Fire Fighting Enterprises IR3 User Manual

This document is the Exd Flame Detector Installation Guide/2010/Issue 3

Flameproof – (Ex d)

IR² and IR³ Flame Detector

Installation Guide

General

This Installation Guide gives information on the Flameproof (Ex d) version of the flame detectors that have been approved by Baseefa. The requirements of the European Community Directive 94/9/EC, the ATmosphere EXplosives ATEX Directive have been met. The approval has been accessed to the following European Standards EN60079-0, EN 60079-1 and EN 60079-26.

Also the flame detector has been accessed and approved to IECEx requirements.

The detector enclosures are certified category II 2 G D, Ex d IIC T4 Gb

Ex tb IIIC T135°C Db IP66 A21

Tamb = -40°C to +125°C

The range comprises dual infra-red (IR²), triple infra-red (IR³) and UV/IR² flame detectors. The detector housings are available in copper free aluminium alloy (LM25) and stainless steel (316).

The guide also provides information on Flameproof (type‘d’) enclosures, the application, maintenance, installation and adjustments of the detectors. Reference to other individual detector publications can be made for more information on none Flameproof issues. These publications are available on request.

Information in this guide is given in good faith, but the manufacturer cannot be held responsible for any omissions or errors. The company reserves the right to change the specifications of products at any time and without prior notice.

Introduction to Flameproof Enclosures

There are many places where an explosive mixture of air and gas or vapour is or may be present, intermittently or as a result of an accident. These are defined as hazardous areas by EN 60079-0 (formally EN 50014), Electrical apparatus for explosive gas atmospheres – General requirements.

Hazardous areas are common in petroleum and chemical engineering plants and in factories processing and storing gases, solvents, paints and other volatile substances.

Electrical equipment for use in these areas needs to be designed so that it cannot ignite an explosive mixture, not only in normal operation but also in fault conditions. There are a number of methods available to achieve this – oil immersion, pressurised apparatus and powder filling, for example, but the two most common used are intrinsic safety and flameproof enclosures.

Flameproof equipment is contained in a box so strong that an internal explosion will neither damage the box nor be transmitted outside the box. The surface must remain cool enough not to ignite the explosive mixture.

When flameproof equipment is interconnected, flameproof wiring must be used. This method is most valuable when high power levels are unavoidable but it is not acceptable for areas in which an explosive gas/air mixture may be continuously present or present for long periods.

For this reason these flame detectors are made intrinsically safe rather than flameproof. Intrinsically safe equipment operates at such low power and with such small amounts of stored energy that it is incapable of causing ignition:

o In normal conditions o With a single fault (for ib type of protection code) o With any combination of two faults (for ia type of protection code)

In any of these conditions every component must remain cool enough not to ignite gases for which it is approved. See Table 4

Classification of Hazardous Areas

EN 60079-0 (formally EN50014) states that electrical apparatus for potentially explosive atmospheres is divided into:

• Gas Group I:

• Gas Group II:

other than mines susceptible to fire damp.

These flame detectors are designed to meet the requirements of Group II apparatus. For the type of protection “d” Flameproof, Group II is subdivided into Equipment Categories, Type of Explosive Atmosphere (Table 1), Type of Protection Code (Table 2), Temperature Class (Table

3) and Gas Group (Table 4).

Electrical apparatus for mines susceptible to fire damp; Electrical apparatus for places with a potentially explosive atmosphere,

Exd System Drawing

Hazardous Area

Flame Detector

Fire Relay

Fault Relay

Fire Relay

Fault Relay

5 6 7 8

EOL

Refer to note 4

Safe Area

Barrier

Required

Barriers

Required

Safe Area Apparatus

Unspecified except that it must not be supplied from nor contain under normal or abnormal conditions a source of potential exceeding 250V RMS or 250V DC with respect to earth.

24V DC Normal

(Break supply to reset

if detector set to latch)

i = See detector data

sheet for details

24V DC Normal

(Break supply to reset

if detector set to latch)

NOTE 1 WARNING – Ensure ALL power is OFF before/during installation/maintenance.

NOTE 2 Ensure the details on the enclosure label comply with the hazardous area specified.

NOTE 3 The installation must comply with national installation requirements (for example to EN 60079-14)

NOTE 4 If required a loading resistor or end of line device (EOL) can be connected between the detector terminals of any circuit. The total power dissipation and temperature classes within the enclosure must not be exceeded, 30W – T4.

NOTE 5 The 24Vdc supply line to the detectors should be fused at 1A.

Zone

Equipment Markings

ATEX

CE Marking & Notified Body Number

EU Explosive Atmosphere Symbol

Equipment

Category

Hydrogen Acetylene, Carbon Disulphide

Ethylene Diethyl ether, Tetrafluoroethylene

Methane Butane, Methanol, Petroleum, Propane, Styrene

Temperature

Class

Referred to

ambient of

-20°C to +40°C

T6 85°C

T5 100°C

T4 135°C

T3 200°C

T2 300°C

T1 450°C

Detectors approved to T4.

Maximum

Surface

Temperature

Health and Safety at Work Act

In the UK all equipment must be installed and disposed of (as required) within the legislative requirements of the Health & Safety at Work Act 1974.

Installation

No modification should be made to the enclosure without reference to the manufacturer as unauthorised modification to an approved enclosure will invalidate the certificate/approval.

1. The enclosures are supplied with drilled and tapped entries. See enclosure drawing

2. The surface of the machined/threaded flamepaths between cover and body must be protected from scratches or damage during installation. Any such damage can destroy the validity of the enclosure.

3. Before the cover is refitted, the flamepath/threaded joint between cover and body must be thoroughly wiped clean of dirt, grit or other foreign substances, and then a thin coating of an approved form of non-setting grease applied to joint/threads. Ensure the gasket o-ring is free from damage.

4. Threaded covers must be screwed on to a minimum of 5 full threads of engagement and then locked in position with the locking screw provided.

5. All tapped entries must be fitted with an approved flameproof (Exd) device which is equivalent or superior to the gas group and temperature of the enclosure.

6. The enclosure should be mounted using the two rear M6 tapped holes.

7. Do not scratch the glass.

8. Glanding of cables should be as in Selection of Cable Gland section.

Enclosure with Front Cover Removed

Exd HOUSING WITH FRONT REMOVED.

Ex tb IIIC T135°C Db

Dust Protection Concept

[See EN61241-1]

Dust Group

IIIC

IIIB

IIIA

Conductive Dust

Non-conductive Dust

Combustible Flyings

Maximum External Surface Temperature

Equipment Protection Level Dust (EPL)

[See EN60079-26]

FLAME SENSOR ELECTRONIC MODULE.

FLAME SENSOR CONNECTION TERMI NALS.

A1A1A2 A3A

Selection of Cable Glands

Application of barrier glands certified and approved to meet EN 60079-14 for Thermo Plastic, Thermosetting and Elastomeric Cables. The external cables and glands used for high temperature application must be compatible with the temperature.

Hazardous Area Type Gland Method

Zone 1, 2 21 & 22 Hazardous areas requiring IIC

1) apparatus

Zone 2 & 22 Hazardous areas requiring IIA & IIB

Exd Barrier Glands mandatory

Any Exd Gland permitted

apparatus.

Table 5 Examples of barrier glands

Enclosure Details

UNITS: mm.

150

146

Entry Thread Type – A1, 2 & 3 3 off – M20 x 1.5

100

150

110

2 & 3

Fixing Holes – B 2 off – M6 (8mm deep)

Flameproof Products

Flameproof Flame Detector (Alloy Housing)

Fig. 1

The flame detectors respond to light emitted from flames during combustion. The detectors discriminate between flames and other light sources by responding only to low frequency flickering produced by flames (typically 1 to 15Hz). The detectors ignore fixed light sources and rapidly flickering illumination predominantly produced by lighting. The flame flicker techniques have the advantage of still allowing the detection of flames through a thin layer of oil, water vapour, ice or dust. This makes these detectors particularly useful in industrial applications.

Full details of the principles of operation, electrical description, and other detailed technical data are published in the products individual data sheet.

Technical Data

Mechanical

Housing Material:

See figure 1

Housing Colour: Red

Housing Dimension:

(Excluding Mount)

Cable Gland Entries:

Electrical

Supply In:

Voltage Current

Polarity sensitive

Optional Input:

Voltage Current

Polarity sensitive

Power Up Time: 2 seconds

Relays Contact Ratings:

Voltage Current

Power

Resistive Loads Only

Environmental

ATEX

Approval Category

CENELEC / IEC

Marking

Ambient Temperature Range:

check detector data sheet.

Apparatus Certificate Numbers

IP Rating IP66

Copper Free Aluminium Alloy LM25

Height = 150mm Width = 146mm Depth = 137mm

3 X 20mm

Terminals 1(+) & 2(-)

14 to 30Vdc 2 to 28mA

Terminals 3(+) & 4(-)

14 to 30Vdc 40µA

30Vdc. Max. 1 Amp. Max. 30W Max.

II 2 G D

Ex d IIC T4 Gb Ex tb IIIC T135°C Db

(Zone 1, 21, 2 & 22)

Tamb -40°C to +125°C

Also

Baseefa08ATEX0270

IECEx BAS08.0073

See data

sheet for detail

typ. @ 24V IN

Terminals 5 to 8

Flameproof Flame Detector (Stainless Steel Housing)

Fig. 2

Technical Data

Mechanical

Housing Material:

See figure 2

Housing Colour: Natural

Housing Dimension:

(Excluding Mounts)

Cable Gland Entries:

Electrical

Supply In:

Polarity sensitive

Optional Input:

Polarity sensitive

Power Up Time: 2 seconds

Relays Contact Ratings:

Resistive Loads Only

Environmental

ATEX

Approval Category

CENELEC / IEC

Marking

Ambient Temperature

Range:

Apparatus Certificate Numbers

IP Rating IP66

Voltage Current

Power

Also check

detector data sheet.

316 Stainless Steel

Height = 150mm Width = 146mm Depth = 137mm

3 X 20mm - typical

Terminals 1(+) & 2(-)

14 to 30Vdc 2 to 28mA

Terminals 3(+) & 4(-)

See data

sheet for detail

14 to 30Vdc

typ. @ 24V IN

40µA

Terminals 5 to 8

30Vdc. Max. 1 Amp. Max. 30W Max.

II 2 G D

Ex d IIC T4 Gb Ex tb IIIC T135°C Db

(Zone 1, 21, 2 & 22)

Tamb -40°C to +125°C

Baseefa08ATEX0270

IECEx BAS08.0073

System Design

Engineers familiar with codes of practice for hazardous area systems should only undertake the design of an flameproof fire detection system. In Europe the standard is EN 60079-0 (formally EN 50014), Electrical apparatus for potentially explosive atmospheres – General requirements.

The fire detector performance is the same as the standard none flameproof counterparts. Performance information given in standard product guides is therefore applicable to the flameproof range.

The Baseefa certification of the flameproof device enclosure covers their characteristics as components of a flameproof system. This indicates that the flame detectors can be used with a margin of safety in such systems.

Service & Repairs

1. Frequent inspection should be made. A schedule for the maintenance check should be determined by the environment and frequency of use but should be regular enough to ensure the detector continues to operate in the designed manner. It is recommended that

Servicing of the fire protection system should be carried out as recommended by the local regulation in force.

it should be at least once a year.

2. External surfaces of the enclosure should be periodically cleaned to ensure dust deposits are not allowed to accumulate.

3. Check flamepath/threads on enclosure body and lid for signs of corrosion. If badly pitted, replace component.

4. All components that are replaced must be in accordance with the manufactures specification. Failure to use such components may invalidate the certication/approval on the enclosure and may make the enclosure dangerous.

5. After inspection and maintenance have been carried out, items 3 & 4 of the installation instructions should be adhered to when resealing the enclosure.

Fire Fighting Enterprises IR3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual