M.C.A. BOLLATE (MI) MISURA - CONTROLLO - AUTOMAZIONE TEL.. 02.35.12.774 FAX 02.33.26.00.70 F840 Simplified (Zone 2) Pressu rized Enciosure system According to EN 60079 -- 2 (pz) Test No. TOV 03 ATEX 2095 X Properties of the Ex pz- System Very compact system, mounting direct in hazardous area (Zone 2) or inside Ex pzhousing ATEX- Certification according to EN 60079 2 (pz), TOV 03 ATEX 2095X Il 3 G, Ex nac [pz] IIC T6 Gc Il 3 D, Ex t fpd] IIIC T70 C Dc IP54 (Dust Ex) Programmable automatic pre- purging, output for solenoid valve Two free programmable output relay contacts (250V / 5A) Proportional working pressure measurement, high overpressure safety (no membrane switch) Visualisation of status, pressure, remaining purge time and failure report via integrated Display Available languages: German, English, French, Spanish, Dutch Solenoid valve fuse easy exchangeable inside of FS840 Integrated spark and particle barrier User is able to build up pressurized enclosure system on his own regarding the operation manual (no additional test report of notified body necessary) Description The use of simplified pressurized enclosures aliows the operation of 'non explosion protected' devices in hazardous areas inside zone 2. The protection type 'pressurisation' is based on the principle of maintaining a constant pressure using air or a protective gas to prevent an explosive mixture forming near the apparatus inside the pressurized enclosure. Generally before start-up, the pressurized enclosure must be purged with air or protective HYPASS ren-o.g ENC.! Ne Impuriung! n 9. A Caution!Itigh ~talpe!. i4zo, Pciit-30 'C -e t" a a. h a i MI in _411; _AC 48_.6214Z 1 1 3 1_ e7 a-ofe gas to remove any explosive mixture that may be inside the enclosure. This automatic procedure is called purging process. A simplified pressurized enclosure system consists of two components and the enclosure. 1. control una FS840 for process control and monitoring 2. Sinter metal throttle SD840 te control air input fed by pressured air network See manual F840 for requirements of pressurized enclosure and integrated ignition capabie apparatus. If the operator is not sure, that the atmosphere inside of the enclosure and the appropriate pipe infrastructure is below 25% of the lower explosive limit (LEL) (EN 60079 14 chapter 13.4), the enclosure must be purged to achieve a safe atmosphere inside of the enclosure. The F840 system can purge the enclosure automatically using the solenoid valve SVD.L In this case the SVD.L replaces the sinter meta! throttle.
Application Technical Details Control unit FS 840 General Mounting inside hazardous area Housing Electrical specifications Ex-protection class II 3 G, Ex na nc [pz] IIC T6 Gc -20 C TA 40 C II 3 G, Ex na nc [pz] IIC T5 Gc -20 C TA 60 C II 3 D Ex tc [p] IIIC T70 C Dc -20 C TA 60 C EC- type certificate Environment protection TÜV 03 ATEX 2095 X IP65 (Remark: without regard of outlet opening) Dimensions H x W x D: 120 mm x 122 mm x 90 mm Material Aluminium, painted / Ral 7035 Main voltage AC: 230V, 115V ; 48..62 Hz DC: 24V Power consumption ca. 2 VA, without solenoid valve Working circuits Terminal 1-4 Solenoid valve te. 5/6 Max. wire diameter U m = 250VAC, I m = 5A at AC1, P m = 1500VA U m = 250VAC, I m = 1,2A at AC15, P m = 300VA U m = 30V DC; I m = 4A at DC1, P m = 150W Output voltage is equal to mains, protected by internal fuse 2,5 mm² Pneumatic Pressure range 0... 22 mbar Mounting Ex p Configuration Environment temperature Humidity Parameter input -20 C...+40 C bei T6-20 C...+60 C bei T5 5-95%, non-condensing LC-Display, menu guided Different languages : German, English, French, Dutch, Spanish
Flow rate table, dependent on pressure and nozzle diameter The table below shows flow rate depending on pre- pressure and nozzle diameter Pressure Flow rate [l/s] ρ Air = 1.293 kg/m 3 [bar] Nozzle diameter [mm] [10 5 Pa] 0,3 0,5 0,7 1 1,5 2 3 4 1,5 0,0275 0,076 0,149 0,304 0,693 1,208 2,676 4,653 2 0,0338 0,094 0,184 0,374 0,838 1,48 3,27 5,651 2,5 0,0391 0,109 0,213 0,433 0,968 1,708 3,759 6,471 3 0,0438,0121 0,238 0,484 1,063 1,908 4,186 7,177 3,5 0,048 0,133 0,261 0,53 1,195 2,087 4,569 7,804 4 0,0518 0,144 0,282 0,573 1,28 2,252 4,917 8,37 4,5 0,0554 0,154 0,301 0,612 1,367 2,404 5,239 8,883 Flow diagram Q The diagram shows the relationship between pressure inside of enclosure and the output flow. The diagram is only valid, without reducing input or output diameters as well as flow reducing pipes. [l/s] 5 4 3 2 1 flow verus pressure 4 6 8 10 12 14 16 18 P [mbar] 20 Q 15 10 5 [m³/h] Type code Control unit FS840 mains: FS840.x 230V AC... 115V AC... 24V DC....0.2.6 We can offer you the complete Solution: System F 840 with Ex p- housing and mounting of your apparatus inclusive system test and ATEX report Solenoid valve SVD.L.x nozzle: SVD.L.x 1 mm... 1,5 mm... 2 mm... 3 mm... 4 mm... 5 mm... adjustable Sinter metal throttle SD840.1.1.5.2.3.4.5 SD840 Dimensions enclosure skin 29 30 Figure 1: Sinter metal throttle SD840 19 pipe connection 8 x 1 mm
Figure 2: Dimensions FS840 [mm] 57 40 86 47 Figure 3: solenoid valve SVD.L.x [mm] 48 drilling 16,5 mm throttle adjustable for leakage compensation 100 3m cable length G3/8" 56 Maximum prepressure: 6 bar 41 Figure 4: Mounting examples M.C.A sas Via Madonna 57 20021 Bollate (mi) tel 02 3512774 fax 02 33260070 www.mcastrumenti.it Gönnheimer printed 03/10, subject to change without notice
M C BOLLATE (MI) MISURA - CONTROLLO - AUTOMAZIONE TEL 02.35.12.774 FAX 523126.00.70 Pressurized Enclosuresystem F850S Use in Ex- Zone 1, 21, 2 and 22 In accordance to EN 60079 Compact - Intelligent - Economie BVS 06 ATEX E 088 Characteristics Compact system, mounting inside hazardous area or inside Ex p-enclosure ATEX certificate Reliable Ex p System with new certificate according to EN 60079: BVS 06 ATEX E 088 Function test acc. to EN 954-1, category 3 Menu guided programmable operation modes: Leakage compensation,(=> Continuous flow Digital solenoid valve <=> Proportional solenoid v. Ex p- system containing a proportionai working pressure and flow sensory No membrane switch, no screws or potentiometer to adjust pressure or flow thresholds or purging time High avallability because of reguiated pressure and proportionai valve High service reliability because of constant pressure No purge medium wasting, just the exact quantity to hold pressure is needed Increasing leakage caused by e.g. enclosure ageing will be balanced and therefore sudden failure will be prevented Almost no flow noise and only a small protettive gas consumption using a solid endosure Purging with pressure regulation Pressure sensitive parts of the endosure, like membrane switch panels or windows, will not be overloaded Purge volume accuracy is achieved by integration of the purge medium flow volume on the outlet Proportional solenoid valve-technique for operation mode continuous flow Prevents overload and burst danger of the Ex p- Enclosure caused by disturbances at the outlet Ex i- operation panel BT851 For ergonomically use and control of the Ex p- system The connection to the control unit counts only 3 wires Display On-line text messages of operation and malfunction states States of pressure or flow are every time available Displays menu and messages as plain text Available Languages: German, English, French, Spanish, Dutch Terminal specifications 2-pole potential free relays terminals Switching capacity 250 V-, 5A, cos > 0,7 lntegrated intrinsically safe interface for additional safety sensory Valve fuse is exchangeable placed inside the control unii FS850S - no separate Exe- fuse box required The build-in spark lattice allows to lei off the purge medium direct finto the hazardous area High operation safety Approved function security acc. to EN 954-1, category 3 Alarm messages on LC-Display Many years of Experience in pressurized enclosures according to 50016 made the development of this Ex p- system possible
Explosion protection: pressurized enclosure The use of pressurized enclosures provides the operation of non Explosion protected devices in hazardous areas of Zone 1, 21, 2 and 22. The protection type pressurisation is based on the principle of maintaining a constant pressure using air or a protective gas to prevent an explosive mixture forming near the apparatus inside the pressurized enclosure. This is achieved by placing and operating the non Exdevices inside of an Ex p- housing. This housing has a a small but constant overpressure of air or protective gas and prevents the infiltration of combustible gases or dusts. In Zone 1 / 2, the pressurized enclosure must be purged with air or protective gas to remove any Explosive mixture that may be inside the enclosure, before the protected devices are energized. This automatic procedure is called purging process. This purging process is not applicable in Zone 21 and 22. For purging, a common and a new integrating method are available: 1. Using the traditional method, purge quantity is the product of a preset minimum flow rate and time. The flow rate depends on the (air) pressure and the size of the internal nozzle (diameter 1...6 mm) of the valve and can be specified by matched charts. The common rule of purging must be considered: flow minimum is less than let in minus leakage loss. This purging method is named as time based purging method. 2. In contrast to the time based method the integrating purging method measures the real volume flow through the enclosure outlet and adds it up to get the real purge volume. Besides, the flow rate is monitored, dependent on the size of the plate orifice of the control unit. If the flow rate sinks below its minimum, it will be ignored and it will not contribute to volume integration. Therefore we achieve a safe and economic purging method. The integration of the real medium stream on the outlet gains a minimizing of the purge gas consumtion indepentend of the supply pressure. The exceeding of predefined flow rate setpoints and the accociated higher purge gas cunsuption are no longer up to date. Ex p- system F850S The pressurized enclosure system F850S contains at least the control unit FS850S and a solenoid valve. Each can be mounted in- or outside the enclosure. Furthermore several remote controls (operation panels) are available to improve ergonomics of operation. It is also possible to connect intrinsically safe sensors to the control unit FS850S. The pressurized enclosure system F850S operates in two different modes: Pressurisation using leakage compensation and Pressurisation using continuous flow of protective gas. Leakage compensation After purging, the control unit FS850S holds the pressure inside the enclosure on at least 0.8 mbar. The minimum and the maximum pressure of the housing are programmable and will be monitored. The protective gas inlet is controlled in two different solenoid vale techniques: digital working solenoid valve (DSV) technique or proportional working solenoid valve (PSV) technique. Digital solenoid valve technique While purging, the DSV opens. After purging it is deenergized and it closes. A bypass choke compensates the leakages of the housing. This choke is integrated into the valve and is mechanical adjustable (diameter 0.3...1 mm). The digital solenoid valve technique has a considerable disadvantage: while purging process and normal operation, a constant rate of protective gas is needed. Of cause of safety the rate must be bigger than leakage rate of the enclosure. The unnecessary protective gas is exhausted by the FS850S. Proportional solenoid valve technique Using proportional solenoid valve technique stops wasting protective gas. The internal proportional working sensory equipment and a proportional valve are combined to an input sided pressure control system. The proportional valve is the actuator of a PID controller and compensates exactly the gas losses of the housing. Therefore the outlet valve of the FS850S is permanently totally closed. Advantages of pressure feedback control are: 1. Considerable less consumption of protective gas - higher costs for prop. valve will be amortised soon 2. Increased service reliability achieved by constant pressure inside enclosure - increasing leakage caused by e.g. ageing of the enclosure will be balanced and sudden failure will be prevented 3. Almost no flow noise and only a small protective gas consumption using a solid enclosure Another advantage using a proportional solenoid valve is; that pressure control is used even during purging. A pre defined pressure set-point controls exactly the housing pressure while the purging phase. This definite pressure conserves the pressure sensitive parts of the enclosure. Membrane switch panels or windows will not be overloaded. Operation mode continuous flow The control unit FS850S supports moreover the operation mode continuous flow. This operation mode is necessary, if, for example, an analyser (analyses combustible gases) could produce
an explosive atmosphere inside the enclosure (containment system). The operation mode continuous flow purges the enclosure permanently. After the (pre-) purging process the FS850S generates a pre defined constant flow rate to dilute the possible combustible atmosphere. Peripherals: Operating panels The control unit FS850S has intrinsically safe in- and outputs to connect different safety components as well as operating and visualization panels: These operating and visualising panels are very advantageous, particularly if the control unit is mounted inside the enclosure: Performance and service 1. Common panels: BT854.1 and BT855.1 On/Off-Switch Key-operated switch for bypass LED-indicator for READY and ON 2. Intelligent operating panel type BT851 This operation panel indicates operation and malfunction reports as text messages. Using the 4 membrane switches offers total command of the control unit. Status, momentary pressure and flow rate as well as remaining purge time are always available. The Ex p- system F850S is proved according to EN 60079 (BVS 06 ATEX E 088). The complete System, consisting of Ex p- housing - ignition- capable apparatus - Ex p- system F850S must be checked by an Ex pert of a notified body. Gönnheimer Elektronic GmbH offers you: System F850S - only the components System F850S inclusive construction and manufacturing of a custom Ex p- housing The complete Solution: System F850S with Ex p- housing and mounting of your apparatus inclusive system test and if valid certification by the EC type certificate DMT 02 ATEX E 086 (inclusive documentation and type sign) We consult you gladly, free of charge and without obligation. Block diagrams Electrical block diagram Pneumatic block diagram
Tables Plate orifice of the FS850S Plate orifice [mm] flow rate [m 3 /h] 4 0,5... 1,1 6 1,1... 2,7 10 2,5... 6,5 14 6... 11 18 9... 15 The suitable diameter of the plate orifice depends on the desired volume flow rate on the enclosure outlet and the built in nozzle of the solenoid valve. Flow rates into enclosure dependent on primary pressure and nozzle diameter. Flow rate table, dependent on pressure and nozzle diameter Pressure [bar] Flow rate [l/s] ρ Air = 1.293 kg/m 3 Nozzle diameter [mm] [10 5 Pa] 0,3 0,5 0,7 1 1,5 2 3 4 5 6 1,5 0,027 0,076 0,149 0,305 0,686 1,220 2,745 4,880 7,625 10,980 2 0,034 0,094 0,184 0,375 0,844 1,501 3,376 6,002 9,378 13,505 2,5 0,039 0,109 0,213 0,434 0,977 1,736 3,907 6,945 10,852 15,627 3 0,044 0,121 0,238 0,486 1,093 1,944 4,373 7,775 12,148 17,494 3,5 0,048 0,133 0,261 0,533 1,199 2,131 4,795 8,524 13,319 19,180 4 0,052 0,144 0,282 0,576 1,296 2,303 5,182 9,213 14,395 20,729 4,5 0,055 0,154 0,302 0,616 1,386 2,463 5,542 9,853 15,396 22,170 Technical details Control unit FS850S General Mounting inside hazardous area Ex-protection class II 2 G, Ex e mb [ib] IIC T6 II 2 D, Ex td [ibd] [pd] A21 IP65 T 70 C Environment IP 65 (Remark: without considering outlet drill) protection Housing Dimensions H x W x D: 220 mm x 120 mm x 90 mm Electrical specifications Material Aluminium, lacquered / Ral 7035 Power consumption about 2.5 VA (without peripherals) Main voltage 24VDC, 110VAC, 120VAC, 220VAC, 230VAC 48...62 Hz Working circuits clamps 11, 12, 13, 14 AC: DC: U 250VAC, I 5A at cos ϕ > 0,7 U 30 VDC, I 5 A, P 150 W Control circuits Terminal 1..10 Ex protection class: intrinsically safe Ex ib IIC see declaration of conformity for further details BVS 06 ATEX E 088 Pneumatic Pressure range 0... 18 mbar Flow rate range dependent on plate orifice, see table above Mounting Position Inlet and outlet of the control unit should be lined up on a horizontal axis. Environment temperature -10 C...+45 C at T6-10 C...+60 C at T4 Humidity 5-95%, non-condensing Ex p Configuration Parameter input LC-Display, menu guided Different languages : German, English, French, Spanish, Dutch Storage Permanently failure proved in EEPROM
Dimensions Figure 1: Dimensions FS850S Figure 2: Mounting examples Figure 3: Dimensions and template BT851 Figure 4: Dimensions BT855, template BT854 Figure 5: Dimensions digital solenoid valve Figure 6: Dimensions proportional solenoid valve Gönnheimer reserves the right, at any time without notice, to change said dimensions and specifications
GONNHEIMER, printed in 05.2011 Type code Control unit FS850S. Mains voltage: 230 VAC... 120 VAC... 24 VDC....0.2.6 Plate orifice: 4 mm, range 0.5...1,1 m 3 /h... 6 mm, range 1.1...2,7 m 3 /h... 10 mm, range 2.5...6,5 m 3 /h... 14 mm, range 6...11 m3/h... 18 mm, range 9...15 m3/h... Accessories: Additive window in control unit FS850S (recommendable, if no operation panel is used)..0.2.4.6.8 Operation panels BT Intelligent operation panel, Ex ib IIC T6, for mounting on the front Intelligent operation panel, Ex ib IIC T6, with IP65 housing Operation panel, Ex ib IIC T6, for mounting on the front with key-operated switch Operation panel, Ex ib IIC T6, with IP65 housing with key-operated switch BT851.0 BT851.5 BT854.0 BT854.1 BT855.0 BT855.1 Purge medium valve: Digital SVD. Continuous flow... Leakage compensation....d.l Nozzle:1 mm....1 1,5 mm....1.5 2 mm....2 3 mm....3 4 mm....4 5 mm....5 6mm....6 Order mains voltage in plain text (e.g.svd.l.2 24VDC). (Ex de IIC T4) Proportional, suitable for Ex p- housing size SVP Up to 300 l... bigger than 300l....3.5 Remark: please order the Ex- solenoid valve fuse separately Fuse for solenoid valve Nominal Order.Nr (Ex-version) 100 ma SI850.0 UNominal 230 VAC, 220 VAC 120 VAC, 110 VAC 24 VAC, 24 VDC SVP 200mA 315mA 1,6 A SVD 100mA 160mA 630mA 160mA 200 ma 315 ma 500 ma 630 ma 1000 ma 1600 ma 2000mA SI850.1 SI850.2 SI850.3 SI850.4 SI850.5 SI850.6 SI850.7 SI850.8 Maximum fuse data dependent on main voltage Main voltage UN 230 V 200 ma 220 V 250 ma 120 V 315 ma 110 V 500 ma 24 V 2000 ma Maximum fuse current Ex p- housings on request To get the correct solenoid valve fuse comply the table above Fuse for solenoid valve. If you want to use an other solenoid valve, with different fuse data, it is important to consider the maximum values in the table on the left side. By each main voltage a safety maximum current rate is given. Example: The main voltage is 220 V. In this case the maximum fuse current is 250 ma. M.C.A sas Via MADONNA 57 20021 Bollate(Mi) Tel 02 3512774 fax 02 332600670 E.MAIL : mca@mcastrumenti.it www.mcastrumenti.it