Operating Instructions
Contents
1. Install and use the device only if it is undamaged dry and clean If you have questions gt Contact the manufacturer Warnings Warnings are sub divided in these operating instructions according to the following scheme A WARNING Type and source of danger gt Possible consequences gt Measures to avoid danger They are always identified by the signalling word WARNING and sometimes also have a symbol which is specific to the danger involved 156113 8625601300 Control unit Ex p 3 2010 07 14 BA00 Ill en 05 8625 1 60 Designated Use 3 3 Conformity to Standards The device complies with the following standards and regulations X Directive 94 9 EC X IEC EN 60079 0 IEC EN 60079 1 IEC EN 60079 2 IEC EN 60079 7 IEC EN 60079 11 IEC EN 60079 18 X IEC EN 61241 0 IEC EN 61241 1 4 Designated Use The control unit 8625 1 60 is an explosion protected device to monitor and control the overpressure in the Ex p housing In connection with an appropriate housing with the ingress protection IP54 IP65 recommended and the air supply unit the control unit offers a pressurized protection In connection with the air supply unit the control unit 8625 1 60 is approved for use in hazardous areas zones 2 and 22 class Ill In the zone 22 the control unit without air escape can only be used for reporting the over pressure and it must be used together with a leakage compensation The control unit contro2. Operating Instructions Control unit Ex p gt 8625 1 60 Contents 1 2 1 2 2 2 3 Contents 1 e Lan EC 2 2 EECHER gege 2 3 General Safety Instructions iii 3 4 Designated USE iene 4 5 TeC CID AU asl 4 6 Transport Storage and Disposal 6 l SR eee eee eee ee ee eer 6 8 Parameters and Operating Modes 10 9 PRUTINO INIO O DEAN 16 IO MAMAN rano 16 11 Accessories and Spare Parts ss 17 12 Type Examination Certificate Page 1 18 13 EC Declaration of Conformity ii 19 General Information Manufacturer R STAHL Schaltgerate GmbH Am Bahnhof 30 D 4638 Waldenburg Phone 49 7942 943 0 Fax 49 7942 943 4333 Internet www stahl ex com Operating Instructions Information ID NO 156113 8625601300 Publication Code 2010 07 14 BAO0 IIT en 05 We reserve the right to make technical changes without notice Symbols used Action request Describes actions to be carried out by the user Reaction sign Describes the results or the reactions to the actions taken Bull n _ ____ __ 1 Describes the notes and recommendations Warning sign danger from energised parts Warning sign Danger due to an explosive atmosphere 156113 8625601300 Control unit Ex p 8625 1 60 2010 07 14 BAO00 IIl en 05 3 1 3 2 General Safety Instructions General Safety Instruction
3. limit value is exceeded 14032TT00 After purging the indication switches back to Operate and again shows the pressure inside the enclosure OPERATE 03 25 mbar 14014T00 When the internal pressure falls to 0 25 mbar or less the device switches to operating mode Purgesafe Display shows the warning Check Pressure and also warns with a CHECK pressure blinking backlight and it indicates the internal pressure The processor independently notices if after a period without the required pressure purging is again required and it initiates purging as soon as pressure and volume flow are sufficient again 14033700 Control unit Ex p 15 8625 1 60 156113 8625601300 2010 07 14 BA00 IIl en 05 Putting into Operation With temperature sensor When a temperature sensor is connected to the 5 pole bushing the value it measures is also indicated besides the overpressure but only in operating mode Operate age ERE nu 14034T00 With Bypass switch To be able to test devices that are connected to control unit 8625 1 60 without overpressure and air flow the control can be bridged with a bypass switch so that contacts K1 and K2 switch over This switch is connected to the 5 pole bushing This must not be done in Ex atmosphere when the contacts turn on devices that are not explosion protected That is why the display backlight blinks in warning when the bypass switch is closed and in the lower l
4. may impair the explosion protection gt The control unit must be repaired only by the manufacturer Note in accordance with the Ordinance on Hazardous Substances In accordance with the Waste Management Act dated 27 08 1986 AbfG 11 Special waste the owner of special waste is responsible for the disposal At the same time the employer is obliged to protect his employees according to the Ordinance on Hazardous Substances dated 1 10 1986 GefStoffV 17 General Protection Duty Therefore we must point out that 1 2 3 4 all the devices and or systems which are sent back to R STAHL for repair must be free from hazardous substances acids caustics solvents explosive gas compounds etc all the devices and or systems which are sent to R STAHL must be handled in a way that they do not contain any dangerous liquids or other hazardous substances Thus devices and or systems that have come into contact with dangerous substances see GefStoffV must be neutralised the measures carried out under 1 and 2 during service and repair works must be confirmed in writing the costs that arise due to the disposal of hazardous substances during a repair will be invoiced to the owner 11 Accessories and Spare Parts Use only original accessories and spart parts from R STAHL Schaltgerate GmbH Use of another company s accessories and spare parts invalidates the warranty of R STAHL Schaltgerate GmbH 156113 86
5. pre purging purging time gt 00 00 min without temperature sensor Initially the overpressure in the enclosure compared to the environment is shown on the display As long as this pressure is below 0 25 mbar Low Pressure is indicated and the pressure that has been measured Regardless of programming both contacts K1 and K2 are open and the LEDs are turned off ci As soon as the pressure exceeds the minimum value of 0 25 mbar the indication shows the flow rate of the purge gas The upper line shows if the flow rate is above or below the programmed value for purging start see PrStart In the lower line the current flow rate may be seen as long as the minimum value for purging has not been reached Low Pressure 00 15 mbar 14029T00 When the minimum flow rate for purging has been reached the lower line shows the remaining purging time if it is less than one minute it is shown in seconds In the upper line it Bunt ow ae LE can be seen if the flow rate is above or below the urging sec programmed value When the flow rate is below the minimum limit value the counter for the purging time is at first only stopped The figure showing the remaining purging time then blinks As soon as there is enough air flow the counter starts working again When the flow rate falls below the limit value for a certain period of time purging is aborted Display again shows the current flow rate and purging will start again as soon as the
6. 00 Control unit Ex p 8625 1 60 2010 07 14 BA00 IIl en 05 Assembly 7 2 Setting leakage air volume on air supply unit L The leakage nozzle is set at factory to an air volume of 15 I min at a pressure of 2 bar The pressure controller is set at factory to a pressure of 2 bar 0 10 20 30 40 50 60 70 80 90 100 l min 06079E00 pressure set at pressure controller Fig 7 2 Leakage air diagram 06080E00 Fig 7 3 Setting the leakage air volume gt Close the adjusting screw on the solenoid valve in clockwise direction as far as possible gt Turn the adjusting screw in anti clockwise direction until the desired leakage air volume is reached see leakage air diagram Fig 7 2 156113 8625601300 Control unit Ex p 7 2010 07 14 BA00 IIl en 05 8625 1 60 Assembly 7 3 Assembly of the components Max 5mm 06358E00 Fig 7 4 Assembly of the components Place the O ring 33 7 x 2 2 mm 3 between housing wall and control unit 4 and fix them with the fixing screws 5 gt Screw the intake screw connection 1 together with the O ring 33 7 x 3 5 mm 2 into the control unit gt Mount the solenoid valve 11 and the sealing disks 9 10 with the connecting piece 8 gt Mount the pressure controller 7 on the connecting
7. 19 2000 EN 50020 1994 EN 50028 1987 EN 50281 1 1 1998 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 This EC type examination certificate relates only to the design examination and tests of the specified equipment in accordance to the Directive 94 9 EC Further requirements of the Directive apply to the manufacturing process and supply of this equipment These are not covered by this certificate The marking of the equipment or protective system must include the following amp ll2 GD EEx e m ia IIC T4 T70 C IP 66 bzw Il 2 GD EEx d m ia lIC T4 T70 C IP 66 T V NORD CERT GmbH Langemarckstrafe 20 45141 Essen accredited by the central office of the countries for safety engineering ZLS Ident Nr 0044 legal successor of the TUV NORD CERT GmbH amp Co KG Ident Nr 0032 The d of thg certification body Schwedt Hanover office Am T V 1 30519 Hanover Fon 49 0 511 986 1455 Fax 49 0 511 986 1590 This certificate may only be reproduced without any change schedule included Excerpts or changes shall be allowed by the TUV NORD CERT GmbH page 1 3 Control unit Ex p 156113 8625601300 8625 1 60 2010 07 14 BA00 Ill en 05 EC Declaration of Conformity 13 EC Declaration of Conformity EG Konformit tserkl rung EC Declaration of Conformity D claration
8. 25601300 Control unit Ex p 17 2010 07 14 BA00 IIl en 05 8625 1 60 Type Examination Certificate Page 1 12 Type Examination Certificate Page 1 LEM A4 VI 18 3 4 5 6 7 8 9 10 11 12 Translation EC Type Examination Certificate TUV NORD i Equipment and protective systems intended for use in potentially explosive atmospheres Directive 94 9 EC Certificate Number T V 06 ATEX 553116 for the equipment Control unit type 8625 1 of the manufacturer STAHL Schaltger te GmbH Address Am Bahnhof 30 74638 Waldenburg Germany Order number 8000553116 Date of issue 2006 06 28 This equipment or protective system and any acceptable variation thereto are specified in the schedule to this certificate and the documents therein referred to The TUV NORD CERT GmbH notified body No 0044 in accordance with Article 9 of the Council Directive of the EC of March 23 1994 94 9 EC 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 Il to the Directive The examination and test results are recorded in the confidential report No 06 YEX 553116 Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 50014 1997 EN 50018 2000 EN 500
9. Pressure and shows the over pressure Low Pressure 00 00 mbar 14025T00 Without pre purging purging time 00 00 min without temperature sensor Initially the overpressure in the enclosure compared to the environment is shown on the display As long as this pressure is below 0 25 mbar Low Pressure is indicated and Low R the pressure that has been measured Regardless of i S programming both contacts K1 and K2 are open and the LEDs are turned off ee As soon as the pressure exceeds minimum value of 0 25 mbar for a longer period of time the display shows for about 2 seconds the flow rate of the purge gas OPERATE b see with pre purging Then it switches to Operate and ASL IL again indicates the pressure in the enclosure 14014T00 Contacts K1 and K2 now react according to programming to the measured pressure and the valve voltage When an LED is illuminated then the respective contact is closed OPERATE mbar P me R I A x 14027T00 When the internal pressure stays below the minimum value of 0 25 mbar for some time the devices switches off the operating mode Operate Indication again shows warning Low pressure Low Pressure and the internal pressure Both LEDs go out _ and contacts K1 and K2 are open again Ka MENU f dr di e dg de INFO Ri 14028T00 156113 8625601300 2010 07 14 BA00 Ill en 05 14 Control unit Ex p 8625 1 60 Parameters and Operating Modes With
10. ay and operating elements Ex pz Control Unit OPERATE 03 25 mbar 14013T00 Display 7 operating clement LED backlit STN LCD display Shows for example the current overpressure in the enclosure volume flow or the programmed thresholds for overpressure purging time or temperature which have an effect on the relay outputs K1 K2 or on the output Valve in clear 2 LEDs Indicate the switching status of contacts K1 and K2 When the LED is illuminated then the respective contact is closed 3 Pushbutton To query parameters INFO or to confirm settings OK Rotary switch for a small To select a ani or change its value by ees EE o Symbols for terminal PE protective earth connections 156113 8625601300 2010 07 14 BA00 Ill en 05 Control unit Ex p 8625 1 60 Parameters and Operating Modes 8 2 Reading of parameters The following parameters may be set or read X Overpressure at which relay K1 or K2 will react adjustable from 0 3 25 mbar in 0 1 mbar steps 30 2500 Pa in 10 Pa steps Switching function of relays K1 and K2 as NC or NO Purging time adjustable from 0 to 255 minutes On and Off delay of contacts K1 and K2 adjustable from 0 to 60 seconds Minimum volume flow at which the purging time is counted adjustable from 0 5 to 4 liters s Temperature at which the valve for cooling will be turned on adjustable from 10 to 55 C if a temperature sensor is connected to the 5 pole bushing x Xx S
11. be set to 0 s Indication of purging time will then be skipped when the parameters are called up with the INFO OK button but it is still accessible in the programming menu Operating Modes Main modes The following main modes are available ex Valve Operation with an Ex valve function n c normally closed the valve is voltage free closed ex valve 00 0 mbar 14023T00 non ex valve Operation with a non Ex valve function n 0 normally open the valve is voltage non ex valve AE CRE 00 0 mbar 14024T00 A WARNING In any case a non ex valve mode non ex valve has to be fitted into the pressurized enclosure After the supply voltage is connected the display will indicate the set mode as described above You may now change to the other mode by pressing the INFO OK button for 5 s 156113 8625601300 Control unit Ex p 13 2010 07 14 BA00 Ill en 05 8625 1 60 Parameters and Operating Modes Please note that the pressure sensors are adjusted to 0 mbar a few seconds after switching between the two modes So no pressure must be existing at the control unit no air must flow through it and the cabinet monitored by the control unit has to be open Normally neither switching of valve type nor calibration of pressure sensors is required from the user because the control is programmed and calibrated in the factory As long as overpressure in the enclosure is too low the display now indicates Low
12. de Conformit CE Wir we nous R STAHL Schaltger te GmbH Am Bahnhof 30 74638 Waldenburg Germany 8625 1 60 erkl ren in alleiniger Verantwortung dass das Produkt Steuereinheit hereby declare in our sole responsibility that the product Control unit d clarons sous notre seule responsabilit que le produit Unit de commande mit der EG Baumusterpr fbescheinigung under EC Type Examination Certificate T V 06 ATEX 553116 avec Attestation d examen CE de type auf das sich diese Erkl rung bezieht mit den folgenden Normen oder normativen Dokumenten bereinstimmt which is the subject of this declaration is in conformity with the following standards or normative documents auquel cette d claration se rapporte est conforme aux normes ou aux documents normatifs suivants Bestimmungen der Richtlinie Nummer sowie Ausgabedatum der Norm terms of the directive Number and date of issue of the standard prescriptions de la directive Num ro ainsi que date d mission de la norme 94 9 EG ATEX Richtlinie EN 60079 0 2006 94 9 EC ATEX Directive EN 60079 1 2004 94 9 CE Directive ATEX EN 60079 2 2004 EN 60079 7 2003 EN 60079 11 2007 EN 60079 18 2004 EN 61241 0 2006 EN 61241 1 2004 2004 108 EG EMV Richtlinie 2004 108 EC EMC Directive 2004 108 CE Directive CEM Qualit tssicherung Produktion Production Quality Assessment PTB 96 ATEX Q006 4 Assurance Qualit Production Kenn Nr der benannten Stelle Notifi
13. e Xx Xx To activate the INFO OK button or the rotary switch the enclosure cover has to be screwed off The display may be read any time through a magnifying window in the cover even when the enclosure is closed During normal operation Operate the display indicates the overpressure that is measured inside the enclosure in mbar ui JE mbar 14014T00 The indication always returns to normal operation when the INFO OK button has not been pressed for 4 seconds By pressing the INFO OK button the following indications are displayed successively Settings of K1 Indication of internal pressure for changing of K1 and the programmed switching function nc or no sa wi Vir Factory setting no pressure 0 3 mbar 30 Pa i 14015T00 Settings of K2 Indication of internal pressure for changing of K2 and the gees programmed switching function nc or no mes Factory setting no pressure 0 5 mbar 50 Pa i 14016T00 Settings of Temp Indication of temperature in C at which a valve for cooling air will be turned on via terminals Valve prerequisite an optional temperature sensor is connected to the 5 pole bushing Factory setting 55 C Settings Temp 70 C 14017700 156113 8625601300 Control unit Ex p 11 2010 07 14 BA00 IIl en 05 E 8625 1 60 Parameters and Operating Modes 8 3 12 Settings of Purge Indication of p
14. e programmable parameter value will blink in the picture it is framed red By turning the MENU switch you will set the desired value in the display Turning the switch to the right will increase the value turning to the left decreases it gt Save the value by pressing OK gt When programming K1 or K2 indication no or nc will blink afterwards Adjust Ki no 00 30 mbar 14022T00 156113 8625601300 2010 07 14 BA00 Ill en 05 Control unit Ex p 8625 1 60 8 4 Parameters and Operating Modes gt Now select function no or nc with the MENU switch and store this setting by pressing OK tas confirmation of the last programmable value with OK the indication will return to normal operation and will show internal pressure no nc A contact that has been programmed as nc normally closed is closed when differential pressure is missing When e g 10 mbar 1000 Pa and nc have been programmed for K1 this means that K1 will open at an overpressure of more than 10 mbar 1000 Pa Purging time Purging time will start when the flow inside the enclosure reaches and keeps or exceeds the value that has been programmed with PrStart When the air flow stays below this value for more than 4 seconds the purging time is reset to 0 No contacts will switch until the purging time is over Purging times from 0 up to 255 minutes may be programmed When no pre purging is required purging time has to
15. ed Body number N de l organisme de certification 0102 Waldenburg 21 Jan 2009 LN LV i LIT Ort und Datum B Limbacher Dr S Jung Place and date Leiter Entwicklung Leiter Qualit tsmanagement Lieu et date Head of Development Director Quality Management Dept Directeur D veloppement Directeur Dept Assurance de Qualit 156113 8625601300 Control unit Ex p 19 2010 07 14 BA00 IIl en 05 8625 1 60 156113 8625601300 2010 07 14 BA00 Ill en 05
16. ine of the display the word BYPASS is shown during any operating mode 14035T00 Putting into Operation Before commissioning ensure that X the cover of the control unit is correctly closed X unused cable entries are sealed with plugs certified to Directive 94 9 EC and unused holes are sealed by stopping plugs certified to Directive 94 9 EC X the operating mode and the purging process is set according to the corresponding zone 10 Maintenance 10 1 Regular Maintenance Work 16 gt Consult the relevant regulations e g IEC EN 60079 17 to determine the type and extent of inspections Plan the intervals so that any defects in the equipment which may be anticipated are promptly detected To check as part of the maintenance schedule X Check if the cables are clamped properly X Inspect the device for signs of visible damage X Compliance with the permitted temperatures in accordance with IEC EN 60079 0 X Make sure that the device is used according to its designated use 156113 8625601300 Control unit Ex p 8625 1 60 2010 07 14 BA00 IIl en 05 Accessories and Spare Parts 10 2 Cleaning Only the viewing window of the control unit must be clean when it is heavily soiled X Clean with a moist cloth X Use water or mild non abrasive non scratching cleaning agents X Never use aggressive cleaning agents or solvents 10 3 Repair work A WARNING Danger due to improper repair gt Improper repairs
17. ls the overpressure in the Ex p enclosure and monitors the states via the output contacts As soon as the preset threshold value is reached compressed air or inert gas is passed in via the air supply unit In zone 2 also the purging or the operation with continuous purging is possible Z WARNING Only use the device for its intended purpose gt Otherwise the manufacturer s liability and warranty expire gt Only use the device under the operating conditions described in the operating instructions gt The device must only be used in areas subject to explosion hazards according to these operating instructions 5 Technical Data Safety data Gas explosion protection Il 2 G Ex e mb pz ia IIC T4 or Il 2 G Ex d mb pz ia IIC T4 Dust explosion protection Il 2 D IP66 T70 C Certificates T V 06 ATEX 553116 Rated operational voltage 12 V 24 V DC 24 V 1 115 V AC 10 48 62 Hz 230 V AC 8 5 10 48 62 Hz 250 VAC 5 15 48 62 Hz Rated operational current 250 MA at 12 24 V DC 300 mA at 24 V AC 60 mA at 115 V AC 30 mA at 230 250 V AC 156113 8625601300 4 Control unit Ex p 8625 1 60 2010 07 14 BA00 Ill en 05 Ambient temperature 30 C lt Tamb lt 60 C Enclosure material Epoxy resin glass fiber reinforced black antistatic Switching threshold of the output relay according to DIN VDE 0435 Contact Type of max current Power factor cos o potential current va
18. lue 250 V AC 6A 12 A 1 240 V AC 3A 0 3 24 V DC 6A 12 A 30 V DC 2 5 A acc to EN 50028 m 12 A acc to EN 60079 18 mb 6 A Terminals Rated current 32 A for rated cross section and T lt 40 C Rated cross section 4 mm 12 AWG Terminal capacity 0 2 4 mm 24 12 AWG Dimensional Drawings All Dimensions in mm Subject to Alterations 144 5 120 E 90 104 75 e 82 x 150 190 06078E00 06657E00 Air supply unit 156113 8625601300 2010 07 14 BA00 IIl en 05 Control unit Ex p 8625 1 60 Technical Data Service category L R AC 15 0 ms DC 13 50 ms Transport Storage and Disposal 6 7 1 Transport Storage and Disposal Transport gt Shock free in its original carton do not drop handle carefully Storage gt Store in a dry place in its original packaging Disposal gt Ensure environmentally friendly disposal of all components according to legal regulations Assembly Le Any mounting position is possible but make sure that the display is still legible Drilling of the assembly bore holes 06357E00 Fig 7 1 Drill pattern for control unit Drill the following assembly holes on the housing wall X 4 threaded holes M5 see Fig 7 1 X 1 hole 35 mm for intake screw connection see Fig 7 1 X 1 hole 17 mm for air supply unit 156113 86256013
19. piece gt Connect the pressure controller to the compressed air supply or the inert gas supply 156113 8625601300 8 Control unit Ex p 8625 1 60 2010 07 14 BA00 Ill en 05 Assembly 7 4 Connection of the components Fig 7 5 Circuit diagram gt Carry out the connection of the control unit to mains supply and the connection between control unit and solenoid valve in accordance with the circuit diagram see Fig 7 5 gt Connect other signalling devices to the potential free contacts K1 and K2 if necessary Close carefully the housing cover of the control unit gt Screw carefully down all the cable entries gt Ensure that unused cable entries are sealed with plugs certified to Directive 94 9 EC 156113 8625601300 Control unit Ex p 9 2010 07 14 BA00 IIl en 05 E 8625 1 60 Parameters and Operating Modes 8 8 1 10 Parameters and Operating Modes Control unit 8625 1 60 purges the enclosure as required and monitors and controls the pressure of the inert gas in the enclosure in regard to the ambient atmosphere during continuous operation The required valves optional are controlled with terminals Valve or two potential free relay contacts Furthermore the internal temperature of the enclosure may be measured and lowered by inserting cooling air when a temperature sensor is connected to the bushing at the side All settings can be done on the front plate which is self explanatory Displ
20. s Safety Instructions for Assembly and Operating Personnel The operating instructions contain basic safety instructions to be observed during installation operation and maintenance Non observance will endanger persons plant and the environment NWARNING Danger due to unauthorised work being performed on the device gt Risk of injury and damage to equipment gt Mounting installation commissioning operation and maintenance must only be performed by personnel who are both authorised and suitably trained for this purpose Before assembly commissioning gt Read through the operating instructions gt Give adequate training to the assembly and operating personnel gt Ensure that the contents of the operating instructions are fully understood by the personnel in charge gt The national installation and assembly regulations e g IEC EN 60079 14 apply When operating the device gt Ensure the operating instructions are made available on location at all times gt Observe safety instructions gt Observe national safety and accident prevention regulations gt Only run the device according to its performance data gt Maintenance or repair work not described in the operating instructions must not be performed without prior agreement with the manufacturer gt Any damage may compromise the explosion protection gt No changes may be made to the devices or their components that compromise explosion protection
21. urging time in minutes when the purging time has not been set to 0 Settings Purg Factory setting 1 minute LUI 14018T00 Settings of Delay Indication of relay delay in seconds Factory setting 1 second Settings Delay 0001 sec 14019T00 Settings of PrStart PrStart Purge Start Indication of minimum gas flow in liters per second from which on the purging time is counted readable under Sek POL Purge i Factory setting 1 5 I s 14020700 Setting of Parameters To change the parameters introduced under 8 2 select these parameters with rotary switch MENU which can be operated with a small screwdriver instead of with INFO OK You can interrupt the programming any time by not doing any settings within ca 4 seconds or by confirming the present values with OK Indication will then return to normal operation and will show internal pressure Turn the MENU switch until the display shows the parameter you want to change It does not matter if you turn the switch left or right with every switching step the indication will show the next parameter When you have reached the desired parameter press button INFO OK gt The display now shows Adjust The value that has been programmed last is indicated Adjust Ki no 00 30 mbar 14021T00 gt When the display shows the parameter that has to be programmed press OK INFO OK button to start programming gt Now th
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