Maximum safety and reliability in explosion-hazardous areas – This is how you protect your systems.
What is an ATEX-certified electromagnetic brake and why is it so important in chemical plants?
An ATEX-certified electromagnetic brake is a safety component specifically designed for use in explosion-hazardous areas, which are common in chemical plants. It is important because it prevents potential ignition sources and thus protects people and equipment in accordance with the ATEX Directive 2014/34/EU .
Which ATEX zones are crucial for the use of electromagnetic brakes in chemical plants?
Crucial are the ATEX zones that define the risk of an explosive atmosphere: Zone 1 (Gases/Vapors, frequent), Zone 2 (Gases/Vapors, rare), Zone 21 (Dusts, frequent) und Zone 22 (Dusts, rare). The choice of brake must be strictly made according to the respective zone classification and the device category.
How do ATEX brakes ensure explosion protection in chemical plants?
ATEX brakes ensure explosion protection through various design principles. These include the avoidance of sparking, the limitation of surface temperatures below the ignition temperature of the atmosphere, the use of antistatic materials and protection types such as pressure-resistant encapsulation (Ex d) or intrinsic safety (Ex i)..
What does “pressure-resistant encapsulation (Ex d)” mean in ATEX brakes?
“Pressure-resistant encapsulation (Ex d)” is a protection type in which parts that could ignite an explosion are housed in a casing. This casing withstands the pressure of an internal explosion and prevents flames or hot gases from penetrating outward and igniting the surrounding explosive atmosphere..
What role does the temperature class (e.g., T4) play in selecting an ATEX brake?
The temperature class (T1 to T6) indicates the maximum permissible surface temperature of the brake during operation. It must be lower than the ignition temperature of the gases or dusts present in the chemical plant. T4, for example, indicates a maximum surface temperature of 135°C, which is relevant for many applications in chemical plants.
Who is allowed to install and maintain ATEX-certified electromagnetic brakes?
Installation and maintenance of ATEX-certified electromagnetic brakes may only be performed by trained personnel. It is essential to strictly follow the manufacturer’s instructions und and use original spare parts to maintain ATEX compliance and safety.
Is an EU type-examination certificate for an ATEX brake sufficient for plant safety?
No, an EU type-examination certificate for a component like an ATEX brake alone does not guarantee the safety of the end product or the entire system. A conformity assessment of the overall system in the chemical plant is required, considering integration and interactions.
What should be considered when using regenerative braking in ATEX areas?
When using regenerative braking in ATEX areas, the system must be designed so that no unacceptable overvoltages or excess currents occur. These could generate sparks or cause the temperature to rise above permissible limits. Careful monitoring and control of the energy recovery process is absolutely required..
ATEX-certified electromagnetic brakes are essential for safety in chemical plants, as they prevent ignition sources through specific designs and thus significantly reduce the pressure-resistant encapsulation (Ex d) und intrinsic safety (Ex i). risk of explosion. The correct selection of an ATEX brake requires careful consideration of the.
Die korrekte Auswahl einer ATEX-Bremse erfordert die genaue Berücksichtigung der ATEX zone, gas/dust group, and temperature class, to ensure compatibility with environmental conditions and to maximize the safety of the plant..
Proper installation and regular maintenance by trained personnel are crucial for maintaining ATEX compliance, ensuring safety and reducing potential downtime in chemical plants by up to 20%. Learn how ATEX-certified electromagnetic brakes save lives and prevent production downtimes in chemical plants. This article highlights important aspects, from certification to selecting the right brake.
Extreme conditions prevail in chemical plants. ATEX-certified brakes are essential here. Are you looking for a reliable solution for your plant? Contact us for personalized advice at.
Erfahren Sie, wie ATEX-zertifizierte elektromagnetische Bremsen in Chemieanlagen Leben retten und Produktionsausfälle verhindern. Dieser Artikel beleuchtet die wichtigsten Aspekte, von der Zertifizierung bis zur Auswahl der richtigen Bremse.
In Chemieanlagen herrschen extreme Bedingungen. ATEX-zertifizierte Bremsen sind hier unerlässlich. Sie suchen eine zuverlässige Lösung für Ihre Anlage? Kontaktieren Sie uns für eine individuelle Beratung unter ATEK Drive Solutions.
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Understanding ATEX basics: Ensuring safety in chemical plants with ATEX-certified brakes.
Introduction to ATEX-certified electromagnetic brakes for chemical plants.
ATEX Certification: Why it is essential in chemical plants.
The ATEX Directive 2014/34/EU protects people and systems, especially in areas where explosion-protected components such as an ATEX-certified electromagnetic brake for chemical plants are used. Incorrect material selection, e.g., sealing rings, can be an ignition source. BASF invests millions in ATEX equipment, including such safety systems and ATEX brakes.
The importance of the ATEX Directive 2014/34/EU for explosion protection.
ATEX requires a comprehensive assessment of ignition hazards, which is crucial for the safe operation of components such as a specialized ATEX brake in chemical plants. Application reduces explosion risks through clear requirements (equipment, protection systems, types of ignition protection). VDMA: 70% of accidents are preventable. Basics on ATEX brakes can be found here.
Risk assessment and zone classification in chemical plants according to ATEX.
A precise zone classification (Zone 1, 2, 21, 22) is crucial for risk determination in chemical plants, especially when selecting a suitable ATEX-certified electromagnetic brake.. Classification defines safety requirements (operating materials, brakes); misjudgment can be fatal. Zone 1: Equipment at 2 faults not an ignition source. ATEX brake motors are often combined with such brakes.
ATEX-certified electromagnetic brakes for chemical plants. Design: safely avoid ignition sources.
Functionality and design of ATEX-certified electromagnetic brakes.
Explosion protection measures in electromagnetic brakes
ATEX-certified electromagnetic brakes for chemical plants. utilize specific protection principles against ignition sources. Avoidance (sparks, hot surfaces, static charging) is a focus in design. Coils of such ATEX-compliant brakes are often encapsulated (no contact with Ex-atmosphere, surface <135°C/T4).
- Basic principle in an ATEX-certified electromagnetic brake.: Use of protective mechanisms to avoid ignition sources.
- Design focus in these Ex-protected brakes: Preventing sparking.
- Important aspect for safety in chemical plants: control and avoidance of hot surfaces in the electromagnetic brake..
- Measure: Reduction of static charging through suitable materials in the ATEX brake.
- Component protection in an ATEX-certified electromagnetic brake.: Frequent encapsulation of coils to isolate from the Ex-atmosphere and limit surface temperature (e.g., <135°C/T4).
- Other protection types for brakes for explosion-hazardous areas: Application of pressure-resistant encapsulation (Ex d) or intrinsic safety (Ex i).
Avoiding ignition sources: Sparks, hot surfaces, static electricity.
Safe gap dimensions and special materials prevent ignition in an ATEX-certified electromagnetic brake for chemical plants.. Hot surfaces (thermal design/cooling), antistatic materials (against discharges) are important. Zone-22 brakes (manufacturers): max. 200°C (in case of failure). Corrosion-resistant brakes can also meet ATEX requirements.
Encapsulation and pressure-resistant housings (Ex d)
“Pressure-resistant encapsulation” (Ex d) is a protection principle that in ATEX-certified electromagnetic brakes for chemical plants contains internal explosions. The casing withstands the explosion pressure, prevents flames/gas escape and thus atmosphere ignition. Strict tests (pressure test at 1.5 times reference pressure) are required for such Ex-brakes.
intrinsic safety (Ex i).
“Intrinsic safety” (Ex i) limits the electric energy in ATEX brakes and is an alternative to Ex-d. Voltage, current, and power are so low that no ignition can occur through sparking or thermal effects (even in faults). This is often relevant for sensors/control lines (mA currents) that are connected to a ATEX-certified electromagnetic brake. . More: electric brakes..Master system integration: ATEX-certified electromagnetic brakes safely incorporate into chemical plants.
Integration of ATEX-certified electromagnetic brakes. into plant systems and safety concepts of chemical plants.
Safety functions and redundancy in brake systems.
Fail-safe mechanisms secure the brake function (emergency) of an ATEX-certified electromagnetic brake for chemical plants.. ATEX brakes are often spring-operated brakes: they fall into place during power failure and ensure safe stopping. Redundancy can be achieved through dual systems, e.g., two ATEX-compliant brakes (each 100% braking torque).
Fail-safe mechanisms and emergency shutdown.
Emergency stop buttons activate ATEX-certified electromagnetic brakes independently of the main control system. Systems switch to a safe state in case of a fault (often results in the brake falling without power). A quick response time (ms) of such safety brakes removes hazards in chemical plants. Safety brakes. provide solutions.
Monitoring of temperature and brake performance
Continuous monitoring is essential for the safe operation of a ATEX-certified electromagnetic brake for chemical plants. is essential. Temperature sensors and wear indicators detect critical states and signal the need for maintenance before an ATEX brake failure. Systems warn when reaching 80% of the temperature threshold. Special hygienic brake solutions can also be ATEX compliant.Select specifically for the application: Suitable ATEX-certified electromagnetic brakes for chemical plants. find
Selection criteria and application areas of ATEX-certified electromagnetic brakes for chemical plants
Selection of the right brake for the respective ATEX zone
The correct zone classification (Zone 1, 2, 21, 22) is the basis for selecting a ATEX-certified electromagnetic brake for chemical plants.. Each zone has specific requirements (device category/ignition protection type); a Zone 2 brake, for example, is not suitable for Zone 1. Zone 1 requires devices of category 2G, for example.
- Foundation for the selection of a ATEX-certified electromagnetic brake.: The correct classification in ATEX zones (e.g., Zone 1, 2, 21, 22) in the chemical plant.
- Zone-specific requirements for the explosion-protected brake: Each zone defines the necessary device category and ignition protection type.
- Compatibility check of the ATEX brake: A brake for a specific zone (e.g., Zone 2) is not automatically suitable for another zone (e.g., Zone 1) in the chemical plant.
- Substance-specific selection of the brake for chemical plants: Consideration of the existing gas groups (e.g., IIB, IIC for hydrogen) and dust groups (e.g., IIIB, IIIC for conductive dusts).
- Temperature management of the ATEX-certified brake: Selection of the appropriate temperature class (T1 to T6) to ensure that the maximum surface temperature of the brake is below the ignition temperature of the atmosphere in the chemical plant.
- Example requirement for a ATEX-certified electromagnetic brake: For Zone 1, for example, devices of category 2G are required.
Consideration of gas groups (IIB, IIC) and dust groups (IIIB, IIIC)
The type of explosive substance in the chemical plant is relevant. Gas groups (e.g., IIC for hydrogen) and dust groups (e.g., IIIC for conductive dusts) determine the ignition propagation capacity. An ATEX-certified electromagnetic brake must be suitable for the existing substances (safe enclosure/energy limitation). A IIB brake (suitable for ethylene) is not suitable for IIC atmospheres. explosion-proof motors are often part of the drive train.
Temperature classes (T1 to T6) and their significance
The temperature class (T1-T6) of a ATEX-certified electromagnetic brake. indicates the maximum allowable surface temperature, thus preventing the self-ignition of substances in chemical plants. The temperature class of the ATEX brake must be lower than the ignition temperature of the existing gases or dusts. T4, for example, means a maximum surface temperature of 135°C. A suitable ATEX gear motor is also crucial for the overall system.Ensure compliance: Certification, installation, and maintenance of ATEX-certified electromagnetic brakes. master
Certification, installation, maintenance, and legal aspects of ATEX-certified electromagnetic brakes for chemical plants
The certification process for ATEX brakes
The ATEX certification of a ATEX-certified electromagnetic brake for chemical plants. is carried out through a conformity assessment by the manufacturer, often involving a notified body. An EU type examination certificate for a component, such as an ATEX brake, does not alone ensure the safety of the end product; an evaluation of the entire system in the chemical plant is necessary. The process can take months and includes tests according to standards such as EN 60079.
EU type examination certificate and conformity assessment
The EU type examination confirms the conformity of a type of a ATEX-certified electromagnetic brake. with the ATEX requirements. The manufacturer declares through an EU declaration of conformity that the series products conform to the tested type and meet the relevant requirements. Annual audits ensure the ongoing conformity of these brakes for chemical plants.
Installation and maintenance of ATEX brakes
The installation and maintenance of ATEX-certified electromagnetic brakes for chemical plants must only be carried out by trained personnel. It is essential to follow the manufacturer’s instructions carefully and to use only original spare parts to maintain the ATEX compliance of the brake. Regular and documented inspections (e.g., every 6 months) are required for the safe operation of these Ex brakes. ATEX bevel gearboxes can be used together with these brakes.
Legal aspects and standards
In addition to the ATEX directive, the EN 60079 series of standards is ATEX-certified electromagnetic brakes for chemical plants. central. It specifies requirements for ignition protection types and testing procedures. Operators must operate their plants, including the integrated ATEX brakes, in accordance with standards and safely. EN 60079-14, for example, deals with electrical installations in explosive atmospheres. Oil/Gas: explosion-proof pneumatic brakes provide an alternative for certain applications.
