JUMO ATH-EXx Operating Instructions Manual

ATH-EXx

Explosion-protected surface-mounted thermostat

for potentially explosive gas atmosphere Zone 1 and

potentially explosive dust atmosphere Zone 21

B 605051.0

Operating Instructions

2011-04-01/00379556

Please read these Operating Instructions before commissioning the instrument.
Keep the manual in a place that is accessible to all users at all times. Please
assist us to improve these operating instructions, where necessary. Your sug­gestions will be appreciated.

Phone[phone]
Fax [phone]

All necessary settings and, where appropriate, alterations inside the instrument
are described in these operating instructions. If any difficulties should still arise
during commissioning, you are asked not to carry out any unauthorized manip­ulations on the unit. You could endanger your rights under the instrument war­ranty! Please contact the nearest subsidiary or the head office in such a case.

Contents

Seite

1 Introduction ............................................................................... 5

1.1 Typographical conventions ...................................................................... 5

1.1.1 Warning signs .............................................................................................. 5

1.1.2 Note signs ................................................................................................... 5

1.2 Application ................................................................................................. 6

1.3 Ex marking ................................................................................................. 6

1.4 Safety notes ............................................................................................... 6

2 Instrument identification .......................................................... 7

2.1 Nameplate .................................................................................................. 7

2.2 Type designation ....................................................................................... 8

3 Mounting .................................................................................... 9

3.1 Dimensions ................................................................................................ 9

3.2 Opening the surface-mounting thermostat .......................................... 10

3.3 Fixing the surface-mounting thermostat .............................................. 10

3.4 Capillary / temperature probe / pocket ................................................. 10

3.4.1 General ...................................................................................................... 10

3.4.2 Approved probes and sheaths .................................................................. 10

3.5 Permissible operating conditions at the pocket .................................. 11

3.5.1 Probe mountings 20 and 22 ...................................................................... 11

3.5.2 Probe mountings 10, 15, 21, 60, 65 .......................................................... 14

3.6 Mounting the probe ................................................................................. 14

4 Installation ............................................................................... 15

4.1 Regulations and notes ............................................................................ 15

4.2 Electrical connection .............................................................................. 16

4.3 Connection diagrams ............................................................................. 16

5 Settings .................................................................................... 17

5.1 Limit setting ............................................................................................. 17

5.1.1 TW, STW, TB (code 7) ............................................................................... 17

5.1.2 STB (code 70) ........................................................................................... 17

5.1.3 TB, STB (code 7-F or 70-F) ....................................................................... 18

5.2 Resetting the TB or STB limiter ............................................................. 19

5.3 Self-monitoring (fail-safe) ....................................................................... 19

5.3.1 Response to a fracture of the measuring system ..................................... 19

5.3.2 Response to low temperature ................................................................... 19

6 Instrument description ........................................................... 20

6.1 Technical data ......................................................................................... 20

7 Appendix .................................................................................. 24

5

1 Introduction

1.1 Typographical conventions

1.1.1 Warning signs

1.1.2 Note signs

abc

1

Footnote

Footnotes are remarks that refer to specific points in the text. Footnotes
consist of two parts:

A marker in the text, and the footnote text.
The markers in the text are arranged as continuous superscript numbers.
The footnote text (in smaller typeface) is placed at the bottom of the page and

starts with a superscript number.

✱ Action

This symbol indicates that an action to be performed is described.
The individual steps are marked by this asterisk, e.g.
✱ Select setpoint

Danger

This symbol is used when there may be danger to personnel if the instruc­tions are ignored or not followed correctly!

Caution

This symbol is used when there may be damage to equipment if the instruc-
tions are ignored or not followed correctly!

Note
This symbol is used when your special attention is drawn to a remark.

Reference
This symbol refers to further information in other chapters or sections.

1 Introduction

6

1.2 Application

Depending on the version, the explosion-protected surface-mounting
thermostat type ATH-EXx can be used as a

■ TW temperature monitor

■ TB temperature limiter

■ STW fail-safe temperature monitor

■ STB break-proof protection temperature limiter

in areas with an explosion hazard caused by gases, vapors or mists, Zone 1 or
in areas with combustible dust or dust/air mixtures, Zone 21.

1.3 Ex marking

II 2G Ex ed IIC T5 bzw. T6

for potentially explosive gas atmospheres

II 2D Ex tD A21 IP65 T95°C bzw.T80°C

for potentially explosive dust atmospheres

Test certificate: PTB 03 ATEX 1187

CE marking and No. of notified body: CE 0044.

1.4 Safety notes

Physical and toxicological properties of the substances that may escape in the
event of a system fracture.

– = no; X = yes

If this surface-mounting thermostat is used inside the hazardous area, the
relevant regulations for mounting and operating equipment in such an area
must be observed.

Cutting through or kinking the capillary of the surface-mounting thermostat,
type ATH-EXx, will result in permanent failure of the instrument!

Only use the ATH-EXx with TZ 679 in areas that are classified as areas with
low mechanical risk.

Filling liquid may escape in the event of a measuring system fracture. At present there is
no restrictive statement from the health authorities concerning any danger to health over
short periods and at low concentration, e.g. after a fracture of the measuring system.

End of scale°CDanger-

ous

reaction

Fire and

explosion hazard

Water

conta-

mination

Toxicological data

Ignition

temp.

°C

Explosion

limit

% v/v

irritant danger to

health

toxic

< +200°C – +355°C 0,6 - 8 V X X X –

 +200°C

 +350°C

– +490°C - - X X X –

> 350°C

 +500°C

– – – ––––

7

2 Instrument identification

2.1 Nameplate

( 1 ) Type ➩ Chapter 2.2 "Type designation", page 8
( 2 ) Type code
( 3 ) Control range or limit value range / ambient temperature at which this

thermostat was calibrated (option)
( 4 ) Ex-protection marking
( 5 ) Testing laboratory / certification
( 6 ) Switching capacity
( 7 ) Permissible ambient temperature
( 8 ) Serial number
( 9 ) Year of production
(10) Week of production
(11) Running serial device number
(12) Extra code

( 4 )

( 3 )

( 2 )

( 1 )

( 5 )

( 6 )

( 8 )

( 9 )

(10)

(11)

( 7 )

( 12 )

2 Instrument identification

8

2.2 Type designation

ATH- EX x- . . - .
ATH Surface-mounting thermostat (with capillary)

ATH- EXx Marking for explosion-protected version
ATH- EX x- ..-. Code number for the function:

2=0Temperature monitor (TW)

with changeover contact.
Limit adjustable within the housing.

7=0Temperature limiter (TB)

with changeover contact and restart lock-out.
Limit adjustable within the housing.

7-F =0Temperature limiter (TB)

with changeover contact and restart lock-out.
Limit is factory-set.

20 =0Fail-safe temperature monitor (STW)

with changeover contact.
Limit adjustable within the housing.

70 =0Break-proof protection temperature limiter (STB)

with change-over contact and restart inhibit.
The limit value can be set by the installing engineer–
before commissioning the plant – within the housing.

70-F =0Break-proof protection temperature limiter (STB)

with change-over contact and restart inhibit.
Limit value set to a fixed value at the factory.

ATH- EX x- . . - .F=0Designation for factory-set limit setting.

Extra code (TZ) 679: Min. operating temperature: -50°C

9

3 Mounting

3.1 Dimensions

90

d

122

120

82

6.4

10.4

106

L

29

25

( 1 )

( 2 )

( 1.1 )

( 1.2 )

( 7 )

( 5 )

( 6 )

( 4 )

( 3 )

(1) Ex cable gland M 20 x 1.5 x 6-12
(1.1) Screw-in thread Tightening torque: 3,75 Nm
(1.2) Compression screw Tightening torque: for cable dia. 06mm=3.5Nm

Tightening torque: for cable dia. 12 mm = 2.5 Nm
(2) Cover screws
(3) Cover
(4) Housing base
(5) Drilling diagram
(6) Ex cable gland for sealing the capillary exit
(7) Temperature probe

3 Mounting

10

3.2 Opening the surface-mounting thermostat

✱ Unscrew the 4 cover screws (2)
✱ Remove cover (3) with seal (not visible)

3.3 Fixing the surface-mounting thermostat

Mounting
position

To DIN 16257, NL 0 — NL 90 (other NL on request)

✱ Drill fixing holes according to the drilling diagram.
✱ Use the 4 screws to secure the housing base.

3.4 Capillary / temperature probe / pocket

3.4.1 General

3.4.2 Approved probes and sheaths

see current data sheet 606710

Make sure that the seal is seated correctly when reassembling!

Cutting through or kinking the capillary of the surface-mounting thermostat will
lead to permanent instrument failure!

Minimum permissible bending radius of the capillary is 5 mm.
The temperature probe must be mounted in a JUMO pocket, otherwise the

approval of the surface-mounting thermostat becomes invalid.

The temperature probe must completely immersed in the medium to be
measured.

To ensure their overall accuracy, the thermostats must only be used together
with the pockets supplied by the factory (diameter D = 8, 10 or 15 mm).

Pockets with a diameter D = 10 mm must only be fitted with probes with
diameter d = 8 mm.

Fitting several probes into a common pocket is only permitted with 2 or 3
probes (mounting type "10", diameter d = 6 mm) and 15 x 0.75 mm pockets.
When fitting 2 probes in a common pocket, the factory-supplied spring clip
must be fitted in the pocket.

For operation in air, probe mounting type "10" (without pocket) must be cho­sen.

11

3 Mounting

3.5 Permissible operating conditions at the pocket

3.5.1 Probe mountings 20 and 22

3.5.1.1 Steel pockets

Materials Tube: St 35.8 I

Weld-in nipple: 16 Mo 3 (no turned groove)

Loading

The values given below refer to the maximum loading on the probe mounting
concerned. The maximum pressure which can be sealed depends on the
mounting conditions and may possibly be lower.

Temperature Tube diameter

8 x 0.75 mm or

conical

10 x 0.75 mm 15 x 0.75 mm

max. permissible

pressure

max. permissi-

ble pressure

max. permissi-

ble pressure
100°C 89 bar 72 bar 48 bar
150°C 83 bar 67 bar 45 bar
200°C 78 bar 63 bar 42 bar
300°C 59 bar 47 bar 32 bar
400°C 46 bar 37 bar 25 bar
450°C 24 bar 19 bar 13 bar

With operating temperatures above 420°C, the permissible operating time is
limited to 200,000 hours. TRD 508 must be observed in this respect.

3 Mounting

12

Permissible
incident flow
velocity

Permissible incident flow velocity “v” at the maximum permissible
pressure loading and different immersion tube lengths “S”

Permissible incident flow velocity “v” at the maximum permissible
pressure loading and different immersion tube temperatures “t”

Temperature: +200°C

Thermal medium:

air (1)
water, oil (2)

Tube diameter D:

08mm

10 mm
15 mm

13

3 Mounting

3.5.1.2 Stainless steel pocket

Materials Tube: X 6 CrNiMoTi 17122

Screw-in/weld-in nipple: X 6 CrNiMoTi 17122

Loading

Permissible
incident flow
velocity

on request

3.5.1.3 Brass pocket

Material CuZn (nickel-plated)

Loading

Permissible
incident flow
velocity

on request

Temperature Tube diameter

8 x 0.75 mm or

conical

10 x 0.75 mm 15 x 0.75 mm

max. permissible

pressure

max. permissi-

ble pressure

max. permissi-

ble pressure
100°C 92 bar 74 bar 50 bar
150°C 88 bar 71 bar 48 bar
200°C 83 bar 67 bar 45 bar
300°C 72 bar 58 bar 39 bar
400°C 67 bar 54 bar 36 bar

Temperature Tube diameter

8 x 0.75 mm 10 x 0.75 mm 15 x 0.75 mm

max. permissible

pressure

max. permissi-

ble pressure

max. permissi-

ble pressure
100°C 50 bar 40 bar 27 bar
150°C 48 bar 39 bar 26 bar

3 Mounting

14

3.5.2 Probe mountings 10, 15, 21, 60, 65

Materials Choice of steel, stainless steel or brass

Loading Only for use in unpressurized media.

*

depending on the control range

3.6 Mounting the probe

Probe mounting 15 60, 65 10, 21
Maximum temperature +55°C +200°C

*

+500°C

*

The temperature probe (2) must be immersed in the medium for its entire
length, otherwise there will be appreciable deviations from the switching point.

In the case of probe mountings 20, 21 and 23, the temperature probe is
secured in the pocket by a clamping clip (1).

( 1 )

( 2 )

15

4 Installation

4.1 Regulations and notes

■ The electrical connection must only be carried out by qualified personnel.

■ The choice of cable, the installation and the electrical connection must

conform to the requirements of VDE 0100 “Regulations on the Installation
of Power Circuits with Nominal Voltages below 1000 V” or the appropriate
local regulations.

■ If contact with live parts is possible while working on the instrument, it must
be completely disconnected from the electrical supply.

■ Earth the instrument at the PE terminal to the protective earth conductor.
This cable must have at least the same cross-section as used for the supply
cables. Earthing cables must be wired in a star configuration to a common
earth point that is connected to the protective earth conductor of the
electrical supply. Do not loop earthing cables, i.e. do not run them from one
instrument to another.

■ Apart from faulty installation, incorrect settings on the thermostat can also
affect the proper functioning of the subsequent process or lead to damage.
Setting up must therefore be restricted to qualified personnel. Please
observe the relevant safety regulations for such matters.

In case of electrical connections in a potentially explosive area, it is necessary
to comply with the relevant specifications.

4 Installation

16

4.2 Electrical connection

✱ Open the housing.

➩ "Opening the surface-mounting thermostat", page 9

✱ Pass the connection cable (cable diameter 6 to 12 mm) through the Ex

cable compression gland (1).

➩ "Dimensions", page 8

✱ Make the connection to the terminals (2) in accordance with the connection

diagram.

✱ Fitting type X (no special tools).
✱ The connecting cable must have a fixed installation

✱ Position the connecting cable in the housing and tighten the Ex cable com-

pression gland (1), using the tightening torque given below:
➩ "Dimensions", page 8.

4.3 Connection diagrams

✱ Connect the protective earth conductor to the PE terminal.

Screw-in thread (1.1) into housing = 3.75 Nm
Compression screw (1.2). = 3.50 Nm for 06 mm cable diameter
Compression screw (1.2). = 2.50 Nm for 12 mm cable diameter

Ensure that connection line for operating temperatures up to -50°C
are low-temperature resistant.

TW / STW

TB / STB

2

4L12

4

1

PE N

12

4

42

L1

N

N

PE

PE

*

1

42

142

(2)

NPE

1

4

2

4L12

17

5 Settings

5.1 Limit setting

5.1.1 TW, STW, TB (code 7)

✱ Open the housing.

➩ "Opening the surface-mounting thermostat", page 9

✱ Set the limit on the setpoint spindle (1).

5.1.2 STB (code 70)

Setting the limit
according to
the scale

✱ Open the housing.

➩ "Opening the surface-mounting thermostat", page 9

✱ Set the limit on the setpoint spindle (1) against the internal scale.
✱ Secure this setting by sealing the setpoint spindle ( 1 ), for instance with

“red” thread sealing wax, temperature resistant to at least +80°C)

05

05

°C

( 1 )

Important note for setup and operation!

When the thermostat is used as a safety device for explosion protection in
accordance with EU Directive 94/9/EC Annex II Sec. 1.5, a functional test is
required that conforms to the applicable regulations.

The switching point must be fixed by the installation engineer after thermally
testing individual items, and secured against alteration. Several aspects
must be observed:

- the probe geometry and thermal coupling

- the maximum ambient temperature

- the maximum product temperature

5 Settings

18

Setting the lim­its according to
specific system
characteristic

✱ Open the housing. ➩ "Opening the surface-mounting thermostat", page 9
✱ Warm up the temperature probe – in the system – to the intended limit

temperature (allow at least 5 minutes for the temperature to equalize), while
using a calibrated reference measuring device to measure and observe the
precise temperature at the temperature probe.

✱ Determine the required switching position (circuit 1-4 opens and circuit 1-2

closes) by rotating the setpoint spindle ( 1 ) from the end of the scale in the
direction of the start of the scale.

✱ Secure this setting by sealing the setpoint spindle ( 1 ), for instance with

“red” thread sealing wax, temperature resistant to at least +80°C.

A = secure the limit setting by sealing the setpoint spindle

with “red” thread sealing wax.

( 2 ) reset arm

5.1.3 TB, STB (code 7-F or 70-F)

(A)

(1)

(1)

(2)

Important note for setup and operation!

When the thermostat is used as a safety device for explosion protection in
accordance with EU Directive 94/9/EC Annex II Sec. 1.5, a functional test is
required that conforms to the applicable regulations.

In addition, suitable measures (such as calculation, thermal testing of
individual items) must be used to document that the switching point set by the
manufacturer prevents the temperature exceeding the given limit. The specific
local and operating conditions must be taken into account, such as:

- the probe geometry and thermal coupling

- the maximum ambient temperature

- the maximum product temperature

- The limit setting is fixed at the factory.

- Alteration is not permitted.

19

5 Settings

5.2 Resetting the TB or STB limiter

If the temperature at the probe goes above the limit that has been set, the
electrical circuit 1-4 is opened and remains mechanically locked out. When the
critical temperature has fallen to about 9-15% below the set limit, the TB or
STB can be reset manually.

✱ Open the housing.

➩ "Opening the surface-mounting thermostat", page 9

✱ Press the reset arm ( 2 ) in the direction of the arrow.

➩ "( 2 ) reset arm", page 18

5.3 Self-monitoring (fail-safe)

5.3.1 Response to a fracture of the measuring system

5.3.2 Response to low temperature

On the STW or STB, in the event of a fracture of the measuring system (leakage)
the circuit 1-4 will remain permanently open.

On the STB, the microswitch is also mechanically and permanently locked out.

If the probe temperature of approx. -30°C (-60°C for the TZ 679) of the STW
and STB is gone below, the power circuit is opened.

When the temperature rises above the minimum probe temperature, the STW
resets itself automatically. The STB requires a manual reset.

➩ "Resetting the TB or STB limiter", page 19

20

6 Instrument description

6.1 Technical data

Ex
marking

II 2G Ex ed IIC T5 bzw. T6

for potentially explosive gas atmospheres

II 2D Ex tD A21 IP65 T95°C bzw. T80°C

for potentially explosive dust atmospheres

Explosion
protection

II 2G Equipment group II, Category 2,

equipment for potentially explosive gas atmospheres

II 2D Equipment group II, Category 2,

equipment for potentially explosive dust atmospheres

Explosion
protection type

Ex General requirements

European Standard EN 60079-0

e Increased safety

European Standard EN 60079-7

d Flameproof enclosure

European Standard EN 60079-1

IIC Gas group
T5 or T6 Temperature class

Application in combustible dusts

European Standard EN 61241-0

EN 61241-1

IP65 Protection to EN 60529-IP65
T95°C or T80°C max. permissible surface temperature

(application in combustible dusts)

Te st
certificate

PTB 03 ATEX 1187

21

6 Instrument description

Permissible
ambient tem­perature in
operation

Max operating temperature of the cable screw-connection for the TZ 679:
70°C.

Permissible
probe tempera­ture

max. limit +15% (+550°C with limit > 450°C)

Permissible stor­age
temperature

max. +50°C, min. -20°C
max. +50°C, min. -50°C et TZ 679

Connecting
cable

diameter 6 to 12 mm, conductor cross-section up to 2.5 mm

2

Switching dif­ferential

in % of control/
limit range

Contact rating

Fusing required see contact rating

Capillary

°C

Thermostat head °C

T6 T5

max. +40 +40

+55 +55

min. -20 (-50 et TZ 679)

Thermostats with end of scale

 350°C

Thermostats with end of scale

 350°C

Switching

action

Nominal

value

Possible

actual

value

Switching

action

Nominal

value

Possible

actual

value

TW 3 3-5 TW 5 5-9

STW 5 5-7 STW 6 6-11

TB / STB – – – – TB / STB – – – –

TW, STW

Terminals 1-4 (break) Terminals 1-2 (make)
AC1: 230 V +10%, 10 A AC1: 230 V +10%, 5 A
AC15: 230 V +10%, 2 A AC15: 230 V +10%, 0.8 A

DC1: 230 V +10%, 0.25 A

TB, STB

Terminals 1-4 (break) Terminals 1-2 (make)
AC1: 230 V +10%, 16 A AC1: 230 V +10%, 10 A
AC15: 230 V +10%, 2 A AC15: 230 V +10%, 1.5 A

DC1: 230 V +10%, 0.25 A

6 Instrument description

22

Enclosure pro­tection

EN 60 529 - IP 65

Operating
medium

Water, oil, air, superheated steam

Time constant
t

0.632

Mode of opera­tion

according to EN 60 730-1
TW,TB: Type 2BL = automatic action with micro-disconnection in

operation, no auxiliary supply required.

STW: Type 2BKL = automatic action with micro-disconnection in

operation, fail-safe.

STB: Type 2BFKL = automatic action with micro-disconnection in

operation, fail-safe, reset only permissible by means of a tool.

Operating posi­tion (NL)

To DIN 16257, NL 0 — NL 90 (other NL on request)

Weight approx. 1.2 kg

Capillary and
probe material

Min. bending
radius of the
capillary

5mm

in water in oil in air / superheated

steam

 45 s  60 s  120 s

End of scale Capillary Probe
up to +200°C copper, Mat. Ref. 2.0090

electro-tinned

1.5 mm diameter

copper, Mat. Ref. 2.0090
electro-tinned
brazed

up to +300°C copper, Mat. Ref. 2.0090

electro-tinned

1.5 mm diameter

stainless steel,
Mat. Ref. 1.4571
brazed

up to +500°C stainless steel,

Mat. Ref. 1.4571

1.5 mm diameter

stainless steel,
Mat. Ref. 1.4571
welded

up to +300°C stainless steel,

Mat. Ref. 1.4571

1.5 mm diameter

stainless steel,
Mat. Ref. 1.4571
welded

23

6 Instrument description

Switching point
accuracy

in % of scale span, referred to the limit value at Ta +22°C.

Mean ambient
temperature
effect

in % of scale span, referred to the limit value.
A deviation of the ambient temperature at the thermostat head and/or the cap-

illary from the +22°C calibration ambient temperature produces a shift in the
switching point:
higher ambient temperature = lower switching point
lower ambient temperature = higher switching point

TW, TB

in upper third of scale

+0

%

-4

at start of scale

+0

%

-6

STW, STB

in upper third of scale

+0

%

-5

at start of scale

+0

%

-7

Surface-mounting thermostats with end of scale

< +200°C  +200°C  +350°C > 350°C

TW

TB

STW

STB

TW

TB

STW

STB

TW

TB

STW

STB

effect due to the thermostat head, % per °C

0.08%/K 0.17%/K 0.06%/K 0.13%/K 0.14%/K 0.12%/K
effect due to capillary, % per °C per meter

0.047%/K 0.054%/K 0.09%/K 0.11%/K 0.04%/K 0.03%/K

24

7 Appendix

25

7 Appendix

7 Appendix

26

27

7 Appendix

7 Appendix

28

29

7 Appendix

7 Appendix

30

JUMO GmbH & Co. KG

Street address:
Moritz-Juchheim-Straße 1
36039 Fulda, Germany
Delivery address:
Mackenrodtstraße 14
36039 Fulda, Germany
Postal address:
36035 Fulda, Germany
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]
Internet: www.jumo.net

JUMO Instrument Co. Ltd.

JUMO House
Temple Bank, Riverway
Harlow, Essex CM20 2TT, UK
Phone: [phone]
Fax: [phone]
e-mail: [e-mail]
Internet: www.jumo.co.uk

JUMO Process Control, Inc.

8 Technology Boulevard
Canastota, NY 13032, USA
Phone: [phone]

1-800-554-JUMO
Fax: [phone]
e-mail:

[e-mail]
Internet: www.jumo.us