Gonnheimer elektronic F840 User Manual

Instruction manual

Pressurized enclosure system

F840

FS840 Seite 2

Content

1 Safety indication for explosion-proof devices........................................................................................				4
2 General requirements to pressurized enclosure system F830/840 ......................................................				5
	2.1	General requirements ....................................................................................................................		5
	2.2	Mechanical requirements to the Ex pzchousing ..........................................................................		5
	2.3	Determination of prepurging phase .............................................................................................		6
	2.4	Purge medium requirements..........................................................................................................		7
	2.5	Temperature class of the Ex pzchousing ....................................................................................		7
	2.6	Particular requirements in Zone 22 (Dust - Ex) .............................................................................		7
	2.6.1		Purging-phase / Cleaning of the housing ...............................................................................	7
	2.6.2		Marking in the housing............................................................................................................	8
	2.6.3		Special conditions in the manual of the Ex pzcsystem (Zone 22)........................................	8
	2.7	Introduction: Pressurized enclosure system F840 with protection pzc..........................................		8
	2.8	Relation between FS830 and FS840.............................................................................................		9
	2.9	Purging phase ................................................................................................................................		9
	2.9.1		Pressurized enclosure system without prepurging...............................................................	9
	2.9.2		Pressurized enclosure system with prepurging..................................................................	10
	2.10		Operation mode Leakage compensation .................................................................................	11
	2.11		Conformity with Standards .......................................................................................................	11
3	Mounting and connection ....................................................................................................................			12
	3.1	Mounting ......................................................................................................................................		12
	3.1.1		Control unit FS840................................................................................................................	12
	3.1.2		Sinter metal throttle SD840...................................................................................................	13
	3.1.3		Optional solenoid valve for purging ......................................................................................	13
	3.2	Connection and Startup ...............................................................................................................		13
	3.2.1		Connection details ................................................................................................................	13
	3.2.2		Terminals of the FS840 ........................................................................................................	14
	3.2.3		Place and exchange of valve fuse........................................................................................	14
	3.2.4		Power off relays ....................................................................................................................	14
	3.2.5		Switch input for passive contacts..........................................................................................	15
	3.2.6		Electrical diagram of the FS840............................................................................................	15
4	Operation.............................................................................................................................................			16
	4.1	Display .........................................................................................................................................		16
	4.2	Alarmsignallamp ......................................................................................................................		16
	4.3	Buttons .........................................................................................................................................		16
	4.4	Indication modes during normal operation...................................................................................		17
	4.5	Bypass, activate and deactivate ..................................................................................................		17
	4.6	Configuration................................................................................................................................		17
	4.7	Menu structure .............................................................................................................................		18
5	Annex		..................................................................................................................................................	21
	5.1	Terminals and terminals Exlimits ...............................................................................................		21
	5.2	Technical details ..........................................................................................................................		21
	5.3	Air pressure values ......................................................................................................................		22
	5.4	Dimensions ..................................................................................................................................		22
	5.5	Flow chart.....................................................................................................................................		24
	5.6	Flow rate table..............................................................................................................................		25
	5.7	Type designation..........................................................................................................................		25
	5.8	Problems and solutions................................................................................................................		26
	5.9	Transport, Storing, Disposal and Repairs....................................................................................		26
	5.10		Marking.....................................................................................................................................	26
	5.11		List of parameters.....................................................................................................................	27

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The symbols DANGER, WARNING, ATTENTION

The signal word calls a danger with a high risk degree which if it is not avoided can cause death or heavy injury.

DANGER

The signal word calls a danger with a middle risk degree which if it is not avoided can cause death or heavy injury.

WARNING

The signal word calls a danger with a low risk degree which if it is not avoided can cause slight or moderate injury.

ATTENTION

This symbol refers to the danger of electric tension which can cause heavy injury or death.

DANGER

Safety measures: Absolutely read and follow

Warning! With the use of this device special care is required. A high electric discharging is possible and can be deadly.

Work at electrical installations and equipment, which are energized are

basically forbidden in explosive areas. Work at intrinsically safe circuits DANGER (Ex i) are excluded. In special cases work at non intrinsically safe circuits

can be carried out if it is ensured that no explosive atmosphere is present during the whole work. The check of the presence of electrical tension should only be done using explosion protected and certified measuring instruments. Grounding and short-circuiting should only be carried out if it is ensured that no hazardous atmosphere is present.

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1 Safety indication for explosion-proof devices

Application and Standards

The instructions and warnings given in this instruction manual must be observed in order to ensure safe and proper operation. The equipment should only be used for its intended purpose. The relevant provisions of the standards IEC/EN 60079 particularly IEC/EN 60079-14 "electrical apparatus for potentiality explosive atmospheres" apply. The use of the equipment is permitted in potentially explosive atmospheres due to gases or vapours. The data provided at the type plate must be observed. When constructing and operating explosion-proof systems and facilities, the applicable national regulations, provisions and valid standards must be observed.

General Instructions

Work on electrical installations and apparatus in operation is generally forbidden in hazardous locations, with the exception of intrinsically safe circuits. In special cases work can be done on non-intrinsically safe circuits, on the condition that during the duration of such work no explosive atmosphere exists.

Proper and safe operation of this device requires appropriate transport, correct storage and assembly as well as careful service and maintenance. Any work at the device may only be carried out by technically trained personnel.

The electrical characteristics shown at the type plate and within the certificates BVS 15 ATEX E 048 X and IECEx BVS 15.0037 X, and, if applicable, their special conditions, have to be considered.

For outdoor installation it is recommended to protect the explosion protected distribution and control panel against direct climatic influence, e.g. with a protective roof. The maximum ambient temperature is 40°C, if not stipulated otherwise.

Terminal compartment in Increased Safety

When closing, it is to be ensured that the gaskets of the terminal compartment remain effective, thus maintaining degree of protection IP 54. Close unused entries by impact-proof stopping plugs, which are secured against self-loosening and turning.

Maintenance Work

The gaskets of Ex e enclosures are to be checked for damages and replaced, if required. Terminals, especially in the Ex e chamber are to be tightened. Possible changes in colour point to increased temperature. Cable glands, stopping plugs and flanges are to be tested for tightness and secure fitting.

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2 General requirements to pressurized enclosure system F830/840

The control unit (FS840) for pressurized enclosure systems can be combined with every Ex pzchousing that fulfils the following requirements.

2.1General requirements

1The Ex pzcsystem must be inspected by a skilled person of accordance to IEC/EN 60079 –2, IEC/EN 60079 –14 and this manual.

2Mount the solenoid valve (purging medium input) and control unit FS840 to a maximum of distance (optimal arrangement is diagonal).

3The operator must not do any technical changes to the control unit FS840. Any change will invalidate the type examination certificate.

4Only Gönnheimer Elektronic GmbH is allowed to repair the FS840.

5Harmed Ex p-pipes and connections have to be repaired/replaced immediately.

6Discharging of flammable gases into the Ex pzc-housing, e.g. for gas analyser applications is prohibited.

7It is necessary to create an instruction manual for the complete system.

2.2Mechanical requirements to the Ex pzchousing

1Regard particularly IEC/EN 60079- 0 + 2.

2The Ex pzchousing must hold the 1,5 – fold of the maximum pressure, which can be reached inside of the cabinet, 2 mbar at least. The operator has to define the maximum pressure of the housing and has to program this pressure value as monitored max. pressure into the FS840 and has to ensure, that the housing holds this maximum pressure by 1,5 times.

3The Ex pzchousing must pass an impact test according IEC/EN 60079-0.

4The protection class of the Ex pzchousing must be greater than IP54.

5Cable glands must have a protection class greater than IP54.

6If the Ex pzchousing has surfaces made of synthetics (e.g. windows), the maximum limits for area and thickness must be complied with IEC/EN 60079-0.

WARNING – DANGER THROUGH ELECTROSTATIC DISCHARGE – SEE INSTRUCTION

MANUAL

7There is no danger of static discharge, if the synthetic surface has a thickness of ≤ 0,2 mm (Group IIC) respectively 2 mm (Group IIB) or less and it is mounted on a metallic ground.

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8If the Ex pzchousing posses internal compartments (closed rooms, compartments that are not purged), the following rules have to be observed:

a)Components with a free internal volume less than 20 cm³ are not considered to be internal compartments requiring purging as long as the total volume of all such components is not more than 1% of the free internal volume of the pressurized apparatus.

b)Provide not less than 1 cm² of vent area for each 1000 cm³, (IEC/EN 60079 – 2; Abs. 5.5.2).

c)Place the vents in a diagonal order, as shown on the picture below, with a minimum vent size of 6,3 mm diameter

drillings

drillings

d)Installer can also remove covers or doors of internal housings if they provide adequate vent diameters alternatively.

e)If the topics above are not applicable, a separate piping must be added to the internal compartment. The purge medium flow through the compartment must be high enough to make sure that the air in the compartment is exchanged at least 10 times higher. For instance:

Inner volume

FS840

Valve

Nozzles for air distribution

Ex pzchousing

2.3Determination of prepurging phase

In (Gas- ) ExZone 2 it is possible to resign to a purging phase, if the atmosphere in the housing and in the corresponding pipes is much lower than the lower explosive limit (e.g. 25% LEL). Additionally gas detectors can be used to check, if the Gas in the Ex pzc housing is ignitable. (See IEC/EN 60079-14)

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2.4Purge medium requirements

1The purging medium must not be derived from hazardous area, it must be contamination free (dry, free of oil and dust). The air quality must be class 533 according ISO 8573-1, Solids 40µm (Class 5); Dew point -20°C (Class 3); Oil quality 1mg/m³ (Class 3).

2If another purge medium than air is used, it is important to regard the minimum oxygen content of the ambient. Maybe it is necessary to install an exhaust pipe from the outlet of the Ex pzchousing to out-of-door.

3The inlet of the purging gas into the Ex pzchousing and the pressurized enclosure control unit FS840 should be located as far away to each other as possible (body diagonal), to achieve a proper purging of the complete housing.

4The pressure loss at the solenoid valve must not be higher than 500 mbar, while prepurging phase.

2.5Temperature class of the Ex pzchousing

The installer has to define the maximum ambient temperature and the resulting maximum temperature class of the Ex pzchousing.

To determine the temperature class, measure, on worst conditions, the hottest point on the surface of the Ex pzchousing and recalculate it to the maximum ambient temperature. The minimum temperature class is the one of the FS840 and its surface temperature.

If some parts inside of the housing get hotter than the temperature class, the installer has to determine the time in which the temperature of those parts falls below the temperature class. He has to place a sign on the Ex pzchousing with the following sentence:

ATTENTION – ALL DOORS AND WINDOWS SHALL NOT BE OPENED UNTIL X

MINUTES AFTER DEENERGIZING.

X is the determined cooling-time that is needed to cool down hot surfaces lower than the temperature limit for the corresponding temperature class.

2.6Particular requirements in Zone 22 (Dust - Ex)

2.6.1Purging-phase / Cleaning of the housing

For the application in the zone 22 the FS840 must not initialize a pre purging phase. Therefore, the automatic purging at the controller FS840 has to be deactivated (Purging = No).

The purging phase before the start-up of the inserted, electrical non-ex equipment, upstream within the gas ex range, is replaced in the zone 22 by inside cleaning the housing.

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2.6.2Marking in the housing

On the housing has to be the following marking in a well visible place:

WARNING – REMOVE ALL DUST FROM INSIDE OF THE ENCLOSURE BEFORE CON-

NECTING OR RESTORING THE ELECTRICAL SUPPLY!

2.6.3Special conditions in the manual of the Ex pzcsystem (Zone 22)

In the manual for Ex p- applications for the zone 22 the following items are supplemented:

The use of the Ex p- application within the zone 22 must take place without pre purging phase. The automatic purging at the controller FS840 has to be therefore always deactivated.

The system may be operated not with a single solenoid valve, but only with a leakage balance mechanism without flushing attitude, e.g. SD840 throttle.

Before start-up of the ignition capable apparatus, the inside of the housing has to be cleaned completely.

The protective class of the Ex pzchousing in dust explosive area with not leading-capable dust has to be at least to IP5X, with leading-capable dust at least IP6X.

2.7Introduction: Pressurized enclosure system F840 with protection pzc

The use of simplified pressurized enclosures allows the operation of ‘non explosion protected’ devices in hazardous areas inside zones 2 + 22. The protection type ‘pressurization’ is based on the principle of maintaining a constant pressure using air or a protective gas to prevent an explosive mixture forming near the apparatus inside the pressurized enclosure. This is achieved by operating the unit in a pressurized enclosure (Ex pzcenclosure) and protecting it from the ingress of explosive gas mixtures by a continuous overpressure with air or an inert gas.

The control unit FS840 provides all necessary functions to install a pressurized enclosure system according IEC/EN 60079-14 and IEC/EN 60079-2 „pzc“: The FS840 measures the internal pressure and alarms or powers off, if the pressure is below the predefined minimum pressure.

Optional the FS840 can also pre purge the housing before automatic powering on the housing. In this case connect a digital working 2/2 way solenoid valve to the appropriate terminals. The solenoid must have a separate certification for zone 2.

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The purge medium that flows in through the valve is blown through the air outlet in the FS840 into the ambient Ex atmosphere. The air outlet is conform to IEC/EN 60079-2 designed and contains the needed spark barrier.

2.8Relation between FS830 and FS840

The pressurized enclosure system control units are certified in the same type examination certificate. The special conditions are written in the type examination certificate.

2.9Purging phase

2.9.1Pressurized enclosure system without prepurging

If the operator is sure, that the atmosphere inside of the enclosure and the appropriate pipe infrastructure is below 25% of the lower explosive limit (LEL) at power up, he can abandon the prepurging of the enclosure in zone 2. In that case the FS840 monitors only the pressure inside of the enclosure of 0.8 mbar at minimum and maximal 22 or 27 mbar at maximum. If any limit is exceeded, the FS840 changes the state on the potential free relay contacts.

The purge medium flows through an adjustable sinter metal throttle into the Ex pzchousing while reducing its pressure.

The FS840 has a mechanical output valve which opens at approximately 5 mbar to let the purge medium out. Before this valve is a spark barrier located thus the purge medium can be exhausted directly to the hazardous area.

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2.9.2Pressurized enclosure system with prepurging

To prepurge the Ex pzchousing connect a digital working 2/2 way solenoid valve to the control unit that switches between purging and pressure maintenance. In the valve is a nozzle integrated to reduce the prepressure and also an adjustable bypass-throttle. For purging, the valve opens and purge air flows through the nozzle into the Ex pzchousing. After prepurging the valve closes automatically and the adjustable throttle of the SVD.L lets a small amount of purge medium into the housing to hold the pressure.

The installer can determine the prepurging time once by doing the attenuation test according IEC/EN 60079-2.

As an alternative he can calculate the purging time without the elaborate attenuation test see below:

The purging time depends on minimum flow (Qmin), free internal volume (V) and the free volume of the connected pipes (Va). Final the calculated time must be multiplied by 10. The purging time tpurge is:

	t purge =	10 ×(V +Va)
		Qmin

The minimum flow (Qmin) depends on the minimum pre pressure (Ppremin), the pressure lost at the valve (PValve), internal pressure of the Ex pzchousing (PInt) and the nozzle diameter

(d). The pressure lost at the valve (PValve) should not exceed 500 mbar. The maximum internal pressure of the housing is defined to be less than 25 mbar. The minimum flow Qmin

can be calculated by:

Q =	2 ×(Ppre min − PValve − PInt )	×	d 2	×π
min	ρ			4

ρ is the density of the purging medium. The density of air is ρ =1,293 kg/m3, the density of nitrogen is 1,25 kg/m3. We calculate the ρ of air for all gases, because the difference is only 3%.

The installer can calculate the purging time of his own or he can use the automatic calculation in the menu of the FS840 (see 4.7)

Example:

kg

m

m

2×(2 −0,5 −0,025)

×10

5

s2

0,0022 ×m2 ×π

kg

Q

=

m2

×

,

mit 1 bar =105

s2

kg

4

m2

Beispiel

1,293

m3

QBeispiel ≈ 0,0015 ms 3 ≈1,5 sl

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2.10Operation mode Leakage compensation

The FS840 works after the prepurging phase or without pre purging phase immediately after the voltage supply in the mode of operation "leakage compensation ".

In this mode of operation will maintain after an overpressure (at least 0.8 mbar) within the Ex pzccabinet. This cabinet minimum pressure as well as also a cabinet maximum pressure are programmable and are monitored constantly.

Leakage losses are compensated by a small bypass. This bypass is integrated in the valve and mechanically adjustable (diameter 0,3 ... 1 mm).

2.11Conformity with Standards

The Ex certified control unit FS840 fulfills the requirements of listed standards in the attachment (Declaration of conformity). It is developed, manufactured and tested in accordance with state-of-the-art engineering practice and ISO9001:2015.

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3 Mounting and connection

3.1Mounting

3.1.1Control unit FS840

The control unit FS840 is suitable for mounting in hazardous area zones 2 / 22. The installer can place it at the outside of the Ex pzchousing, the position is arbitrary.

The installer can mount the control unit using the 4 mounting holes in the housing rear, but the fixing on the air inor outlet is sufficient.

While mounting, observe local safety guidelines and the regulative: IEC/EN 60079-14.

CAUTION!

The reference output (=M5 internal thread at the left side of the control unit) must have contact to the ambient pressure.

If the control unit is placed into the Ex pzchousing, the reference output must be connected to the ambient with a pipe or tube.

CAUTION!

Additional see general requirements to pressurized enclosure system F830/840 (Chapter 2).

Additional regulations for mounting in GasEx- Zone

When the FS840 is used as a device of Gas Ex Group IIC, the pressurized enclosure must have at least degree of protection IP54.

CAUTION!

Additional regulations for mounting in DustEx- Zone

When the FS840 is used as a device of Dust Ex Group IIIB, the pressurized enclosure must have at least degree of protection IP5X.

CAUTION!

When the FS840 is used as a device of Dust Ex Group IIIC, the pressurized enclosure must have at least degree of protection IP6X.

CAUTION!

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3.1.2Sinter metal throttle SD840

While operation mode “leakage compensation” a small amount of purging gas enters through the sinter metal throttle SD840 into the Ex pzchousing to provide the desired overpressure. Dispensable purge gas will be exhausted at an overpressure of about 5 mbar through the integrated outlet valve of the control unit FS840.

3.1.3Optional solenoid valve for purging

The installer can mount the solenoid valve SVD.L.x-AIxx in or outside of the Ex pzchousing, see details from manufacturer documentation.

3.2Connection and Startup

3.2.1Connection details

When connecting the Ex e terminals, the following limits must be observed

Min. and Max. clamping torque	Min. 0,4 Nm
	Max. 0,5 Nm
Min. and Max. wire cross-section	Stiff: 0,2 – 2,5 mm²
	Flexible: 0,2 – 2,5 mm²

When connecting and commissioning, the following points should be observed

Mains VOLTAGE! Extreme caution is advised when handling this device. High electrical discharge is possible and can be fatal.

See installation regulative and the conformity statements BVS 15 ATEX E 048 X and IECEx BVS 15.0037 X.

Do not exceed terminal safety limits of each termi-

CAUTION! nal.

See limits in technical details or conformity statements.

The internal valve fuse must be adapted to the solenoid valve that is used.

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