BigBox - EEx - Manual - - company
Contents
1. 24 PS PC Gea E ATTUATORI Page 1 Introduction Kind Customer We at G T Attuatori congratulate You for preferring us in the choice of your new accessories G T Attuatori has been for a long time in pneumatic actuators field in which we distinguished for manufactoring accuracy by using the most advanced mechanical technologies Our Technical Office staff developes solutions for installations problems by using superior level software optimizing the projects according to all kind of sollecitations involved in machinery operation The G T Attuatori BEP BOX is characterized by its comple te and essential structure wich allows a quick and safe use assuring high performance and precision being manufactured by using selected high fidelity and long duration components and materials Page 2 a B ATTUATORI LEFT 1 2 4 o 6 8 BEP Ia BU 6 L Bk 8 PROXIMITY SENSOR D PROXIMITY SENSOR C LEGEND BN BROWN BU BLUE BK BLACK BOARD RIGHT Supply of C sensor 10 60 VDC max 200mA C negative ground PNP positive output for user Supply of D sensor 10 60 VDC max 200mA D negative ground PNP positive output for userper utilizzatore BOARD In the version with four micro swit2. Eun p c B pe quld ese Board BEP M2 connections Common A micro switch max 250V 5A N O normally open A micro switch N C normally closed A micro switch Common B micro switch N O normally open B micro switch N C normally closed B micro switch Qu Oi I EZ B ATTUATORI Page 20 a Safety and caution general conditions The same construction of the box is practically the protections agaist all the parts in motion all placed inside the box Possible damaged power cable must be replaced For all the works regarding installation starting up equipping use utilization and using mode modifications ordinary maintenance and inspections must be followed the putting out of service procedures specified in this Operator s manual The Operator s manual must be always to hand in order to have the possibility to look it up to verify correct operating cicle every time there are doubts or it is necessary a new setting up pem epu Gea E ATTUATORI Page 5 Page 6 ur Putting out of service Whenever it is requested to put out of service the box it is necessary to follow some basic rules able to protect the operator health and the environment too Sheaths flexible tubes and plastic materials or in any case non metallic parts must be disassembled and disposed separately Pneumatic and electrical components as valves solenoid valves switche
3. A ey B Een g trevisan g iol it e G N A L E X E E P Edition 04 of 04 2005 Certificate of conformity ATEX 94 9 CE LES CERTIFICATE Notes Gens Elettrotecnico 1 EC TYPE EXAMINATION CERTIFICATE Sperimentale Italiano Giacinto Motta SpA Via R Rubattino 54 2 Equipment or Protective System intended for use 20134 Milano Italia P e Telefono 39 022125 1 in potentially explosive atmospheres SRM eno H Directive 94 9 EC Capitale sociale 8 550 000 d interamente versato 3 EC Type Examination Certificate number Codice fiscale e nume iscrizione CCIAA 00793580150 Registro Imprese di Milano CESI 03 ATEX 302 Sezione Ordinaria N R E A 429222 i P I IT00793580150 4 Equipment Switch box type GT BEP 5 Manufacturer GT ATTUATORI S r l 6 Address Viale Europa 17 20090 Cusago MI Italy 7 This equipment or protective system and any acceptable variation thereto is specified in the schedule to this certificate and the documents therein referred to 8 CESI notified body n 0722 in accordance with Article 9 of the Council Directive 94 9 EC of 23 March 1994 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 are recorded in confident
4. easily self adapt to the two different top drillings required by NAMUR standard for the Board BEP I2 connection fixing of the box to the actuator body that are mm 30x80 or mm 30x130 with the simple reversal of the two feet brackets from left to right and vice versa The adjustment of the switches control cams is done by two screws LEGEND BN BROWN BU BLUE BK BLACK PROXIMITY SENSOR 1 Common C micro switch max 250V 5A which allow a fine positioning of same cams with a system to unblock 2 N O normally open C micro switch and block them against unintentional rotation 3 N C normally closed C micro switch The terminal boards are pull out type to make easier the cables 4 Common D micro switch connection 5 N O normally open D micro switcn All G T Attuatori boxes may be provided with the patented 6 N C normally closed D micro switch tridimensional indicator Perry visible by the top and by the side Cams command rod and all the fasteners are in stainless steel EA ESCH Page 22 Gea E ATTUATORI Ea T uon Page 3 Warnings BEP M4 The installation and the starting up of the BEP BOX have to be done as described on following instructions The device can be put in service only by personnel which know t
5. number Page 14 dcum Ea E ATTUATORI Page 11 Technical data FLAT INDICATOR EXTERNAL GROUND Protection type Protectiontype Approximate weight 3 8Kg Body and brackets Dye cast aluminium UNI 5076 alloy powder coated Electrical connections Extractable 1 5mm terminals AWG14 Stainless steel AISI 304 Connection cables fittings Must be certified as standard user instraction EN50014 EN 50018 and EN 50281 1 1 ATEX directive 94 97CE and witha IP66 minimum protection grade Rotation way Adjustment By block and unblock cams Mechanical microswitches OMRON SSG 5L2P 250V 5A max 4 d c 200mA Inductive sensors P F PL1 F25 B23 S 25 30V DC Allowable environment 20 470 C on work temperature 40 80 C stock P66 o Z 0 000000000 O IDENTIFICATION NAMEPLATE PERRY INDICATOR EXTERNAL GROUND SS lpi a AZ d Qu A IDENTIFICATION NAMEPLATE Teu e Oe NI LLL EX a a Page 13 gen Page 12 Gea E ATTUATOR B ATTUATORI
6. FT BOARD MICROSWITCHES 1 O SOCKET HEAD SCREWS M5x8 2 steel AISI 304 UNI 7687 9j SOLENOID VALVE BOARD 1 10 PIN SPACERS M5x50 2 brass OT68 11 SCREWDRIVER OSTAFORM 2 SCREWDRIVER HOLDERS y OSTAFORM 5 BOX COVER GREY 7035 1 Aluminium alloy EN AB46100 4 SOCKET HEAD SCREWS M5x20 8 steel AISI 304 UNI 5931 5 UPPER DIE CUT SEAL NBR 70 SH 6 OBILE BLACK RING ABS HALF LOWER YELLOW INDICATOR ABS 8 HALF UPPER YELLOW INDICATOR ABS 9 FIXED GREY 7035 INDICATOR RING ABS 20 TRANSPARENT INDICATOR DOME POLYCARBONATE 21 SOCKE EAD SCREWS M5x15 steel AIS 304 UNI 5931 22 SOCKE EAD SCREWS M5x10 2 steel AISI 304 UNI 7687 25 TOOTHED WASHER 45 2 steel AISI 304 UNI 8842 24 FLAT WASHER 5 4 steel AISI 304 UNI EN ISO 7089 25 WIRE TERMINAL 2 26 WIRE TERMINAL ANTI ROTATION WASHE 2 steel AISI 304 27 ANTI ELECTROSTATIC CAGE 1 Steel Fe 360 UNI EN 10025 Le T emie Page 15 Identification Spare parts On top of box cover is present an identification plate showing the U A box type identification an the serial number of the box S On the lower left corner close to the logo Ex is indicated the switches type and related technical data D Box type aT e ub c ge Cams number Microswitches number Serial number i 00004 Production year Progressive production
7. RIVENDITORI i _ NIZ Sc H r Ge E ATTUATORI ui ENS AUSTRALIA DENMARK CHINA SINGAPORE GREECE Feci duc ave Geo cad Geer Se da Rd 12 18 aka 2825 Pacific Drive PNEUMATIC ACTUATORS AND ACCESSOHIES ISO 9001 2000 Cert n 0210 3 Agrinion Str 3 P O BOX 640 Bayswater 7100 Vejle Denmark International Plaza Tauros 17778 Norcross Ga 30071 U S A 3153 Victoria http www danskventilcenter dk 079903 Singapore http www chryssafidis gr http www unitorq com http www acrodyne com E mail mail danskventilcenter dk E mail bryangoh singnet com sg E mail purchase chryssafidis gr E mail sales unitorg com m E E ATI NI A NI DO SS LZ GERMANY BENELUX ram SPAIN i FRANCE TEA UNITED KINGDOM Gr SWEDEN Bar GmbH IMI Norgren s a Meca Inox Groupe Sgd Pacific Valves Co Ltd Ventim Venil amp Instruments AB Auf der Hohl D Calle Aire 3 32 Rue des Routis Unit 14 Parkside Ind Est Edge Flygplatsvagen 19 53547 Dattenberg Pol Ind Els Bellots 60850 Le Coudray St Germer Lane Street Royton Oldham OD 6DS 39241 Kalmar http Awww bar gmbh de 08227 Terrassa http www meca inox tm fr http www pacific valves co uk http www ventim se E mail wertrieb bar gmbh de E mail norgren norgren es E mail infos meca inox tm fr E mail pacificvalves btconnect com E mail info ventim se ll 2 GD CESI 03 ATEX 302 EExd IIB IP66 T85 C Geel E c t ATTUATORI S r Viale Europa 17 20090 Cusago MI ITALY Tel 39 2 903 903 22 Fax 39 2 903 903 68 No
8. bustible dusts can be present The technical requirements of the electrical installations in the classified areas are established by the standards EN 60079 14 choice installation maintenance and repairing of the electrical constructions to be used in dangerous areas and EN50281 1 2 electrical constructions destined to environments where there are combustible dusts Electrical constructions protected by means of an envelope Choice installation and maintenance According to these technical and legislative provisions the choice of the box must consider the following factors type of installation surface installations group Il area classification 0 1 2 20 21 22 for which equipment of 1 2 3 category respectively is suitable characteristics of the inflammable substances present in the form of gases vapours or fogs and dusts layer sub group IIA IIB IIC 16 temperature class it defines the ignition temperature of gases IP 66 degree of protection 2 Rotate and pull up the cover taking care to T maximum surface temperature do not deform the indicator rod mri Page 17 r3 Page 8 Gea E ATTUATOR B ATTUATORI Safety instructions Description The GT BEP model box has been conceived and constructed according to the Directive ATEX 94 9 CE Gruppo ll category 2 GD with reference to the standards EN 50014 EN 50018 and EN 50281 1 1 The protection mode is EExd IIB T6 IP66 T 85 C El
9. ches an additional card for the eventual control of an electro valve is introduced v a I Q E OOo OSe O eoo eec OUT ee p E Ae e E F Additional card Ea Ff auos Page 23 Generality BEP Ie TP The GT BEP explosion proof indicating box conceived and con structed according to the Directive ATEX 94 9 CE with reference to the European Standard EN 50014 general requirement EN 50018 Cd explosion proof boxes and EN 50281 1 1 electrical constructions destined to environments in which there are combustible dusts is in stalled on a rotating pneumatic actuator mounted on a ball valve but terfly valve male valve roller shutter valve or on a mechanical organ A which requires a position indication and as a consequence an electri LXII cal signal Made by die cast aluminium and painted with epoxy polyester powder the signal Boxes of G T ATTUATORI have the possibility to be adjusted in height towards the upper surface of the actuator Usable without distinction with shafs having protrusion over the actuator top of 20mm NAMUR 20 30mm NAMUR 30 40mm and 50mm NAMUR 50 due to the possibility of easy adjustment by fixed steps obtainable simply changing the position of the screws which fasten LEFT BOARD XB SIE RIGHT BOARD the feet brackets on the box body Other peculiarity of BEP BOX is the possibility to
10. ectrical features EE Proximity sensors Inductive sensors Micro mechanical mr gg voltage 10 60 v 25 30 V DC 250 V Maximum nominal current 200 mA 100 mA 3000 Hz o NEE TOT 20 70 C 20 70 C 20 70 C ii 69 uecp Marking of compliance with the applicable European directives e Ip n of notified organism for ATEX surveillance notified organism for ATEX surveillance toe of compliance with the directive a e and with the relative technical rules Group II surface asd v 2 apparatus vapours fogs and dusts Type of protection gas group class of temperature IP66 Degree of protection temperature eem with the Directive ATEX 94 9 C Page 16 B ATTUATORI The adjustment of BEP BOX cams is possible operating by means of proper screwdriver present on the box on the proper adjusting screws present on the top cam Push the screw A to unblock the lower cam then rotate the screw to move the cam to desired position and lastly release the screw to block the cam Repeat same operation with the screw B to unblock the upper cam then rotate the screw to move the cam to desired position and lastly release the screw to block the cam Cams adjustmant by means of the proper plastic tool pm Sea Gea E ATTUATORI Page 9 In the case of BEP BOX with 4 cams it is possible to adjust the 2 lower cams by inserting the tool into the 2 holes present on the top of upper cams Finis
11. he contents of these instructions Pnematic actuators pruduce a strong torque consequently during the installation and the staring up must be observed safety instructions to avoid possible injuries Before to open the box cover be sure that power has been previously switched off E m Strongly screw in the screws UNI 5931 in AISI 304 which close the cover before the staring up C NO NC Take care that may be present residual electrostatic charge For cleaning use damp cloth only Eun ES GET BS Besides the ground connection foreseen inside the box the latter is equipped with a second externally positioned ground BEP M4 additional bord connections connection Common C micro switch max 250V 5A N O normally open C micro switch N C normally closed C micro switch Common D micro switch N O normally open D micro switch N C normally closed D micro switch AE DE Pd ra EX BEEN B ATTUATORI Gea E ATTUATORI Page 21 Page 4 a Electrical connections CAUTION 7o be sure that power is switched off before to proceed with electrical connections BEP M2
12. hed the adjustment proceed with the riassembling of the box cover CAUTION During disassembling and cams adjusting it is possible that the O Ring placed on the top of box body comes out of proper seat Take care that the O Ring is well placed into his seat before to re assemble the cover to avoid malfunction of the BEP BOX and or leakages of the sealing Adjustment of lower cams Page 10 B ATTUATOR Spare parts ID Descrizione Q t ateriale Riferimenti 1 BENZING CIRCLIP 10 2 Stainless steel UNI 7434 2 BOX Eexd 4 x 3 4 NPT GREY 7035 1 Aluminium alloy EN AB46100 5 O Ring 9190 18x2 62 1 NBR 70 SH OR 3750 4 BRONZE BUSH 916x9 9 2 brass OT68 5 O Ring 6 75x1 78 2 NBR 70 SH OR 106 6 ROD CAMS ASSEMBLY FERES 325 7 E
13. ial report n EX A3 038115 9 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 50014 1997 A1 A2 EN 50018 2000 Al EN 50281 1 1 1998 Al 10 If the sign X is placed after the certificate number it indicates that the equipment or protective system is subject to special conditions for safe use specified in the schedule to this certificate 11 This EC 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 12 The marking of the equipment or protective system shall include the following x 112GD EExdIIBT6 IP66 T85 C This certificate may only be reproduced in its entirety and without any change schedule included Date 12 November 2003 Translation issued the 12 November 2003 Prepared Verified Approved Ulisse Colombo ga es vanati Mirko Balaz ES dL cu CENTRO ELETTROTECNICO SPERIMENTALE ITALIANO Unit Certificazione I CESA EXA Schema di certificazione I CESI stato autorizzato dal governo italiano ad operare quale organismo di certificazione di apparecchi e sistemi destinati a essere utilizzati in atmosfera Page 1 3 potenzialmente esplosiva Example of connect
14. ion with two inductive sensors BEP l2 Pepperl Fuchs inductive sensors Connections m Re uw jJ rF TI D Vae Pin 1 7 L S CH i temp E Page 24 B ATTUATORI igvmwe imeem ELE ETT IT D tT PTT 2 EXIRET TT T TET T DIT TI MT 3 YWarnihNh geons i reee Ar EEE A E ern awa be ANa hn eae ors cl Safety and caution general conditions eee 5 PEEN OUC OF GEV CE xs aoa ean awa pie weiss Gc CU C EE OR E 6 Je rer E ee EE VA EENEG E te EA ett SE gn E Ee e cler eI IC B BIOL i da aai ad DR Seded VR XA T ENTERS EE EE 11 PC Fila alll GNC Se EE 12 ANH OUD ids ck eet ar Uc esc e ole e cee eee Ies Do e e ER dte Se EAR a 13 Sare DAES epini Erra It e ors EE Reta oe heat 14 Safety INStructioOns nen an eee 16 HOSCE RTI T ee ee T Te T QUI 16 leie Le gh e El 16 Kabel ee athe GOs serui EE 16 Safety instructions for the installation in dangerous areas sssssssss 222us2222222uu2us uuu u 2 17 Suitability of the GT BEP Box for the installation site areas with presence of gases inflammable vapo rs or fogs and distbts sccssboesusam te zaexe used deet o eect 44 el e 18 S5FPOUME CONMECCIOM wists chad d a E AER e ARA wt UL RC eR EE sheen ee Ra 18 Checks and maintenance of the explosion ppPoof DOXGS i1 xa e n RR RR Aske dad RR CR RO e awe dE Electrical connectiOns AN SCC REENEN EENEG Nee euo BERNIA ik os eebe e eg E eeh Ee MS 20 BEP Maa CUTEM 21 Si EE EE cc BE EE ceo mam
15. o as not to alter the specific properties of the protection mode as it is indicated in the standard EN 50018 paragraphs 13 1 and 13 2 for the EEx d boxes explosion proof protection mode When the cable input is made by means of a cable gland it must be correctly chosen with respect to the type of installation and cable The cable gland must be strictly tightened so that the sealing rings can create the pressure necessary to a avoid the transmission of mechanical strains onto the terminals b guarantee the mechanical protection IP degree of the box The cable inputs must be made with EEx d locking junctions or cable glands certified according to the standards EN 50014 EN 50018 and EN 50281 1 1 Furthermore any fittings which are not supplied by the manufacturer cannot be added An anti loosening blocking mechanism for the UNI 338 cylindrical threads must be produced using a Loctite sealing procedure Ground connection Besides the ground connection foreseen inside the box the latter is equipped with a second externally positioned ground connection It must be connected to the general ground of the installation using a suitable section conductor According to the S section of the line conductor the section of the ground conductor must be Q 16mm For 16 mm S 35 mm For S 35 mm Page 18 B ATTUATORI Installation Adjust the feet brackets at desired height in order to insert the milled bottom pa
16. rt of the box rod into the slot on the upper part of the actuator shaft The feet brackets may be inverted to change the wheelbase of fixing bolts from 80 mm to 130 mm Fix the box to the actuator by mean the bolts issued with the box pum peg Gea E ATTUATORI Page 7 Adjustment Safety instructions for the installation in dangerous areas To adjust the cams of BEP BOX please to proceed as shown on below picture Installation of the explosion proof boxes Before installing the BOX carefully read the user and maintenance manual Suitability of the GT BEP BOX for the installation site In the case it is used in areas with danger of explosion it is important to check that the box is suitable for the area classification and for the characteristics of the inflammable substances present on the installation The fundamental safety requirements against the risk of explosion in the classified areas are established by the European directives 94 9 CE of 23 March 1994 with reference to the equipment and 1999 92 CE of 16 December 1999 with reference to the installations Areas with presence of gases inflammable vapours or fogs and dusts uu i The criteria for the classification of the areas with a risk of explosion are established 1 Unscrew the fixing screws using an by the standards EN 60079 10 classification of the dangerous areas due to the exagonal wrench of 4 mm presence of gases and EN 50281 3 classification of the areas in which com
17. s and transformers if any sould be disassembled to be re used if in good conditions otherwise to be overhauled and recycled when possible Metal parts sould be disassembled and grouped together by metal type to be casted again in order to allow the recycling of the materials forming the box EZ B ATTUATORI Checks and maintenance of the explosion proof boxes The BEP BOX needs no extraordinary maintenance In fact inside it there are no organs which need it When it is necessary to open the box unscrew the 8 fixing screws ONLY AFTER CUTTING THE VOLTAGE The terminals of the electrical connections must be strictly tightened to avoid high contact resistance and consequent overheating The cover must be strictly tightened and blocked against the loosening of the suitable locking screw The replacement of fittings and parts of the cable inputs must be carried out using identical components to those supplied by the manufacturer in order to guarantee a suitable protection The surfaces of the explosion proof joints must not be modified and no seals must be introduced different from those supplied by the manufacturer These surfaces must be kept clean When substituting the clamping screws please make sure you use screw type A2 70 UNI 5931 e RR Page 19 B ATTUATORI Cable inputs The connections must be made by means of cable inputs or piping complying with the standard EN 60079 14 The cable input must be made s
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