctioning operation is referred to as maximum surface temperature T max. Unless otherwise indicated, all temperature information listed above refers to a maximum ambient temperature of +40 C. Additional information about dust explosion protection can be found in the publication "Drive Engineering Practical Implementation Explosion-Proof Drives to ATEX 100a." 8 Latest News Explosion-Proof Drives to ATEX 100a

Standards 1 1.5 Mechanical explosion protection Directives and standards The Directive 94/9/EC (better known as ATEX 100a) contains essential safety and health requirements for equipment, components and protection systems to be used in potentially explosive atmospheres. It was the start for creating a new legal foundation for explosion protection throughout Europe. The directive of the European Parliament defines "equipment" as follows: " Equipment means machines, apparatus, fixed or mobile devices, control components and instrumentation thereof and detection or prevention systems which, separately or jointly, are intended for the generation, transfer, storage, measurement, control and conversion of energy for the processing of material and which are capable of causing an explosion through their own potential sources of ignition." In contrast to the regulations which continue to be valid during the transitional period, the explosion protection in accordance with 94/9/EC covers electrical equipment as well as mechanical equipment. Implementing the directive and putting it into concrete terms using harmonized European standards is still on-going. The corresponding standards of the series EN13463 (for non-electrical equipment) are currently being established. It is noteworthy in this context that the fundamental requirements of the directive can also be met without applying the harmonized standards. The scheduled standards series EN13463 consists of eight parts. The first standard EN13463-1 of the series has already been adopted. It is entitled "Non-electrical equipment for potentially explosive atmospheres Basic method and requirements." This standard, combined with EN1127-1:1997, "Explosive atmospheres Explosion prevention and protection Basic concepts and methodology," provides the foundation for explosion protection of non-electrical equipment. Based on the first part, the remaining standards pren13463-2-8 describe the design measures to achieve a protection type leading to the approval of the mechanical unit in a unit category. Standard Type of protection Description pren13463 P.1 and 2 fr Restricted breathing pren13463 P.1 and 3 d Flameproof enclosure pren13463 P.1 and 4 g Inherent safety pren13463 P.1 and 5 c Design safety pren13463 P.1 and 6 b Protection by control of ignition sources pren13463 P.1 and 7 p Pressurized enclosure pren13463 P.1 and 8 k Liquid immersion The types of protection c (Design safety) and k (Liquid immersion) are relevant for gear units. Latest News Explosion-Proof Drives to ATEX 100a 9

1 Standards Types of protection Ignition sources occurring at industrial mechanical equipment include: Hot surfaces through acceleration/braking or overheated bearings Heated surfaces Electrical sparks through electrostatic charging Sparks from friction and striking for example at housing segments These ignition sources are ruled out for explosion-proof mechanical equipment by applying design measures and these circumstances are demonstrated and confirmed through corresponding tests. The standard pren13463-2-8 describes various protection concepts for non-electrical equipment for use in potentially explosive atmospheres: pren13463-2 Part 2: Protection by flow-restricting enclosure The "flow-restricting enclosure" is a type of protection that can only be used for equipment of category 3 in gas explosion protection. In this case, a sufficiently sealed housing enclosing the ignition source is to prevent a potentially explosive atmosphere from building inside the housing. pren13463-3 Part 3: Protection by flameproof enclosure The first draft of the "flameproof enclosure" type of protection for mechanical equipment strongly follows the electrical standard for the "flameproof enclosure" of EN50018. Components that may ignite a potentially explosive atmosphere are enclosed in a housing which can resist the pressure of an explosion. pren13463-4 Part 4: Protection by inherent safety At this time it appears to be doubtful whether this standard about "inherent safety" will be established at all. pren13463-5 Part 5: Protection by constructional safety The "Protection by constructional safety" type of protection is specifically tailored to the interests of non-electrical, i.e. mechanical equipment. Here, one important aspect is the assumption that well-built equipment will keep the probability for malfunctions leading to ignition sources so low that they will meet the requirements of the corresponding category. pren13463-6 Part 6: Protection by control of ignition sources The basic idea behind the "control of ignition sources" type of protection is that potential ignition sources can be controlled using measurement devices and controlling systems (e.g. through thermal protectors, level switches, speed and vibration monitors, etc.) so that they are "switched off" before they can become effective. 10 Latest News Explosion-Proof Drives to ATEX 100a

Standards 1 pren13463-7 Part 7: Protection by pressurized enclosure The "pressurized enclosure" type of protection for mechanical equipment also follows the electrical standard. The creation of a potentially explosive atmosphere inside a housing is prevented by using a protective gas to maintain an internal overpressure with respect to the surrounding atmosphere. pren13463-8 Part 8: Protection by liquid immersion During the design for liquid immersion it should be noted that oils (similar to electrical equipment) as well as other liquids can be used. The basic idea of immersing the ignition source and separating the ignition source and the potentially explosive atmosphere was expanded to include cooling and lubrication. Unit categories and conformity evaluation methods Several options and alternatives are available for the conformity evaluation method and the approval of the unit for use in a potentially explosive area. In the first place, they are dependent upon the assignment to one of the desired unit groups or categories. The following discussion does not include unit group I (mining) but only group II Industrial application other than mining with unit categories 1, 2 and 3. The requirements for avoidance of ignition sources (here for group I) comply with the unit category: Unit category Cat. 3 Cat. 2 Cat. 1 No occurrence of ignition sources during standard operation in foreseeable equipment faults even in rare equipment faults But first, it must be specified for each unit whether it will be used for gases/vapors or dusts and in which zone it will be used. ATEX 137 defines the zones that must be specified by the operator of the plant. The zone classification determines which unit category must be used. Zone G (gases, vapors) Zone D (dusts) Unit category 2 22 Cat. 3 1 21 Cat. 2 0 20 Cat. 1 Latest News Explosion-Proof Drives to ATEX 100a 11

1 Standards The types of inspections are graded in accordance with the requirements for the unit categories. In general, inspections can be divided into two groups: those which may be conducted by the manufacturer and those which must involve an outside institution (designated authority). Designated authority Conformity evaluation method for non-electrical (mechanical) equipment of Cat. 1 Cat. 2 Cat. 3 Forward documentations to designated authority - EC prototype test certificate Manufacturer QA production or Inspection of production Manufacturer s declaration andi nternal production check Result: Product meets the requirements EC statement of conformity may be issued Unit designation CE marking Manufacturer s declaration and internal production check Examples of designated (registered) authorities: Physikalisch-Technische Bundesanstalt (PTB), Braunschweig TÜV Product Service GmbH, Munich TÜV Hannover / Sachsen-Anhalt e. V. DMT - Certification authority of the Gesellschaft für Forschung und Prüfung mbh, Essen A manufacturer must prove that the equipment meets EN 13463-1 to designate gear units as equipment of category 3. The designation for this category does not include any type of protection. If gear units must be designated as equipment of category 2, two sections of the standard series EN 13463 must be met. It is left to the manufacturer to decide which part (2 through 8) will be met next to part 1. The protection type is defined depending upon the selected part. Independent of the categories, the mechanical units must also be assigned to one of the temperature classes T1 through T6. EN13463-5 "Design safety" with relevant protection type "c" and EN13463-8 "Liquid immersion" with relevant protection type "k" present the highest degree of importance for drive engineering. SEW-EURODRIVE offers mechanical units (gear units) for category 2 in temperature class T4. Category 2 automatically meets all requirements of category 3. SEW-EURO- DRIVE will also offer gear units of category 2 if only category 3 is required. 12 Latest News Explosion-Proof Drives to ATEX 100a

The Product 2 2 The Product 51101AXX 2.1 ATEX 100a motor As a rule, the asynchronous AC motors are produced and delivered in the four types of protection: d = flameproof enclosure e = increased safety na = non-sparking (restricted breathing) The motor in protection type "d" (flameproof enclosure) can be designed up to temperature class T6, the motor in protection type "e" (increased safety) can be designed up to temperature class T4. Product description of SEW motor conforming to ATEX 100a SEW-EURODRIVE provides asynchronous AC motors for above-ground applications (unit group II) for categories 2 and 3 larger than 1 kw and 4-pole as EFF2 motors larger than 1 kw and 2-pole as EFF3 motors in the design II2G EEx e II T3 or T4 in the design II2G EEx ed IIB T3 in the design II3G EEx na II T3 in the design II2D 120 C or II2D 140 C in the design II3D 120 C or II3D 140 C Latest News Explosion-Proof Drives to ATEX 100a 13

2 The Product Category 2: Mains-operated motor The approval of motors in category 2 was granted for mains operation only. Category 3: Mains or inverter-operated motor Mains operation and operation with inverter is possible. A fixed assignment of the individual motor sizes of category 3 (gas and dust) to one inverter size must be maintained. The following 4-pole motor sizes can be combined: 71D4... 225M4 with MOVITRAC 31C 90S4... 225M4 with MOVIDRIVE MDF/MCF 60A (1.5 kw is the smallest available MOVIDRIVE size) The combination with MOVIMOT has been approved for the 4-pole motor in category 3D (for zone 22) only. The maximum permitted power is reduced by one frame size compared to the standard design. Example: DT71D4 /II3D DT71D4/MM03/II3D DT71D4/MM05/II3D P max = 0.37 kw (50 Hz, mains) P max = 0.25 kw (50 Hz, star connection) P max = 0.37 kw (100 Hz, delta connection) Lubricant The ATEX 100a motor for mounting on the ATEX 100a gear units is equipped with ball bearings with synthetic grease filling. Seals / oil seals The ATEX 100a motor with pinion shaft for direct mounting on ATEX 100a gear units from SEW-EURODRIVE is supplied with the VITON oil seal. Detailed project planning notes can be found in the "Explosion-Proof Drives" catalog. 14 Latest News Explosion-Proof Drives to ATEX 100a

The Product 2 Unit designations for AC motors and options Category 2G for use in zone 1, gas explosion atmosphere: Category Unit designation AC motors II2G EEx e II Number of poles / temperature class Options 2G Foot-mounted: edt.. edv.. Flange-mounted: edft.. edfv.. Foot or flange-mounted: edt..-f.. edv..-f.. Mount-on motor for gear unit: edt.., edv.. 4-pole / T3 71D... 180L 4-pole / T4 80N... 100M 6-pole / T3 71C, 80K... 100M, 112M, 132S 6-pole / T4 71C, 80K... 100M Motor options: /TF Thermistor sensor (PTC resistance) /C Protection cowl /BC EExdIIB brake "flameproof enclosure" (for 71D4... 100L4) /HR With self-resetting manual brake release not all motor sizes feature 60 Hz approval Category 2D for use in zone 21, dust explosion atmosphere: Category Unit designation AC motors Number of poles / temperature class Options Foot-mounted: edt.. edv.. Flange-mounted: edft.. edvf.. 4-pole / 120 C 71D... 180L Motor options: /C Protection cowl Is part of the qualified product and always listed in the designation: /TF Thermistor sensor 2D Foot and flange-mounted: edt..-f.. edv..-f.. Mount-on motor for gear unit: edt.. edv.. Latest News Explosion-Proof Drives to ATEX 100a 15

2 The Product Category 3G for use in zone 2, gas explosion atmosphere: Category Unit designation AC motors II3G EEx na II Number of poles / temperature class Options 3G Foot-mounted: DT../II3G DV../II3G Flange-mounted: DFT../II3G DFV../II3G Foot and flange-mounted: DT..-F../II3G DV..-F../II3G 4-pole / T3 71D... 225 M 6-pole / T3 71D... 180L 8-pole / T3 71D... 180L Motor options: /RS Backstop /TF Thermistor sensor /C Protection cowl /BM(G)Brake (reduced noise) /HF...with lockable manual brake release /HR... with self-resetting manual brake release /ES.. Spreadshaft encoder /EV.. Solid shaft encoders /ES..A Mounting device for spreadshaft encoder /EV..A Mounting device for solid shaft encoder Mount-on motor for gear unit DT../II3G DV../II3G Category 3D for use in zone 22, dust explosion atmosphere: Category Unit designation AC motors Number of poles / temperature class Options 3D Foot-mounted: DT../II3D DV../II3D Flange-mounted: DFT../II3D DFV../II3D Foot and flange-mounted: DT..-F../II3D DV..-F../II3D Mount-on motor for gear unit: DT../II3G DV../II3D 2-pole / 120 C 71D... 180L 4-pole / 120 C 71D... 225M 6-pole / 120 C 71D... 180L 8-pole / 120 C 71D... 200L 4/2-pole / 120 C 71D... 225M 8/4-pole / 120 C 71D... 225M Motor options: /RS Backstop /TF Thermistor sensor /TH Thermostat (bimetallic switch) /C Protection cowl /MM MOVIMOT /MSW MOVI-SWITCH /BM(G)Brake (reduced noise) /HF...with lockable manual brake release /HR... with self-resetting manual brake release /ES.. Spreadshaft encoder /EV.. Solid shaft encoders /ES..A Mounting device for spreadshaft encoder /EV..A Mounting device for solid shaft encoder 16 Latest News Explosion-Proof Drives to ATEX 100a

The Product 2 2.2 Gear units to ATEX 100a The approval of mechanical equipment is completely new and we do not know which types of protection will establish themselves in the future. SEW-EURODRIVE selected the "c" and "k" types of protection for approval, which makes us the first company offering this type of protection for mechanical equipment. Product description gear units to ATEX 100a SEW-EURODRIVE carried out the approval in accordance with ATEX 100a in category 2 for gas and dust for temperature class T4. In doing so, this design also meets all requirements of category 3 for gas and dust. It is operated as such by SEW-EURODRIVE and made available to the customer. Available types The design of gear units with fixed ratio of the 7 Series and SPIROPLAN gear units in accordance with ATEX 100a are available for: Helical gear units of sizes 17-167 Parallel shaft helical gear units of sizes 27-157 Helical bevel gear units of sizes 37-187 SPIROPLAN gear units of sizes 20-30 Helical-worm gear units of sizes 37-97 Not available are: Helical gear units of size 07 SPIROPLAN gear units of size 10 Overhead conveyor drives of series HK, HW and HS in all sizes Also approved are: all output designs (e.g. solid shaft with flange, hollow shaft with shrink disc, etc.) all gear ratios all low-backlash gear ratios all series shafts (e.g. output shafts with dimensions in inches) all output flange designs all corrosion protection designs extended storage Latest News Explosion-Proof Drives to ATEX 100a 17

2 The Product Lubrication Only lubrication with synthetic oil according to the following table has been approved: Gear unit series Synthetic oil Food-industry oil Biodegradable oil R, F, K CLP HC VG220 S CLP HC VG460 HCE VG460 E VG460 W SEW PG460 CLP PG VHG460 - Anti-friction bearings K HC 2R-40 Oil seal EURALGREASE EP2 (KHCP 2R-60) ARAL BAB EP2 (KPE 2K-30) The lubricant fill corresponds to the standard design (see GM catalog). A grease filling is not allowed. Seals / oil seals On principle, the following applies to the output side of the gear unit: Use oil seals made of VITON Double seals are required Do not use VITON oil seal in SPIROPLAN gear units. Spatial mounting positions Only the fixed spatial mounting positions M1 through M6 have been approved. Inclined mounting positions with changing spatial mounting positions are not allowed for the ATEX 100a design of the gear unit. A fixed position between two spatial mounting positions must be checked by the technical department (EG) for its acceptability. This check requires venting of the gear unit. There may be some instances when fixed spatial mounting is not possible. In such cases, different circumstances may lead to an exclusion. Most of the exclusions are caused by exceeding the maximum operating temperature of the lubricant. The non-approved spatial mounting positions are indicated as such in the selection tables for the respective gear ratios. Screws All screws at the gear unit are secured with Loctite. Exceptions are the cover plate screws of helical gear unit sizes 17 and 27 as well as the parallel shaft helical gear unit in size 27. The cover plate must remain detachable at the customer site to check the oil level. The oil level check at the customer site is part of the approval. The corresponding details are described in the operating instructions. Nameplate The ATEX 100a gear unit receives a separate nameplate. Certificate of conformity The certificate of conformity is available and can be downloaded at the SEW Internet site. 18 Latest News Explosion-Proof Drives to ATEX 100a

The Product 2 Service / maintenance Service and maintenance tasks are described in detail in the new operating instructions. Repairs must be performed by SEW-EURODRIVE customer service. The customer service uses only genuine spare parts corresponding to the latest spare parts lists. Temperature class / surface temperature Since there is no differentiation between gas and dust protection for gear units and the maximum permitted oil temperature presents a physical limitation, the gear units from SEW-EURODRIVE in accordance with ATEX 100a are grouped into temperature class T4 or with 120 C maximum surface temperature. Project planning / application The ATEX 100a gear units from SEW-EURODRIVE are approved for the following applications: Mounting of 4 and 6-pole motors in accordance with ATEX 100a with 50 Hz mains operation according to the selection tables Inverter operation of the 4-pole ATEX 100a motor up to 1500 1/min Operating factor f B SEW 1 The rated power of the motor is smaller than the maximum permitted power of the gear unit. Geared motor combinations with shrink disc (SEW type designation FH.., KH.., SH..). Exceptions are the FH27 and isolated combinations which are identified in the selection tables. Different circumstances can lead to an exclusion (such as gear ratio x maximum braking torque of the brake motor or starting torque of the motor is greater than the holding torque of the shrink disc). SEW-EURODRIVE should be consulted with respect to the application: when mounting an SEW ATEX 100a motor with MOVIMOT when mounting an SEW ATEX 100a motor with 60 Hz mains operation when mounting 8-pole SEW ATEX 100a motors Information on the overhung load F Ra is limited to a gear unit design (e.g. FA..) in the selection tables with inverter operation of the SEW ATEX 100a motor above 1500 1/min with mounting 2-pole SEW ATEX 100a motors Latest News Explosion-Proof Drives to ATEX 100a 19

2 The Product 2.3 Identification key according to EC directive 94/9/EC EC directive 94/9/EC (ATEX 100a) links the types of protection to the equipment groups, categories, explosion atmospheres, minimum protection types and temperature classes. Example: Equipment in "flameproof enclosure" protection type. 0102 II 2 G E Ex d IIC T3 CE marking Code number of the designated authority Identifier for the prevention of explosions (ATEX 100a) Unit group II: Use above ground Category 2: for zones 1, 2, 21, 22 3: for zones 2, 22 PE atmosphere G: Gas D: Combustible dust European standards EN Explosion protection Type of protection p: Pressurized enclosure d: Flameproof enclosure e: Increased safety n: Protection type n na: Protection type n; A: Nonsparking equipment c: Mechanical safety k: Liquid immersion Explosion group II Maximum width of gap A: d 0.9 mm B: 0.9 mm > d 0.5 mm C: 0.5 mm > d Temperature class Temperature limit T1: max. 450 C T2: max. 300 C T3: max. 200 C T4: max. 135 C T5: max. 100 C T6: max. 85 C The designation IIA, IIB and IIC applies only in connection with protection type "d." For all other protection types, only II is listed here. 20 Latest News Explosion-Proof Drives to ATEX 100a

The Product 2 2.4 Declaration of conformity The declaration of conformity documents that a unit meets the EC directive 94/9/EC and which standards are taken into account. But the validity of the statement of conformity is tied to the operating instructions. If the operator does not adhere to the operating instructions, conformity is immediately invalidated. This requirement is the result of the maintenance and service measures listed in the operating instructions necessary for sufficient risk control. In addition, it must be observed that units undergo a risk analysis with respect to their suitability for use in a potentially explosive atmosphere. The analysis is based on predetermined boundary conditions, e.g. standard environmental conditions for SEW gear units (freely accessible geared motors, no heat input from the customer, etc.). If these environmental conditions described in the operating instructions are not present, the declaration of conformity becomes invalid and the manufacturer should be contacted immediately. In this context, customer-specific unit modifications must be taken into account, such as special designs of SEW gear units. The declaration of conformity is valid exclusively for the standard series-produced types. If modifications are necessary, the manufacturer should be consulted. Latest News Explosion-Proof Drives to ATEX 100a 21

3 Documentation 3 Documentation The documentation is divided into several publications. Explosion-Proof Drives GX2002 catalog The complete catalog of explosion-proof geared motors, including introductions, descriptions and motor data, will be released under the same publication numbers as the preliminary version. The preliminary version is superceded by the publication of the complete catalog. 1055 3703 GX2002, German 1055 3711 GX2002, English 1055 372x GX2002, French System description The existing ATEX 100a system description is being revised and expanded by including supplements for the ATEX 100a gear units. New publication number Old publication number German 1056 0408 1050 1509 English 1056 0416 1050 1517 Drive Engineering - Practical Implementation The existing volume on the ATEX 100a topic is being revised and expanded by including supplements for the ATEX 100a gear units. New publication number Old publication number German 1056 0203 1050 1908 English 1056 0210 1050 1916 Operating instructions The validity of the statement of compliance is tied to the following the operating instructions. If the operator does not adhere to the operating instructions, the conformity becomes invalid immediately. This is the result of the maintenance and service measures listed in the operating instructions which are required to provide sufficient risk control. Every ATEX 100a drive is delivered with all necessary operating instructions (OI): 1x operating instructions for the gear unit 1x operating instructions for the motor additional operating instructions, if necessary Until all translations mandated by the EU are available, the following arrangement is in effect: Buyer in Customer in Language version of BA Germany Germany German United Kingdom English France France French - All other countries English 22 Latest News Explosion-Proof Drives to ATEX 100a

Documentation 3 OI ATEX 100a gear unit To provide descriptions of the special tasks of the user with respect to maintenance and service intervals, separate operating instructions are created for the gear units with fixed ratio of the 7 series (incl. SPIROPLAN gear units). Publication number OI ATEX 100a gear unit, German 1055 520x OI ATEX 100a gear unit, English 1055 5218 OI ATEX 100a gear unit, French 1055 5226 OI ATEX 100a motors The relevant information that applies to the motor in a potentially explosive atmosphere is contained in the explosion-proof motors operating instructions. Publication number OI ATEX 100a motors, German 1053 3605 OI ATEX 100a motors, English 1053 3613 OI ATEX 100a motors, French 1053 3621 OI ATEX 100a variable speed gear unit The single variable speed gear units come with separate operating instructions. Publication number OI ATEX 100a VARIBLOC VU/VZ variable speed gear unit, GE 1050 6004 OI ATEX 100a VARIBLOC VU/VZ variable speed gear unit, EN 1050 6012 OI ATEX 100a VARIBLOC VU/VZ variable speed gear unit, FR 1050 6020 OI ATEX 100a VARIMOT D variable speed gear unit, German 1050 6802 OI ATEX 100a VARIMOT D variable speed gear unit, English 1050 6810 OI ATEX 100a VARIMOT D variable speed gear unit, French 1050 6829 OI ATEX 100a MOVIMOT The combination with MOVIMOT in category II3D (use in zone 22) has separate operating instructions. Publication number OI ATEX 100a MOVIMOT, German 0918 5801 OI ATEX 100a MOVIMOT, English 0918 581x OI ATEX 100a MOVIMOT, French 0918 5828 Explosion-proof drives brochure The existing brochure "Explosion-proof geared motors from SEW" (1050 270x, German) is being revised and expanded by including supplements for the ATEX 100a gear units. The translation into English for the new brochure has been arranged. Gear units spare parts lists The existing spare parts lists for R, F, K, W and S gear units are supplemented with sections for ATEX 100a or the parts required for ATEX 100a design are identified. Motor spare parts lists The spare parts lists for the design of ATEX 100a motors are created separately. The currently available spare parts lists are supplemented. Latest News Explosion-Proof Drives to ATEX 100a 23

4 Contact 4 Contact For product care, inquiries, suggestions Mr. Wieder / PMS Ph. -1940, Fax -1948 e-mail: claus.wieder@sew-eurodrive.de For project planning, applications Mr. Uhlmann / GE-ATE Ph. -1298, Fax -3298 e-mail: volker.uhlmann@sew-eurodrive.de For training Mr. Kropp / GE-T Ph. -1113, Fax -1139 e-mail: michael.kropp@sew-eurodrive.de For marketing, advertising Mr. Will / ML Ph. -1140, Fax -1129 e-mail: rene.will@sew-eurodrive.de For documentation Mr. Schneider / MD Ph. -1125, Fax -1129 e-mail: stephan.schneider@sew-eurodrive.de For service in Germany Mr. Rüdinger / VSR Ph. -1750, Fax -1715 e-mail: bernd.ruedinger@sew-eurodrive.de 24 Latest News Explosion-Proof Drives to ATEX 100a

SEW-EURODRIVE GmbH & Co P.O. Box 3023 D-76642 Bruchsal/Germany Phone +49 (0) 72 51 / 75-0 Fax +49 (0) 72 51 / 75-19 70 http://www.sew-eurodrive.com sew@sew-eurodrive.com