Exp Manual - Electromach BV
Contents
1. The control device does not connect the electrical devices after the pre purging phase ON OFF switch bridge is not connected on terminals 19 and 20 Turn on the ON OFF switch connect bridge on terminals 19 and 20 Pressure in the housing exceeds the switching value of MAX Reduce the air flow of the leakage air nozzle After the purging time the control device switches off the electrical devices after a time Housing has a leak pressure Switches MIN A and MIN B set too low Seal the housing PAGE 16 21 ELECTROMACH delay of 5 seconds Leakage compensation valve on Increase the air flow of the digital valve is too small leakage air nozzle Digital valve connects Housing has a leak valve connection Seal the housing or increase the temporarily during the attempts to retain the internal flow capacity of the leakage air operating phase only under pressure level by opening the nozzle 5 0 purging air nozzle When the pressure drops Is the bridging key switch switched Switch off the key switch electrical devices do not switch on off j Please consult with Electromach b v before operating under conditions which deviate from the standard operating conditions 8 INSTALLATION Mains connection e The wiring connection must be made very meticulously e The wiring insulation must extend all the way to the terminal When baring wires the condu2. Certicate may only be reproduced in 45 entirety and without any change Quality B V Utrechtseweg 310 6812 AR Arnhem Box 5185 6802 ED Arnhem The Netherlands T 31 263 58 20 00 F 31 28 3 52 58 00 customer kema com www kema com Registered Arnhem 09085396 Experience you can trust PAGE 20 21 ELECTROMACH 14 DECLARATION OF CONFORMITY EG Konformit tserkl rung EC Declaration of Conformity ELECTROMACH CE D claration de Conformit Wir we nous ELECTROMACH BV Jan Tinbergenstraat 193 7559 SP Hengelo erkl ren in alleiniger Verantwortung da das Produkt EEx p steuerung EBP hereby declare in our sole responsibility that the product EEx p control system EBP d clarons de notre seule responsabilit que le produit EEx p coffret de commande EBP auf das sich diese Erkl rung bezieht mit der den folgenden Norm en oder normativen Dokumenten bereinstimmt which is the subject of this declaration is in conformity with the following standard s or normative documents auquel cette d claration se rapporte est conforme aux norme s ou aux documents normatifs suivants Bestimmungen der Richtlinie Titel und oder Nr sowie Ausgabedatum der Norm terms of the directive title and or No and date of issue of the standard prescription de la directive litre et ou No ainsi que date d mission des normes 94 9 EG Ger te und Schutzsysteme 1997 A1 A2 zur bestimmungsgemafen Verwendung 2002 explosionsgef hrdete
3. ELECTROMACH ELECTROMACH member of the R STAHL Technology Group OPERATING INSTRUCTIONS EEX P CONTROL UNIT ELECTROMACH B V T 431 0 74 2 472 472 Bank ABN AMRO 59 01 14 573 Bank Fortis 24 35 24 439 Leveringen geschieden Jan Tinbergenstraat 193 F 431 0 74 2 435 925 IBAN NL29ABNA05901 14573 IBAN NL67FTSB0243524439 overeenkomstig de voorwaarden 7559 SP Hengelo info electromach nl BIC ABNANL2A BIC FTSBNL2RXXX Deliveries subject to general The Netherlands www electromach com VAT BTW NL 003578458B01 KVK nr 06040491 conditions of sale ELECTROMACH INDEX OPERATING MANUAL FOR EEXP CONTROL UNIT rrr 3 1 SAFETY INSTRUCTIONS icici cnn ccc 4 2 GENERAL REMAKRS AND WARNING NOTES eren nen 4 555 ad B RC REX 5 A TECHNICAL DATA FUNCTION sssrinin 5 4 1 FUNCTION FOR UTILISATION AS A PRESSURISED ENCLOSURE WITH COMPENSATION OF LE AKAGELOS IIo 5 4 2 FUNCTION FOR UTILISATION AS A PRESSURISED ENCLOSURE WITH CONTINUOUS RINSING 7 4 3 TECHNICAL DATA pe 8 SCHEMATIC STRUCTURE saute 9 TSBDIUSTMENTOF AIR ET 10 5 CONNECTION OF THE ELECTRICAL WIRES nae i ic ik a 1 6 STATE TABLE ee 12 7
4. Max value the system is switched on again without delay Please check the input pressure and that the measurement aperture is functioning correctly The purging time and switching values of the pressure switches are pre setat the factory This also applies for relays K4 5 4 3 TECHNICAL DATA Explosion protection Test certificate Ambient temperature Degree of protection to IEC CEI 60529 Permissible humidity Measurement operating voltage Optional Purging time Pressure values Sensor range Conversion Relays K2 3 1 4 6 DMT O1ATEX E116U During storage and transport 20 80 Operation 20 40 max IP 54 minimum lt 90 relative humidity annual average 230 VAC 48 62 Hz 10 115 VAC 10 Adjustable from 0 99 min Tolerance of each pressure sensor 2 of the range System range mbar Sensorrange 0 25 0 300 0 1000 DIFF A 0 25 0 29 9 0 29 9 DIFF B 0 25 0 29 9 0 1000 MIN A 0 25 0 300 0 1000 MIN B 0 25 0 300 0 1000 MAX 0 25 0 300 0 1000 MAXI 0 25 0 300 0 1000 100 Pa 1 mbar 20 001 N m 10 mm WS 1 bar 20 1 mPa Switching capacity max 5A for cos phi 1 253 VAC Time delay 5 sec PAGE 8 21 ELECTROMACH Relays K4 and K5 Safety related values Max 100mA 10V Max 30 mA 30V Output Al Connection of the input valve max 7 VA Connection terminals Max 1x 2 5mm per terminal Protective gas Inert gas or dr
5. SETTING THE 5 12 BINSTALLATION iiccidi anii nace nib cl REMEDIUM E CERO M RU FL cL NA RE 17 9 COMMISSIONING snn 18 10 MAINTENANCE AND REPAIR erre renes ire n 18 11 ACCESSORIES SPARE PARTS bubo c dc DD Codd 19 12 WASTE DISPOSAL ninincniiiasi nihi nisetb c cnr mirc tni cb cct E ua c s eR E n 19 ISEC TYPE EXAMINATION CERTIFICATE RR oc a d 20 14 DECLARATION OF 21 PAGE 2 21 ELECTROMACH OPERATING MANUAL FOR EEXP CONTROL UNIT When work takes place in hazardous areas the human safety and the safety of systems are contingent on the adherence to all relevant safety regulations Forthis reason the installation and maintenance personnel working in such systems have a special responsibility The precondition for this is an accurate knowledge of the applicable regulations and provisions This manual briefly summarises the most important safety measures It is intended to supplement the relevant regulations which must be studied by the personnel responsible PAGE 3 21 ELECTROMACH 1 SAFETY INSTRUCTIONS Only employ the control unit for the permitted purpose Incorrect or non permissible deployment and or non compliance with the instructions of this op
6. TRICAL WIRES OPTIONS MEASURE AND INDICATING MODULE TEMPERATURE KEY SWITCH DN OFF BRIDGE FOR B625 1 30 25 CONTROL SWITCH ADJUSTMENT oO Keen ia CONTROL MODULE B625 1 40 15 01 ONLY FOR MANUFACTURER 1 MAX SA EEx p ENCLOSURE MAIN SUPPLY FOR MAIN SUPPLY INLET CONTROL CIRCUIT CONTACTS NON Ex CONTROL SYSTEM 4fSV OR 230V AC EEx PURGE VALVE MAX 26V 0 05 CDMPONENTS 48 82 Hz FOR EACH CONTACT PAGE 11 21 ELECTROMACH 6 STATE TABLE The monitoring unit is constructed in accordance with EN 50016 and satisfies the requirements specified therein The workflows of the various states are detailed below CONDITIONS ALL OF WHICH MUST RESULT WHEN ALL SEN FULFILLED CONDITIONS ARE SATISFIED Preparation for the start of a the control device b Mains voltage connected Internal pressure less than MAX Pre purging time determined and set Pre purging time has notelapsed Control device ready for pre purging Pre purging is running a Internal pressure greater than MIN A Internal pressure greater than MIN B Internal pressure less than MAX Minimum flow greater than DIFF A Minimum flow greater than DIFF B f Pre purging time has not elapsed Pre purging time is running P re purging finished a Internal pressure greater than MIN A Voltage supply of the non b Internal pressure greater than MIN B E
7. a leakage loss This triggering of the magnetic valve usually indicates that the sealing of the system needs to be checked If the housing pressure exceeds the switching value Max during the operating phase the power of terminals 34 and 35 is switched off immediately but only for the duration of the excess pressure After the pressure falls back below the Max value the system is switched on again without delay Please verify the safety function relief of the measurement aperture PAGE 6 21 ELECTROMACH The purging time and switching values of the pressure switches are pre setat the factory This also applies for relays K4 5 4 2 FUNCTION FOR UTILISATION AS A PRESSURISED ENCLOSURE WITH CONTINUOUS RINSING After the safety mechanism is switched on a pressure builds up in the housing The pressure sensors in the display measurement module monitor the internal pressure of the housing and the differential pressure on the measuring aperture If the pre set measurement values Min A B and Diff A B are exceeded then the pre set purging time starts The relevant LED in the control unit lights up and the residual purging time in the display measurement module tends towards zero If too high a housing internal pressure is reached during the purging phase due to an impermissibly high flow resistance on the protective gas output the purging operation is terminated It is only possible after elimination of the possible cause to switch on
8. again by pressing the switch 55 ofthe control module turn to pos 0 turn back to pos 1 Ifa too low protective gas flow is measured on Diff A or Diff B during the purging phase then the residual purging time is reset to the maximum purging time value Please check the input pressure on the reducing valve housing seal and doorlocks After the purging time has elapsed the voltage supply of the control unitis enabled via the contacts K2 K3 on terminals 34 and 35 Contacts K4 and K5 switch in accordance with the configuration The Operation LED in the control module lights up The residual purging time display goes out and the existing housing internal pressure is indicated on the sensor module If the housing pressure falls below the switching value Min A or Min B during the operating phase K2 3 and the configured K4 5 are released This switches off the power of any connected non Ex devices Simultaneously a new pre purging phase commences The voltage is enabled after a time delay approximately 5 seconds in order to compensate any possible protective gas fluctuations in the mains Please check the housing seal the doorlocks and whether the input pressure is still adequate PAGE 7 21 ELECTROMACH If the housing pressure exceeds the switching value Max during the operating phase the power of terminals 34 and 35 is switched off immediately but only for the duration of the excess pressure After the pressure falls back below the
9. ctor itself must not be damaged notched e By appropriately choosing the wires being utilised and by properly laying the wires it must be ensured that the maximum permissible conductor temperatures are not exceeded e Pay attention to the specifications in the technical data relating to the terminals e Protect the measurement aperture against spraying water Additional specifications P rotective earth conductor connection The connection of a protective earth conductor is essential potential equalisation PAGE 17 21 ELECTROMACH 9 COMMISSIONING Before you commission the control unit please ensure that e the control unit was installed in accordance with the regulations e the equipmentis not damaged e extraneous particles are present in the control unit e the control unitis connected correctly e the cables are inserted properly e all bolts and nuts are tightened firmly e the wires are connected firmly e unutilised wire entry points are sealed with plugs which are certified in accordance with Directive 94 9 EU and unused drill holes are sealed with plugs which are certified in accordance with Directive 94 9 EU 10 MAINTENANCE AND REPAIR Maintenance repair and servicing work on the EEx devices must only be performed by personnel who are both authorised and suitably trained for this purpose Before commencing any such work switch off the power of the devices A Please pay attention to the national regu
10. erating manual shall invalidate any warranty by us Modifications and constructional alterations to the control unit which impair the explosion protection are not permitted The control unit must only be operated in an undamaged and clean condition When installing and operating utilising the control unit the following must be paid attention to e The national safety regulations e The national accident prevention regulations e The national installation and assembly regulations e The generally accepted rules of technology e The safety instructions of this operating manual e The characteristic values and measurement operating conditions specified on the type and data plates e Other instruction plates labels on the control unit Any damage can compromise and even neutralise the explosion protection 2 GENERAL REMAKRS AND WARNING NOTES e Work on live parts other than intrinsically safe circuits is fundamentally prohibited while a danger of explosion exists e A protective earth conductor must be connected to the protective earth conductor connection before any other connections are made e Before switching on it must be ensured that the operating voltage corresponds with the values specified on the type plate PAGE 4 21 ELECTROMACH e tmustbe ensured that only safety fuses of the specified type and of the nominal rated amperage be utilised as a replacement as spare parts The use of shorted out safety fuses or short c
11. fthe control module turn to pos 0 turn back to pos 1 Ifa too low protective gas flow is measured on Diff A or Diff B during the purging phase the residual purging time is reset to the maximum purging time value Please check the input pressure on the reducing valve housing seal and doorlocks After the purging time is over the magnetic valve protective gas is switched off and the voltage supply of the control unitis enabled via the contacts K2 K3 on terminals 34 and 35 Contacts K4 and K5 switch in accordance with the configuration The Operation LED in the control unit lights up The required leakage loss is compensated by the integrated needle valve The residual purging time display goes out and the existing internal pressure of the housing is displayed on the sensor module If the housing pressure falls below the switching value Min A or Min B during the operating phase K2 3 and the configured K4 5 are released This switches off the power of any connected non Ex devices Simultaneously a pre purging phase commences The voltage is enabled after a time delay approximately 5 seconds in order to compensate any possible protective gas fluctuations in the mains Please check the housing seal the doorlocks and whether the leakage loss compensation is still adequate Please note that if the value in the display measurement module PD1 sinks below the pre set value DP 1 the magnetic valve opens briefly in an attemptto compensate
12. ial Health and Safety Requirements relating to the design and construction of equipment and protective systems intended for use in potentially explosive atmospheres given in Annex II to the directive The examination and test results are recorded in confidential test report number 2021567 2 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 50014 1997 A1 A2 EN 50016 2002 EN 50018 2000 A1 EN 50019 2000 EN 50020 2002 EN 50028 1987 If the sign X is placed after the certificate number it indicates that the equipment is subject to special conditions for safe use specified in the schedule to this certificate This EC Type Examination Certificate relates only to the design examination and tests of the specified equipment according to the Directive 94 9 EC Further requirements of the directive apply to the manufacturing process and supply of this equipment These are not covered by this certificate The marking of the equipment shall include the following 126 IIC 5 T3 This certificate is issued on 4 October 2006 and as far as applicable shall be revised before the date of cessation of presumption of conformity of one of the standards mentioned above as communicated in the Official Journal of the European Union B V es Manager Page 13 integral pubscation of this certificate and adjcining reports is alowed This
13. int MIN B and actual value 5 Display of set point MAX and actual value 6 1 7 Min P 8 9 Display of the function of K5 Switches S 11 to S 13 of the display measurement module 8625 1 30 25 Switches S 11 to S 13 are used for changing and storing set points selected using S 1 A change of value is only possible after connection of the safety bridge on terminals 23 and 24 8625 1 30 Anzeige Me amp 8modul OP 0 25 mbar 0 300 mbar Actual value S witching value Target value PAGE 13 21 BO 511 512 513 SET ELECTROMACH Pressing the or keys once causes the value to change by 0 1 mBar After pressing more than 25 values continuously the value changes in steps of 1 mBar By pressing the key the value can be changed to a minimum of zero By pressing the key the value can be changed to a maximum of 100 of the current value The stored value is indicated by a Switch S 1 to position 8 and 9 By pressing the key itis possible to select between function 0 and function 10 for the relays e A function change does not take place until after the system is restarted using S 5 Switch position Parameter Switches if the key switch is set to bypass 0 Switches at the same time as K2 1 Switches if the set point of DIFF A is exceeded 2 Switches if the set point of DIFF B is exceeded 3 Switches if the set point of MIN A is exceeded 4 S
14. ircuit bridges is not permissible e Ifthe possibility exists that safe operation can no longer be ensured the control unit must be Switched off and prevented from being switched on again i We will gladly send you a copy ofthe EU design test certification together with the relevant appendix on request 3 NORM COMPLIANCE The device fulfils the following regulations and norms e Directive 94 9 EU EN 50014 19974A1 A2 EN 50016 1995 EN 50018 2000 EN 50019 2000 EN 50020 1994 EN 954 1 1996 4 TECHNICAL DATA FUNCTION 4 1 FUNCTION FOR UTILISATION AS A PRESSURISED ENCLOSURE WITH COMPENSATION OF LEAKAGE LOSSES After the safety mechanism is switched on a pressure builds up in the housing The pressure sensors employed in the display measurement module monitor the internal pressure of the housing and the differential pressure on the measurement aperture If the pre set measurement values Min A B and Diff A B are exceeded then the pre set purging time starts The relevant LED in the control unit lights up and the residual purging time in the display measurement module tends towards zero PAGE 5 21 ELECTROMACH If due to an impermissibly high flow resistance on the protective gas output a too high housing internal pressure is reached during the purging phase the purging operation is terminated It is only possible after elimination of the possible cause to switch on again by pressing the switch 55 o
15. lations applicable in the country of deployment The following points must be verified before any maintenance work is carried out e thatthe terminal wires are properly positioned e thatthe correct operating temperature is the case e thatthe switch cabinetis sealed PAGE 18 21 STAHL ELECTROMACH 11 ACCESSORIES SPARE PARTS Only use original accessories and original spare parts manufactured by R STAHL Electromach b v 12 WASTE DISPOSAL Please observe your national waste disposal regulations i If you have any specific questions do not hesitate to contact us Please contact the R STAHL Electromach organisation responsible PAGE 19 21 ELECTROMACH 13 EC TYPE EXAMINATION CERTIFICATE EC TYPE EXAMINATION CERTIFICATE Equipment and protective systems intended for use in potentially explosive atmospheres Directive 94 9 EC EC Type Examination Certificate Number KEMA 04ATEX2103 Issue Number 2 Equipment Pressurized Enclosure Type EBP 1 A Manufacturer Electromach B V Member of the R STAHL Technology Group Address Hamerstraat 10 7556 MZ Hengelo The Netherlands This equipment and any acceptable variation thereto is specified in the schedule to this certificate and the documents therein referred to KEMA Quality B V notified body number 0344 in accordance with Article 9 of the Council Directive 94 9 EC of 23 March 1994 certifies that this equipment has been found to comply with the Essent
16. minals 17 and 18 Switch off key switch remove bridge LED Purging time is running does not flash during the purging time Protective gas not connected Connect protective gas EEx digital valve does not open Check that the supply voltage terminals 31 to 33 is connected to the digital valve Check the valve connection to ensure that extraneous particles are not present in the mechanical part PAGE 15 21 ELECTROMACH A sufficient volume of protective gas is not flowing through the Ex p housing Increase the input pressure to the nominal required value The nominal required pressure of the reducing valve is not attained Protective gas supply too low Increase the cross sectional area of the supply line During the pre purging phase housing is leaking on account of excessive internal pressure Seal the housing by taking appropriate measures After the pre purging phase EEx digital valve does not switch over to the small nozzle only under 5 1 Valve connection does not close Check that the supply voltage of the valve connection is switched off Check that there are no extraneous particles in the mechanical part of the valve connection Temperature sensor is connected Internal temperature is too high Wait until the internal temperature has dropped as a result of the increased flow or else check the setting ofthe temperature switching value
17. n Bereichen 1 94 9 Equipment and protective systems 2002 intended for use in potentially explosive r 1987 atmospheres 94 9 CE Appareils et syst mes de protection destin s tr utilis s en atmosph res explosibles 89 336 EWG EN 60947 1 1999 Elektromagnetische Vertraglichkeit EN 60439 1 1999 89 336 EEC Electromagnetic compatibility 89 336 CEE Compatibilit lectromagn tique EG Baumusterpr fbescheinigung EC Type Examination Certificate KEMA 03 ATEX 2103 X Attestation d examen CE de type Qualit tssicherung Produktion Production Quality Assessment KEMA 01 ATEX Q3201 Assurance Qualit e Production e Hengelo 05 04 2006 Ort und Datum J F W Wijnen W H Moelard Place and date Gesch ftsf hrer Leiter Qualita tsmanagement lieu et date Managing Director Head of quality management dept Directeur Gen ral Chef du dept assurance de qualit PAGE 21 21
18. witches if the set point of MAX is exceeded 5 Not used 6 Switches if the purging time counts off 7 Not used 8 9 Switches at an internal malfunction Bypass key switch The bypass key switch switches off the safety mechanism When the bypass key switch is pressed the LCD display of the display measurement module indicates the following K2 Function K2 Function Close K2 Open K2 With With PAGE 14 21 ELECTROMACH The pushbutton switches and on the display measurement module can be used to switch the release protection on and off Parameters ofthe control device can be modified by manufacturers using the RS 485 interface However parameters can only modified by authorised personnel because functional changes invalidate the EU design test certification and conformity declaration Because of danger of explosion special permission must be obtained before pressing the bypass key switch After properly connecting all external electrical and mechanical equipment a check should first be made that the electrical equipment is set up and connected correctly Malfunction Possible cause Remedy Device is not operating LED Mains is not lighting Mains voltage not connected Check the mains voltage supply wire Device defective The electrical devices are connected without a pre purging phase Key switch switched on bridge on ter
19. x devices switched on Internal pressure less than MAX Pre purging time has elapsed ON OFF switch closed K2 K3 closed K4 K5 closed SETTING THE PARAMETERS All parameters such as Min A Min B Diff A Diff B Max DP 1 function K4 K5 purging time temperature adjustment time delay for switching off the power are set at the factory If the pre settings or the control unit are modified without the written consent of Electromach then the warranty is invalidated PAGE 12 21 ELECTROMACH Rotary switch S 5 of the control module Rotary switch S 5 is a reset switch and is used to restartthe system during adjustment operations Rotary switches S 2 to S 4 of the control module The purging time is set using the rotary switches S 2 to S 4 It is possible to set the minutes in steps of 10 and 1 The seconds can only be set in steps of 10 Rotary switch S 1 of the control module The various switching values of the control devices can be displayed and adjusted using rotary switch S 1 The following parameters are assigned to the switch positions SWITCH POSITION PARAMETER 0 Display of the internal pressure of the housing target reference value and residual purging time value Display ofthe function of K4 1 Display of set point value DIFF A and actual value 2 Display of set point DIFF B and actual value 3 Display of set point MIN A and actual value 4 Display of set po
20. y oil free industrial compressed air Temperature control optional Thermostat NO closing 4 4 SCHEMATIC STRUCTURE AIR OUTLET VIZLLLLLIIIIITIIIIUITITIIII WES PRESSURE LONTROL UNIT 8625 1 10 30 DRIFICE PLATE CONTROL MODULE 8625 1 40 AIR FLDW EXIT EExp ENCLOSURE SPARK ARRESTOR i i ATMOSPHERE LA 7 Ser CH E NET SUPPLY NTA TEE 115V OR 230V AC i OFF B AIR SUPPLY N Ss eben LE ES kt AIR INLET MN A A M MEASURE AND INDICATING MODULE i t 48 62 Hz INTERIOR PRESSURE MIN A MIN B H Len ran ENCLOSURE A Ge i l LEAKAGE COMPENSATION PAGE 9 21 ELECTROMACH 4 5 ADJ USTMENT OF AIR VOLUMES P urging air volumes and compensation leakage air losses are values determined at the factory If necessary the setting for leakage air loss can be adjusted as follows Rinsing air nozzle Max d 2 5mm Leakage air nozzle with sound absorber The air volume can be varied by turning the adjustment screw which is accessible through the purging air nozzle to the necessary value using a suitable screwdriver Turning in the counter clockwise direction increases the leakage loss volume PAGE 10 21 STAHL ELECTROMACH 9 CONNECTION OF THE ELEC
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