859-8379-001-02-501864 DTC. The main motor control parameters are updated 40,000 times a second. This allows extremely rapid response on the shaft and is necessary so that the motor model (see step 2) can update this information. It is this processing speed that brings the high performance figures including a static speed control accuracy, without encoder, of ±0.5 percent and the torque response of less than 2 ms. Basic control theory Technical guide No. 1 | Direct torque control 31 1 Speed control Step 5 Torque reference controller Within the torque reference controller, the speed control output is limited by the torque limits and DC bus voltage. It also includes speed control for cases when an external torque signal is used. The internal torque reference from this block is fed to the torque comparator. Step 6 Speed controller The speed controller block consists both of a PID controller and an acceleration compensator. The external speed reference signal is compared to the actual speed produced in the motor model. The error signal is then fed to both the PID controller The aim of this Technical guide No. 2* is to give a straight-forward explanation of how the various EU Council Directives relate to power drive systems (PDSs). For an explanation of the terminology of PDSs, see pages 21 and 22. While Electromagnetic Compatibility (EMC) is the subject of most concern within the industry, it must be realised that the EMC Directive is only part of the overall EU initiative on common safety standards. It is the intention of this guide to offer users of AC or DC power drive systems - whether machine builders, system designers, distributors, OEMs, end-users or installers - some clear practical guidelines and courses of action. *Notes 1 The content of this technical guide is ABB Oy’s, Drives interpretation of events as of July 2007. However, we reserve the right to develop and evolve these interpretations as more details become available from notified bodies (see chapter 6), competent authorities (see chapter 6), organisations and from our own tests. 2 Other technical guides available in this series include: Technical guide No. 1 - Direct torque control (3AFE58056685) Technical guide No. 3 - EMC compliant installation and configuration for a power drive system (3AFE61348280) Technical guide No. 4 - Guide to variable speed drives (3AFE61389211) Technical guide No. 5 - Bearing currents in modern AC drive systems (3AFE64230247) Technical guide No. 6 - Guide to harmonics with AC drives (3AFE64292714) Technical guide No. 7 - Dimensioning of a drive system (3AFE64362569) 10 EU Council Directives | Technical guide No. 2 Introduction Technical guide No. 8 - Electrical braking (3AFE64362534) Technical guide No. 9 - Guide to motion control drives (3AFE68695201) Technical guide No. 10 - Functional safety (3AUA0000048753) How to use this guide The guide is divided into 7 sections. Section 4 looks at purchasing decisions for PDSs. Please note the following about the structure of this section: Responsibilities and actions Each type of purchaser is offered an explanation of their responsibilities. This is for awareness. No action is needed. Following the responsibilities is a set of actions. If the purchaser follows these actions, step-by-step, then conforming to the relevant directives will be straightforward. Tickboxes Alongside the actions are tickboxes. Purchasers can photocopy the relevant pages and use them as a checklist with each item being ticked off as it is achieved. Cross-referencing Because of the complexity of conforming to each directive, this guide inevitably carries a lot of cross-references to other sections. In the margin you will come across: Defined on page XX You are advised to turn to the page number reference. You will also notice other references within the text. These can be referred to if the item is unclear but is not essential for achieving compliance. Key point: Within the text you will see: Key point These are key observations that must be observed. Technical guide No. 2 | EU Council Directives 11 2 Chapter 2 - General questions and answers It is very important that users of PDSs fully understand all the various rules and regulations and how they apply to PDSs. That is the purpose of this guide. What are these EU Council Directives? It is important to realise that EMC cannot be divorced from other European legislation. So before answering this question, we need to look at the other legislation and how it affects the purchase and installation of drives. Quite simply there are three directives that mainly affect a drive’s safety against risks and hazards. These are: But more on each of these directives later. Let us first explain EMC and look at some concerns of the industry. How does EMC affect me? From January 1, 1996 the EU Council’s Electromagnetic Compatibility Directive (89/336/EEC and it’s successor 2004/108/EC) has been compulsory. It applies to all electrical and electronic equipment sold within the EU and affects virtually all manufacturers and importers of electrical and electronic goods. Key point: Electrical equipment that does not conform to the regulations may not be sold anywhere in the EEA (European Economic Area). What is EMC? EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate problem-free within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other products or systems within its locality. Directive Mandatory Page Machinery Directive 1995-01-01 pg 55 Low Voltage Directive 1997-01-01 pg 56 EMC Directive 1996-01-01 pg 57 12 EU Council Directives | Technical guide No. 2 General questions and answers What is an electromagnetic environment? The electromagnetic environment is everywhere but it varies from place to place. The reason is that there are many different sources of disturbance which can be natural or man-made. Natural sources consist of electrical discharge between clouds, lightning or other atmospheric disturbances. While we cannot influence these sources we can protect our products and systems from their effects. Man-made disturbances are those generated by, for example, electrical contacts and semiconductors, digital systems like microprocessors, mobile radio transmitters, walkie-talkies, portable car telephones and power drive systems. Such a variety of equipment, each with its own emission characteristics, is often used so near to other electrical equipment that the field strengths they create may cause interferences. Key point: It is important that all PDSs are immune to these natural and man-made disturbances. While drives manufacturers strive to make their products immune, the directive lays down minimum standards for immunity, thereby ensuring all manufacturers achieve the same basic level. How does electromagnetic interference show up? Electromagnetic interference shows up in a variety of ways. Typical examples of interference include a poorly suppressed automobile engine or dynamo; an electric drill causing patterning on the TV screen; or crackling from an AM radio. The microprocessor and power electronic component, switch rapidly and therefore, can cause interference at high frequencies, unless proper precautions are taken. What emissions can drives cause? The normal operation of any drive involves rapid switching of high voltages and this can produce radio frequency emission. It is this radiation and emission that have been seen to have the potential to disturb other circuits at frequencies below 200 MHz. Modern equipment contains considerable communications and other digital electronics. This can cause considerable emissions at frequencies above 200 MHz. Technical guide No. 2 | EU Council Directives 13 2 General questions and answers How is this emission seen? The main emission is via conduction to the mains. Radiation from the converter and conducting cables is another type of emission and it is especially demanding to achieve the radiated emission limits. How do I avoid electromagnetic interference? You need to ensure two things: – that the equipment generates minimum emission. – that the equipment is immune to outside effects. Key point: In the case of power drive systems, a lot depends on the quality of the installation. Electromagnetic interference needs to be conducted to earth (ground potential) and no system can work unless it is properly grounded. Drives manufacturers must comply with EMC standards then? Unfortunately, the process is not that simple. Virtually everyone in the supply chain has a responsibility to ensure a product, a system and an installation complies with the essential requirements of the EMC Directive. The key is to clearly understand who has responsibility for what. In the forthcoming pages we take a look at various types of purchasers and examine the steps each should take to meet all three directives mentioned on page 11. Everyone from manufacturer to installer to user has a responsibility in complying with EMC rules. If a drive is CE marked, I need not worry. True? Again this is a big misconception. Just because a drive has CE marking does not necessarily mean it meets the EMC Directive. 14 EU Council Directives | Technical guide No. 2 Key point: This will all become clear by referring to the section purchasing decisions for PDSs, page 21. CE marking according to the EMC Directive cannot normally be applied to a module that is no more than a chassis with exposed terminals. General questions and answers Technical guide No. 2 | EU Council Directives 15 2 Chapter 3 - CE marking What is CE marking and how relevant is it for drives? CE marking, shown below, is the official signature of the Declaration of conformity (see pages 43 and 44) as governed by the European Commission. It is a very specific graphic symbol and must be separated from other marks. CE marking is a system of self certification to identify equipment that complies with the relevant applicable directives. If a drive is the subject of several directives and, for example, conforms with the Low Voltage Directive (see page 56), then, from 1997, it is compulsory that it shows CE marking. That marking shall indicate that the drive also conforms to the EMC Directive (page 57). CE marking shall indicate conformity only to the directive(s) applied by the manufacturer. Key point: NOTE: There must be technical documentation supporting the Declaration of conformity. For more on technical documentation, please refer to pages from 36 to 40. What is CE marking for? CE marking is mainly for the benefit of authorities throughout the EU and EEA countries who control the movement of goods. CE marking shows that the product complies with the essential requirements of all relevant directives, mainly in the area of technical safety, compatibility issues and conformity assessment. There are three directives that are relevant to drives, but CE marking may be attached to indicate compliance with one of them only (see the previous page). 16 EU Council Directives | Technical guide No. 2 CE marking Is CE marking a quality mark? Most definitely not. As CE marking is self certification, you can be assured that certification has been carried out. What is the legal position regarding CE marking? Anyone applying CE marking is legally liable and must be able to prove the validity of his actions to the authorities. CE marking confirms compliance with the directives listed in the Declaration of conformity (see pages 43 and 44). What is the importance of CE marking for purchasers of drives? As far as a purchaser of a drive is concerned, anything that carries the CE mark must have a functional value to him. Thus, a complete drive product, which can be safely cabled and powered up on its own, shall carry the CE marking. If I buy a CE marked drive, will I meet the technical requirements of the directives? In practice, you will see drive products with CE marking. But it is important to understand just why the product was given CE marking in the first place. Basically a drive has no functional value. It is only of practical use when connected to, say, a motor which in turn is connected to a load. Therefore, as far as the Machinery Directive is concerned a drive cannot have CE marking unless it is part of a “process” comprising the drive, motor and load. As for the EMC Directive, the equipment that make up a “process” include cabling, drives and motor. CE marking can only be affixed if all items forming such a “process” conform to the requirements of the directive. Therefore, the drive manuals include detailed instructions for installation. However, in the eyes of the Low Voltage Directive, a built drive does have functionality. That is, through the drive’s parameters you can program the drive and obtain an input and output signal. Thus, if a drive conforms to the Low Voltage Directive it can carry CE marking. Refer to pages from 58 to 60 for explanations of the three directives. Technical guide No. 2 | EU Council Directives 17 2 CE marking What happens if, as an end-user, I put together a system - do I have to put CE marking on? Yes. Anyone putting together a system and commissioning it is responsible for the appropriate CE marking. Key point: Turn to page 31 for more details about the end-user’s responsibilities. What about spare parts that I buy for a drive? Do I negate the CE mark if I replace a component? Equipment supplied before the application of the directives, can be repaired and supplied with spare parts to bring it back to the original specification. However, it cannot be enhanced or reinstalled without meeting the directives. For equipment supplied after the application of the directives, the use of the manufacturer’s spare parts should not negate the CE marking. However, the manufacturer or supplier should be consulted about upgrading, as some actions could affect the CE marking criteria. If drives are classed as components, on subassemlies they cannot be EMC certified or carry a CE mark. Is this true? You need to first understand the terminology now being applied to drives. See below and pages 21 and 22 for this. A complete drive module (CDM) is normally a component in a system and as such has no functional value unless it is connected to the motor when it becomes a PDS. The CDM shall be CE marked if it is to be installed with simple connections and adjustments that do not require any EMCknowledge. If awareness of the EMC implication is needed in order to install a CDM, it is not considered as an apparatus. Thus, it shall not be CE marked according to the EMC directives. If a CDM or BDM is intended for incorporation in PDS by professional manufacturers only (panel builders, machine builders), it shall not be CE marked, nor is Declaration of conformity given by the CDM/BDM manufacturer. Instead installation instructions shall be supplied in order to help the professional manufacturers. 18 EU Council Directives | Technical guide No. 2 In summary The EMC Directive defines equipment as any apparatus or fixed installation. As there are separate provisions for apparatus and fixed installations, it is important that the correct category of the equipment is determined. In technical-commercial classifications the following terminology is frequently used: components, sub-assemblies, finished appliances (ie, finished products), a combination of finished appliances (ie, a system), apparatus, fixed installations and equipment. The key issue here is whether the item to be considered is for end users or not: – If it is meant for end users, the EMC directive applies – If it is meant for manufacturers or assemblers, the EMC directive does not apply Components or subassemblies intended for incorporation into an apparatus by the end users A manufacturer may place components or sub-assemblies on the market which are: – For incorporation into an apparatus by the end-user, – Available to end users and likely to be used by them. These components or sub-assemblies are to be considered as apparatus with regard to the application of the EMC. The instructions for use accompanying the component or sub-assembly should include all relevant information, and should assume that adjustments or connections can be performed by an end-user not aware of the EMC implications. Some variable speed power drive products fall into this category, eg, a drive with enclosure and sold as a complete unit (CDM) to the enduser who installs it into his own system. All provisions of the EMC Directive will apply (CE mark, Declaration of conformity and technical documentation). Components or subassemblies intended for incorporation into an apparatus by the other manufacturer or assembler Components or sub-assemblies intended for incorporation into an apparatus or an other sub-assembly by other manufacturers or assemblers are not considered to be “apparatus” and are therefore not covered by the EMC Directive. These components include resistors, cables, terminal blocks, etc. CE marking Technical guide No. 2 | EU Council Directives 19 2 Some variable speed power drive products fall into this category as well, eg, basic drive module (BDM). These are meant to be assembled by a professional assembler (eg, panel builder or system manufacturer) into a cabinet not in the scope of delivery of the manufacturer of the BDM. According to the EMC Directive, the requirement for the BDM supplier is to provide instructions for installation and use. Note: The manufacturer or assembler of the panel or system is responsible for CE mark, Declaration of conformity and technical documentation. Finished appliance A finished appliance is any device or unit containing electrical and/or electronic components or sub-assemblies that delivers a function and has its own enclosure. Similarly than components, the interpretation finished appliance can be divided into two categories: it can be intended for the end users, or for the other manufacturers or assemblers. Finished appliance intended for the end users A finished appliance is considered as apparatus in the sense of the EMC Directive, if it is intended for the end-user and thus has to fulfill all the applicable provisions of the Directive. Finished appliance intended for the other manufacturer or assembler When the finished appliance is intended exclusively for an industrial assembly operation for incorporation into other apparatus, it is not an apparatus in the sense of the EMC Directive and consequently the EMC Directive does not apply for such finished appliances. Systems (Combination of finished appliances) A combination of several finished appliances which is combined, and/or designed and/or put together by the same person (ie, the system manufacturer) and is intended to be placed on the market for distribution as a single functional unit for an end-user and intended to be installed and operated together to perform a specific task. All provisions of the EMC Directive, as defined for apparatus, apply to the combination as a whole. CE marking 20 EU Council Directives | Technical guide No. 2 CE marking Apparatus Apparatus means any finished appliance or combination thereof made commercially available (ie, placed on the market) as a single functional unit, intended for the end-user, and liable to generate electromagnetic disturbance, or the performance of which is liable to be affected by such disturbance. Fixed installation A particular combination of several types of apparatus, equipment and/or components, which are assembled, installed and intended to be used permanently at a predefined location. Equipment Any apparatus or fixed installation Technical guide No. 2 | EU Council Directives 21 2 Chapter 4 - Purchasing decisions for PDSs What you need to know and do Starting on page 23, we offer a step-by-step guide relating to your purchasing requirements for power drive systems. Key point: Before turning to page 23, you need to know the following terms for PDSs and their component parts, which may be unfamiliar to many users. 1. Basic drive module (BDM) consists of the converter section and the control circuits needed for torque or speed. A BDM is the essential part of the power drive system taking electrical power from a 50 Hz constant frequency supply and converting it into a variable form for an electric motor. 2. Complete drive module (CDM) consists of the drive system without the motor and the sensors mechanically coupled to the motor shaft. The CDM also includes the Basic Drive Module (BDM) and a feeder section. Devices such as an incoming phase-shift transformer for a 12-pulse drive are considered part of the CDM. 3. Power drive system, or PDS, is a term used throughout this technical guide. A PDS includes the frequency converter and feeding section (the CDM and BDM), motors, sensors, all cabling, filters, panels and any other components needed to make the PDS work effectively. Note: The load is not considered part of the PDS, but the CDM can incorporate the supply sections and ventilation. TERMS THAT YOU MUST KNOW 22 EU Council Directives | Technical guide No. 2 Now we strongly advise you turn to page 23, to discover the type of person you are. Purchasing decisions for PDSs Power drive system ( PDS) CDM ( Complete drive module) Feeder section Field supply Auxiliaries Others Motor & sensors Driven equipment or load Installation or part of installation HOW THE TERMS FIT TOGETHER BDM ( Basic drive module) Control section Converter section System control and sequencing Technical guide No. 2 | EU Council Directives 23 To make this technical guide easy to use, we have also identified certain types of people who will be involved in the purchasing of drives. Please identify the type nearest to your job function and turn to the relevant section Continued overleaf... 2 Purchasing decisions for PDSs WHO ARE YOU? 25 IF THIS IS YOU, TURN NOW TO PAGE... Machine builder is a person who buys either a PDS, CDM or BDM and other mechanical or electrical component parts, such as a pump, and assembles these into a machine. Note: A machine is defined as an assembly of linked parts or components, at least one of which moves. It includes the appropriate actuators, control and power circuits joined together for a specific application, in particular for processing, treatment, moving or packaging of a material. System designer carries out all the electrical design of the power drive system, specifying all component parts which comprise a PDS. End-user is the final customer who will actually use the machine, PDS or CDM/BDM. Panel builder constructs enclosures into which a panel builder will install a variety of components, including a CDM/BDM and sometimes the motor. However, the built enclosure does not constitute a machine. 28 31 32 24 EU Council Directives | Technical guide No. 2 Panel builder - page 32 Distributor - page 34 System designer - page 28 Panel builder - page 32 Machine builder or OEM - page 25 Installer - page 35 Installer - page 35 Purchasing decisions for PDSs End-user - page 31 Drive manufacturer WHO ARE YOU? IF THIS IS YOU, TURN NOW TO PAGE... 25 28 32 Distributor acts as the sales distribution channel between the CDM/ BDM manufacturer and the end-user, machine builder, OEM, panel builder or system designer. Installer carries out the entire electrical installation of the PDS. Original equipment manufacturer ( OEM) For the purposes of purchasing drives, an OEM will normally fall into the category of a machine builder, system designer or panel builder. Therefore, if you identify yourself as an OEM, refer to the relevant pages for each of these job functions. 35 34 Technical guide No. 2 | EU Council Directives 25 2 NOTE: Before reading this section we strongly urge you to familiarise yourself with the terms explained on pages 21-24. If you are a machine builder buying a PDS... ...You have the following responsibilities: 1. Because you are building a complete machine, which includes coupling up the motors to the PDS and providing the mechanical guarding and so on, you are liable for the total mechanical and electrical safety of the machine as specified in the Machinery Directive. Therefore, the PDS is ultimately your responsibility. You need to ensure that the entire PDS meets the Machinery Directive. Only then can CE marking be applied to the whole machine. 2. You are also responsible for the electrical safety of all parts of the PDS as specified in the Low Voltage Directive. 3. You must ensure electrical equipment and components are manufactured in accordance with the EMC Directive. The manufacturer of these parts is responsible for EMC for that particular part. Nevertheless you are responsible for EMC for the machine. You may choose electrical parts not in accordance with the EMC directive, but then you have the responsibility for compliance of parts. Note: Be aware that combining CE marked sub-assemblies may not automatically produce an apparatus that meets the requirements. 4. You must ensure that the PDS or its component parts carry declarations of conformity in accordance with the electrical safety requirements of the Low Voltage Directive. 5. You must be able to assure an authority and customers that the machine has been built according to the Machinery Directive, the Low Voltage Directive and the EMC Directive. It may be necessary to issue technical documentation to demonstrate compliance. You must keep in mind that you and only you have responsibility for compliance with directives. 6. A Declaration of conformity according to the directives above must be issued by the machine builder and CE marking must then be affixed to the machine or system. 7. Any machine that does not comply must be withdrawn from the market. Purchasing decisions for PDSs 26 EU Council Directives | Technical guide No. 2 Actions you must take To meet the Machinery Directive (see page 55) you need to: a. Comply with the following mechanical safety checklist. The aim is to eliminate any risk of accident throughout the machinery’s life. This is not a complete list, the detailed list is contained within the Machinery Directive: Eliminate risk as far as possible, taking the necessary protective measures if some risks cannot be eliminated. Inform users of the residual risks; indicate whether any training is required and stress the need for personal protective equipment. Machinery design, construction and instructions must consider any abnormal use. Under the intended conditions of use, the discomfort, fatigue and stress of the operator must be reduced. The manufacturer must take account of the operator’s constraints resulting from the use of personal protective equipment. Machinery must be supplied with all essential equipment to enable it to be used without risk. b. Comply with the following electrical safety checklist: To ensure the electrical safety of all parts of the PDS as specified in the Low Voltage Directive (refer to page 56) you need to comply with the following safety checklist, which is not necessarily complete. The electricity supply should be equipped with a discon- necting device and with emergency devices for prevention of unexpected startup. The equipment shall provide protection of persons against electric shock from direct or indirect contact. Purchasing decisions for PDSs Technical guide No. 2 | EU Council Directives 27 2 The equipment is protected against the effects of: overcurrent arising from a short circuit. overload current. abnormal temperatures. loss of, or reduction in, the supply voltage. overspeed of machines/machine elements. The electrical equipment is equipped with an equipotential bonding circuit consisting of the: – PE terminal. – conductive structural parts of the electrical equipment and the machine. – protective conductors in the equipment or the machine. The control circuits and control functions ensure safe operation including the necessary inter-lockings, emergency stop, prevention of automatic re-start, etc. Defined on page 40 c. Compile a technical file for the machine, including the PDS. Key point: Generally, must carry CE marking and have a Declaration of conformity. For machines that pose a high risk of accident, a type certification (see page 46) is required from a notified body. Such machinery is included in Annex IV of the Machinery Directive. The type certificate issued should be included in the technical file for the machine or safety component. Refer now to page 40. 2. Declarations of conformity from each of the component suppliers whose products make up the PDS and incorporate them into the technical documenta- tion, referring to all three directives. If buying a PDS from a system designer (see below), he should be able to provide all declarations. If system designer or component supplier cannot provide a Declaration of conformity, the responsibility of demonstrating compliance according to EMC Directive or Low Voltage Directive lies on machine builder. Purchasing decisions for PDSs 28 EU Council Directives | Technical guide No. 2 3. Pass this technical documentation to a notified body. The machine builder SHOULD NOT pass the file on to an end-user. Based on the technical documentation, obtain a Certificate of Adequacy or technical report from a notified body. Defined on pages 43, 45 and 46 4. Issue a Declaration of conformity for the entire machine. Only then can you apply CE marking. 5. Pass the Declaration of conformity related to all three directives on to the end-user of the machine. 6. Apply CE marking to the machine. 7. Congratulations! You have successfully complied with the main requirements for safe and efficient operation of a machine. If you are a system designer You have the following responsibilities: 1. The PDS is a complex component of the machine. Therefore, the Machinery Directive has to be complied with by issuing a Declaration of incorporation. 2. Because a PDS is not a machine, the only directives which need to be complied with are the Low Voltage Directive and the EMC Directive. 3. The responsibility for Declaration of conformity and applying CE marking rests with both the system designer and the supplier of the component parts which make up the power drive system. The system designer has to decide if he is going to place his delivery on the market as a single functional unit or not – if the answer is YES, the delivery shall be classified as a system. – if the answer is NO, the delivery shall be classified as an installation. Purchasing decisions for PDSs Technical guide No. 2 | EU Council Directives 29 2 A. If the delivery is classified as a system, the system designer has to choose one of two paths to follow: Path 1 All components have EMC compliance 1. EMC behaviour is based on a component’s performance. 2. Responsibility lies with the component suppliers for CE marking of individual complex components 3. PDS is an system according to the EMC Directive (as placed on the market as a single functional unit). 4. The Declaration of conformity as well as the instructions for use must refer to the system as whole. The system designer assumes responsibility for compliance with the Directive. Note 1: The system designer is responsible for producing the instructions for use for the particular system as whole. Note 2: Be aware that combining two or more CE marked subassemblies may not automatically produce a system that meets the requirements. 5. No CE marking is required for a system as whole, as long as each part bears the CE mark. Actions you must take 1. Follow all installation guidelines issued by each of the component suppliers. 2. Issue instructions for use in order to operate the system. 3. Issue technical documentation for the system. 4. Issue a Declaration of conformity. 5. DO NOT issue a CE mark.
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