ATEX 05 11
Contents
1. 12 Appendix 2 MAX PRESSURE VALUES ALL MODELS Models Discharge Inlet any prefix letter Pressure Pressure 20 Series 100 bar 7 bar 70 bar max G20 F20 17 bar max non metallic heads 3 Series 83 17 bar 70 bar max X cams 17 bar max non metallic heads 10 12 Series 70 bar 17 bar 17 bar max non metallic heads 15 17 Series 170 bar 25 Series 70 bar 17 bar 17 bar max non metallic heads 13 Appendix 3 Manufacturer s approach Wanner Hydra Cell Industrial Pump Range for ATEX Group II Categories 2 amp 3 Preliminary observations A Technological knowledge which can change rapidly must be taken into account as far as possible and be utilised immediately B For the devices referred to in articles 1 2 the essential requirements shall apply only in so far as they are necessary for the safe and reliable functioning and operation of these devices with respect to the risk of explosion 1 COMMON REQUIREMENTS FOR EQUIPMENT AND PROTECTIVE SYSTEMS 1 0 1 0 1 General requirements Principles of integrated explosion safety Equipment and protective systems intended for use in potentially explosive atmospheres must be designed from the point of view of integrated explosion safety In this connection the manufacturer must take measures above all if possible to prevent the formation of explosive atmospheres which may be produced or released by equipment and by protective systems themselves to prevent the2. The two Low level switches must be wired independently to their own individual IS Barrier circuit whilst the two High Level switches can be wired in series or parallel to a common IS Barrier circuit The Low level switches are the most critical to ensure liquid is always present in the pump housing Accordingly ATEX Regulations demand that all critical sensors are duplicated hence two switches must be employed However the High level switches are not so critical and simply prevent over fill and spillage of liquid from the oil reservoir bowl therefore one switch is effectively redundant and can be used as a spare in the event of a switch failure see appendix 5 Approved circuit drawing All switches should operate from a normally closed position LL low level opens when oil level decreases LH high level opens when oil level rises All switches should operate from a normally closed position Float level switch specs Voltage Free switches held in place by a Noble metal magnet normally closed position Type Reed switches 30VA rating SPST with Rhodium contacts SS 316 stem No current is required to operate switch When magnet moves away due to oil level change switch will open indicating a fault 4b Oil Level Sight Bowl Category 3 Zone 2 This category covers areas where an explosive atmosphere is less likely to occur and does not demand that an automatically actuated protective system be installed
3. Accordingly a simple oil level sight bowl can be fitted see appendix 8 In this case the end user must take responsibility to ensure oil is always present in the pump hydraulic end by physically monitoring the level in the sight bowl ELECTROSTATIC DISCHARGE The oil level sight bowl has a top and bottom support plate made of Aluminium and a clear Acrylic sight bowl Reference is therefore made to an extract from EN 13463 1 2001 E Section 7 4 4 in order to verify that the exposed area of acrylic is within the recommendations for non conductive parts see appendix 7 5a Markings of Conformity Category 2 Zone 1 All ATEX nameplates are fixed via pop rivets to the main pump housing Material is stainless steel plate with markings clearly engraved The pump s unique serial number and model configuration is stamped onto the standard nameplate during manufacture before supply ATEX nameplates contain following markings EEx k ia IIB T4 130 C 10 40 C 4 CE 2004 Ex Il 2G D OUTSIDE Il 3G INSIDE Max PROCESS 90 C CERT No ITSO4ATEX11919 Depending on the Hydra Cell pump Series supplied then a particular design of nameplate is fitted see following drawing references WI ATEX 1035 3 4 10 12 15 17 25 35 Series WI ATEX 2021 20 Series markings WI ATEX 2221 20 Series support block 5b Markings of Conformity Category 3 Zone 2 All ATEX nameplates are fixed via pop rivets to the main pump housing Material is
4. agency called Intertek ETL SEMKO in order to obtain ATEX Certification for Hydra Cell pumps carrying out a comprehensive risk assessment and compiling the Technical File Intertek ETL SEMKO is accredited by UKAS the UK Accreditation Service and authorised to carry out product safety testing and Certification of equipment under European Directives such as ATEX See appendix 1 Type Examination Certificate Hydra Cell pumps are approved for use in ATEX environments Category 2 zone 1 when installed with an oil level monitor unit or if the pumped liquid is deemed to be inert or non hazardous a flow meter can be employed to monitor the flow rate of the pump see appendix 4a CE MARKING Due to the changes made to the Machinery Directive 2006 42 EC all Hydra Cell pumps are supplied with the CE mark on the pump manufacturers label Certificate Number ITSO4ATEX11919 Category 2 Zone 1 Hydra Cell ATEX Certification covers the supply from Wanner International of bare shaft pumps only and not complete pump and electric motor sets 2 Operating Conditions The normal operating environment is an indoor or outdoor above ground industrial environment in which flammable dust could be present The intended external ambient operating temperature range is minus 10 C to 40 C The intended internal operating temperature range is minus 10 C to 90 C This is the maximum temperature range for Hydra Cell pumps with ATEX Certain
5. diaphragm materials have operating limits within this temperature range Contact Wanner International for more information and assistance Wanner International has obtained Type Certification for conditions outside the pump as follows CE Ex Il 2G amp D outside T4 amb max process temperature 90 C Group Il Zone 1 Category 2 G gasses amp D dust T4 135 C auto ignition temperature By designing equipment suitable for use in Category 2 Zone 1 areas operation in Category 3 Zone 2 area is also permitted Category 3 Zone 2 only Where the end user will take responsibility to ensure oil is always present in the pump hydraulic end then a simple oil level sight bowl can be fitted see appendix 8 The user must never start or continue running the pump when oil is not visible The pump is not intended to pump dusts but is intended for use in dust hazardous atmospheres 3 Drive Motors Hydra Cell ATEX Certification covers the supply from Wanner International of bare shaft pumps only and not complete pump and electric motor sets The supplier of the drive motor and motor control system must provide over current and short circuit protection that is capable of shutting down the pump before the motor produces more than 85 of the input power limit of the hydraulic end The input power limit can be calculated using the Hydra Cell standard power requirements formula see product specification sheets on website at maximum speed and
6. ignition of explosive atmospheres taking into account the nature of every electrical and non electrical source of ignition Should an explosion nevertheless occur which could directly or indirectly endanger persons and as the case may be domestic animals or property to halt it immediately and or to limit the range of explosion flames and explosion pressures to a sufficient level for safety 14 Appendix 4 Approximate capacities To cold fill level 180ml To Low cutout 100ml To High cutout 350ml 15 Cold fill level Appendix 5 Category 2 Zone 1 requirements Intrinsically Safe approved electrical connection drawing Please note Wanner does not supply any electrical box or electrical equipment only the cables connected to the level switches contacts normally closed Ui 15v li 300mA_ Pi 1 2w IS Intrinsically Safe Installation Diagram in accordance with EN50039 Note 1 Any single channel shunt Zener diode safety barrier certified by an EEC approved body to EE ia IIC and having the following or lower output parameters Uo 15y lo l5O0mA Po 0 56w The output current of the barrier must be limited by a resistor R such that lo Uo R All barriers must have same polarity SAFE AREA motor shut off Certified circuit IS Barrier See note 1 motor shut off Certified circuit IS Barrier motor shut off Certified circuit IS Barrier 16 HAZARDOUS AREA Appendix 6 Sugg
7. stainless steel plate with markings clearly engraved The pump s unique serial number and model configuration is stamped onto the standard nameplate during manufacture before supply ATEX nameplates contain following markings CE 2004 Ex II 3G D OUTSIDE EEx k ia IIB T4 130 C 10 40 C Il 3G INSIDE Max PROCESS 90 C Depending on the Hydra Cell pump Series supplied then a particular design of nameplate is fitted see following drawing references WI ATEX 1035Z2 3 4 10 12 15 17 25 35 Series WI ATEX 2021Z2 20 Series markings WI ATEX 2221 20 Series support block 6 Earthing Grounding An earth stud is fitted to each HydraCell F z ATEX certified pump and should be ee ee ven FASTENERS connected to ground during installation Every Hydra Cell ATEX certified pump with Oil Level Monitor or Oil Level Sight Bowl mounted in position is tested for earth continuity before despatch to the customer EARTH CONTINUITY CHECKS amp PROCEDURE Earth Continuity Device used Portable Appliance Tester PAT 5001 Equipment Class 1 Ser Nr 003401 Specifications mains 230v 50Hz max power 250 VA Fuse 2 amps Checking procedure 1 Cable A is clipped to the top of the oil bowl metal casing 2 Cable B is connected to the earth stud that is screwed into the main body of the pump 3 These cables are also plugged into the PAT device see appendix 7 4 The earth bond is then measured on the deflection meter
8. W WANNER INTERNATIONAL Wanner International and ATEX Directive 94 9 EC Covers Category 2 Zone 1 and Category 3 Zone 2 requirements Date of issue 9 07 Contents Page 1 Wanner International and the ATEX Directive 94 9 EC 4 2 Operating Conditions 5 3 Drive Motors 5 4 a Oil Level Monitor Unit Category 2 Zone 1 6 b Oil Level sight Bowl Category 3 Zone 2 5 a Markings of Conformity Category 2 Zone 1 7 b Markings of Conformity Category 3 Zone 2 6 Earthing Grounding 8 7 Pumpable Materials 9 8 Maintenance 10 9 General notes 10 Appendix 1 Copy of Certificate 1 Appendix 2 Max pressure values all models 13 Appendix 3 Manufacturers approach 14 Appendix 4 Schematic of oil level monitoring unit 15 Appendix 5 Circuit diagrams Oil level monitoring units 16 Appendix 6 Filling oil reservoir bowl 17 Appendix 7 Portable Appliance Tester 18 Appendix 8 Oil Level sight Bowl 19 1 Wanner International and the ATEX Directive 94 9 EC ATEX Directive 94 9 EC is a directive adopted by the European Union EU to harmonise the technical and legal requirements in the Member States for products intended for use in potentially explosive atmospheres The Directive covers electrical and non electrical equipment and became mandatory in July 2003 when adopted by the EU The Directives are known as ATEX from the French ATmospheres EXplosibles Wanner International Ltd has worked with an outside specialist
9. an oil filled gear chamber hydraulic end An intrinsically safe IS oil level system is used to ensure that the hydraulic end is completely filled with oil The IS barrier parameters and connection details are shown in the Installation Instructions An external earthing facility is provided The Labels to be applied to each range are Drawing WI ATEX 1035 for Series 3 4 10 12 15 17 25 and 35 Drawing WI 2021 for Series 20 16 FILE REFERENCE Intertek Ref 03010842 17 SPECIAL CONDITIONS FOR SAFE USE None 18 ESSENTIAL HEALTH AND SAFETY REQUIREMENTS EHSR S The relevant EHSR s have been identified and assessed for compliance supporting information is held in the Technical Dossier 19 DOCUMENTS Document Description Product Description Data Sheets Industrial Pump Selection Manual 20 VARIATION ONE Removal of the requirement to fit oil level monitoring when used to pump non flammable liquids The requirement to maintain a regular manual level check remains as identified in the manual Intertek Testing amp Certification Limited Intertek House Cleeve Road Leatherhead Surrey KT22 7SB Tel 44 0 1372 370900 Fax 44 0 1372 370977 http www uk intertek etlsemko com Registered No 3272281 Registered Office 25 Savile Row London WIX 1AA This Certificate is the property of Intertek Testing and Certification Ltd and is subject to Intertek Testing and Certification Conditions for Granting Certification Sheet 2 of 2
10. ent or protective system is subject to special conditions for safe use specified in the schedule to this certificate This Type Examination Certificate relates only to the design examination and tests of the specified equipment or protective system in accordance to the directive 94 9 EC Further requirements of the Directive apply to the manufacturing process and supply of this equipment or protective system These are not covered by this certificate The marking of the equipment or protective system shall include the following Ex 112GD Outside I3 G 130 C Inside EEx k ia IIB T4 130 C T amb 10 C to 40 C maximum process temperature 90 C A TO A x ELA AT Intertek Testing amp Certification Limited A T Austin Intertek House Cleeve Road Leatherhead Surrey KT22 75B Certification Engineer Tel 44 0 1372 370900 Fax 44 0 1372 370977 7 April 2011 hitp Avww uk intertek com Registered No 3272281 Registered Office 25 Savile Row London WIX 1AA This certificate may only be reproduced in its entirety and without any change schedule included and is subject to Intertek Testing and Certification Conditions for Granting Certification Sheet 1 of 2 Intertek 13 Schedule 14 TYPE EXAMINATION CERTIFICATE NUMBER ITSO4ATEX11919 Issue 2 15 DESCRIPTION OF EQUIPMENT OR PROTECTIVE SYSTEM HYDRA CELL RANGE OF PUMPS comprising Series 3 4 10 12 15 17 20 25 and 35 each pump consists of a wet pump chamber and
11. ested procedure for fitting and filling oil reservoir bowl 1 Typical mean oil level in pump reservoir 2 When fitting oil reservoir bowl remove red oil filler cap fill the pump housing to max capacity and replace with oil level monitor unit WI ATEX LSO1 or AO1 116 3400 Screw into pump body until sealed against O ring 3 Fill to level indicated on the oil level label Note this is a guide only and allowance should be made for expansion and contraction of oil during operation 17 Appendix 7 D Portable Appliance Tester Dat S001 I 1 g E ict 110V 16A Test Mains Supply Monitor K OV 13 A Test Appendix 8 Oil Reservoir Sight Bottles Oil reservoir assemblies easily screw in where the oil fill cap is located on all Hydra Cell pump models D G 03 and larger Pumps equipped with an oil reservoir provides more volume for oil expansion and allows for quick visual monitoring of the oil level and its condition Three different reservoir bottles are available The low level floatswitch in the 16 oz bottle outputs a low voltage signal in the event the oil level in the pump housing drops Oil Reservoir Sight Bottles 16 oz 474 ml volume sight bottle 16 oz 474 ml volume sight bottle with low level float switch Part Number A01 116 3400 A01 116 3410 A oz 119 ml volume sight bottle A01 116 3500 19 Wi WANNER INTERNATIONAL LTD 8 9 Fleet Business Park Sandy La
12. installed in an ATEX defined area Zone 1 the working condition of the pump can be safely monitored using a flow meter to monitor the flow rate of the pump The flow meter must be continually monitored and give the operator a signal if the flow rate of the pump drops more than 10 below the expected flow rate from the pump at the running speed An oil sight bowl will be supplied and must be fitted to facilitate a visual check that the oil is present and monitor its condition PUMPING HAZARDOUS LIQUIDS For pumping liquids that are regarded as hazardous whether they are flammable toxic or corrosive an oil level monitor must be used to continually monitor the oil level in the pump An ATEX approved Intrinsically Safe IS oil level monitoring device is available from Wanner International The Wanner Oil Level Monitor or Protective System is mentioned and included in the ATEX Type Certification See appendix 1 This Type Certification allows us to offer our Protective System with every Hydra Cell ATEX pump without the need for additional certification 5 ELECTROSTATIC DISCHARGE The oil level monitor has a top and bottom support plate made of Aluminium and a clear Acrylic sight bowl Reference is therefore made to an extract from EN 13463 1 2001 E Section 7 4 4 in order to verify that the exposed area of acrylic is within the recommendations for non conductive parts see appendix 7 ATEX INTRINSICALLY SAFE IS CIRCUIT
13. listed and should NOT be pumped Mixing of corrosive and or aggressive chemicals should be avoided Hydrogen Sulphide HS reacts adversely with SS 304 and 316 Care must be taken when selecting materials from Hydra Cell s standard options 8 Maintenance As part of the regular maintenance procedure the following routine checks must be made Please refer to the Hydra Cell Installation Service Manual and supplements for more detailed instructions on maintenance and checking methods 1 Wanner Oil Level Monitoring Unit check oil level periodically 2 Wanner Oil Level Monitoring Unit check is functioning as intended 3 Wanner Oil Level Sight Bowl check oil level daily 4 Pressure relief by pass valve is functioning as intended 5 All head and casing bolts are secured refer to torque values 6 Check for electrical earth continuity 7 Check the integrity of the external shaft seals and pump head O rings 8 Check the hydraulic end to determine whether replacement bearings are required 9 General Notes Lubricating oil should be changed in accordance with guidelines stated in the pump Installation Service manual The type of oil recommended and the frequency of oil change will vary in accordance with the pump materials of construction the model the duty speed and pressure and liquid temperature Hydra Cell Pumps are not suitable for total immersion in liquid Only genuine replacement parts and mechanical comp
14. ne Church Crookham Hampshire UK GU52 8BF Telephone 44 O 1252 816 847 Facsimile 44 0 1252 629 242 e mail sales wannerint com web www wannerint com WANNER PUMPS LTD Room 1111 11 F New Kowloon Plaza 38 Tai Kok Tsui Road Tai Kok Tsui Kowloon HONG KONG Tel 852 3428 6534 Fax 852 3188 9145 email jloo wannereng com WANNER ENGINEERING INC 1204 Chestnut Avenue Minneapolis MN 55403 USA Tel 612 332 5681 Fax 612 332 6937 e mail phage wannereng com web www WannerEng com
15. onents must be used because only genuine parts will have the chemical and mechanical properties that have been developed to achieve explosion safety Appendix 1 Intertek TYPE EXAMINATION CERTIFICATE Equipment or Protective System Intended for use in Potentially Explosive Atmospheres Directive 94 9 EC Type Examination Certificate Number ITSO4ATEX11919 Issue 2 Equipment or Protective System HYDRA CELL RANGE OF PUMPS Manufacturer WANNER INTERNATIONAL LTD Address 8 9 Fleet Business Park Sandy Lane Church Crookham Hants GU52 8BF This equipment or protective system and any acceptable variation thereto is specified in the schedule to this certificate and the documents therein referred to Intertek Testing and Certification Limited certifies that this equipment or protective system has been found to comply with the Essential 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 together with a copy of the Technical Dossier are held in file Ref 03010842 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN13463 1 and 13463 8 EN5014 and EN50020 except in respect of those requirements referred to at item 18 of the Schedule If the sign X is placed after the certificate number it indicates that the equipm
16. pressure for any given pump see appendix 2 This is necessary to ensure that the bearings are operating with a 25 safety margin satisfying the explosion safety design concept described in clause 1 0 1 in the Technical File see appendix 3 4a Oil Level Monitor Unit Category 2 Zone 1 For ATEX compliant installations the pumps must carry appropriate markings of conformity The certification is based on the principle that a Hydra Cell pump does not create a source of ignition while the lubricating liquid is present in the drive end of the pump ESTABLISHING THE REQUIRED PROTECTION LEVEL If the liquid to be pumped is flammable and therefore deemed hazardous the monitoring oil bowl must be employed When pumping non flammable liquids it must be defined as either hazardous or non hazardous as part of the end users risk assessment If a liquid is defined as hazardous as part of that risk assessment due to it being corrosive or toxic the monitoring oil bowl must be employed If the pumped liquid has been assessed to be as non hazardous the oil monitoring bowl is not required FI i Monitoring Non flammble but Oil bowl toxic corrosive Oil level site bowl Non hazardous And flow meter Flammable Oil level site bowl Non flammable but Oil level site bowl Toxic corrosive Non hazardous Oil level site bowl PUMPING NON HAZARDOUS LIQUIDS Ifthe pumped liquid is regarded as non hazardous or inert but the pump is to be
17. when the red earth bond button is depressed on the PAT device see appendix 7 1 5 Values of below 0 1 ohms can be expected and as such are acceptable The actual value should be recorded against each pumps unique Serial No 8 7 Pumpable Materials Preventing the formation of explosive atmospheres both within the pump and external to it is not within the control of Wanner International It is the users that are responsible for ensuring that pumps are not allowed to pump potentially explosive atmospheres for prolonged periods or as part of the normal operation The chemicals to be pumped are predefined by the user and outside of the control of Wanner International However the following is a list of material categories that are considered to be suitable for use in a Hydra Cell pump These pumps are designed to handle flammable liquids and other liquid chemicals Acetone Gasoline Acetate Heptane Ethanol Propylene Oxide Ethylene Pentane Methyl Ethyl Ketone Kerosene Butane Benzene Turpentine Pitch Oil Stoddard Oil Propanol Xylene Toluene Methanol Tall Oil White Spirit Degassed Crude Oil N Hexane Lubricating Oil Please note Wanner International must be informed in writing if other chemicals are likely to be involved Accordingly an Application Questionnaire should be completed and returned to Wanner International with details of the process liquid Hydrogen Peroxide which reacts exothermically with many oils is not
Download Pdf Manuals
Related Search