3G Operating instructions Type: 03-5110-00.. Document no.: 03-5110-7D0001 Version: 01. July 2011/Rev. 0
Operating Instructions Type: 03-5110-00.. Document no.: 03-5110-7D0001 Version: 1 July 2011 / Rev. 0 Contents Page English 1 24 Appendix EC Declaration of Conformity EC Type Examination Certificate BARTEC GmbH Tel.: +49 7931 597-0 info@bartec.de Max Eyth-Strasse 16 Fax: +49 7931 597-119 www.bartec.de 97980 Bad Mergentheim Germany Reservation: Technical data subject to change without notice. Changes, errors and misprints may not be used as a basis for any claim for damages.
Table of Contents 1 Safety 1 1.1 This Manual 1 1.1.1 Languages 2 1.2 Handling the Product 2 1.3 Use in Accordance with the Intended Purpose 2 1.3.1 Use Exclusively for the Intended Purpose 2 1.3.2 Improper Use 2 1.4 Owner s/managing Operator s Obligations 2 1.5 Safety Instructions 3 1.5.1 General Safety Instructions 3 1.5.2 Safety Instructions for Operation 3 1.6 Standards Conformed To 4 1.7 Ex Protection Type Marking and Certification 4 1.8 Warranty 5 2 Product Description 6 2.1 Mode of Operation 6 2.2 Configuration 7 3 Installation 8 4 Connections 9 4.1 Directions for Wiring to the 9 4.2 Electrical Connection 10 5 Operating 11 6 Commissioning 12 6.1 Inspections Before Commissioning 12 6.2 Adjusting the Rate of Loss through Leakage 12 6.3 Commissioning 12 7 Operation 13 8 Maintenance and Care 14 9 Malfunctioning and Troubleshooting 15 10 Technical Data Sensor Module 16 11 Order Numbers 17 12 Appendix 18 12.1 Dimensions 18 12.2 Rate of Air Leakage 19 13 Declarations of Conformity and Approvals 20 13.1 EC Declaration of Conformity for the 20 Technical data subject to change without notice.
Safety 1 Safety 1.1 This Manual O p e r a t i n g I n s t r u c t i o n s It is essential to read and observe the contents of this documentation and this chapter in particular before you install and operate the Purge Gas Valve 3G. This manual contains the information necessary for using the Purge Gas Valve 3G in accordance with the intended purpose. It is addressed to technically qualified personnel. Familiarity with and the technically perfect implementation of the safety instructions and warnings described in this manual are preconditions for safe installation and commissioning. The safety notes and warnings given in this documentation are given in a general way and only qualified personnel will have the necessary specialised knowhow to interpret and implement them correctly in specific cases. This manual is an integral part of the scope of supply even if for logistical reasons it can be ordered and delivered separately. If you need any further information, please ask the BARTEC branch that is near you or responsible for your area. Particularly important points in this documentation are marked with a warning symbol: D A N G E R The DANGER sign draws attention to a danger which will lead to death or serious injury if not avoided. W A R N I N G WARNING draws attention to a danger which can lead to death or serious injury if it is not avoided. C A U T I O N CAUTION draws attention to a danger which can lead to an injury if it is not avoided. A T T E N T I O N ATTENTION draws attention to measures to be taken to prevent damage to property. N o t e Important instructions and information on effective, economical and environmentally compatible handling. Technical data subject to change without notice. Page 1 of 22
Safety 1.1.1 Languages 1.2 Handling the Product N o t e The original operating instructions were written in German. All other available languages are translations of the original operating instructions. The operating instructions are available in various languages. They are enclosed with the product in the languages German, English, French, Italian, Spanish and Russian. If you require any other languages, please ask BARTEC or request them when placing the order. The product described in these operating instructions has been tested and left the factory in perfect condition as regards meeting safety requirements. To maintain this condition and ensure that this product operates perfectly and safely, it may be used only in the manner described by the manufacturer. Appropriate transportation, suitable storage and careful operation are also essential for the perfect and safe operation of this product. The Purge Gas Valve 3G must be mounted properly and securely onto the Ex p operating equipment if it is to work perfectly and correctly. 1.3 Use in Accordance with the Intended Purpose 1.3.1 Use Exclusively for the Intended Purpose The Purge Gas Valve 3G serves exclusively as a purge gas inlet for Ex p operating equipment and is intended for use in Explosion Group II, Category 3G and Temperature Class T4. 1.3.2 Improper Use The permissible operating data for the device being used must be observed. Any other use is not in accordance with the intended purpose and can cause damage and accidents. The manufacturer will not be liable for any use beyond that of its exclusive intended purpose. 1.4 Owner s/managing Operator s Obligations The owner/managing operator undertakes to restrict permission to work with the Purge Gas Valve 3G to people who: are familiar with the basic regulations on safety and accident prevention and have been instructed in the use of the Purge Gas Valve 3G have read and understood the documentation, the chapter on safety and the warnings. The owner/managing operator must check that the safety regulations and accident prevention rules valid for the respective application are being observed. Page 2 of 22 Technical data subject to change without notice.
Safety 1.5 Safety Instructions 1.5.1 General Safety Instructions 1.5.2 Safety Instructions for Operation Take the device out of the hazardous area before wiping it with a dry cloth or cleaning it! Do not open devices in a hazardous area. The general statutory regulations or directives relating to safety at work, accident prevention and environmental protection legislation must be observed, e.g. the German industrial health and safety ordinance (BetrSichV) or the applicable national ordinances. In view of the risk of dangerous electrostatic charging, wear appropriate clothing and footwear. Avoid the influence of heat that is higher or lower than the specified temperature range. Keep the devices away from moisture. Upkeep For electrical systems the relevant installation and operating regulations must be complied with (e.g. Directive 99/92/EC, Directive 94/9/EC and the national applicable ordinances IEC 60079-14 and the DIN VDE 0100 series)! The disposal of this equipment must comply with the national regulations on the disposal of waste. Maintenance Regular servicing is not necessary if the equipment is operated correctly in accordance with the installation instructions and environmental conditions. Inspection Under IEC 60079-19 and EN 60079-17, the owner/managing operator of electrical installations in hazardous areas is obliged to have these installations checked by a qualified electrician to ensure that they are in a proper condition. Repairs Repairs on explosion-protected operating equipment may be done only by authorised persons working in accordance with the latest developments in technology and using original spare parts. The applicable regulations must be observed. Commissioning Before commissioning, check that all components and documents are there. Technical data subject to change without notice. Page 3 of 22
Safety 1.6 Standards Conformed To The sensor module conforms to Directive 94/9/EC for devices and protective systems for their use to the intended purpose in hazardous areas (ATEX Directive). Pursuant to this directive, the following standards serve as a basis for the : Standard Designation EN 60079-0:2006 Electrical apparatus for explosive gas atmospheres - Part 0: General requirements EN 60079-15:2005 Explosive atmosphere DIN VDE 0580:2000 EN 60204-1:2004 Part 15: Construction, test and marking of type of protection "n" electrical apparatus Electromagnetic devices and components - General specifications Safety of machinery- Electrical equipment of machines Part 1:General requirements EN 60529:1991+A1:2000 EN 61000-6-2:2005 Degrees of protection provided by enclosures (IP code) Electromagnetic Compatibility (EMC) - Part 6-2: Generic standards - Immunity for industrial environments 1.7 Ex Protection Type Marking and Certification The following markings showing Ex protection and certification are affixed to the device: ATEX II 3G Ex na II T4 Page 4 of 22 Technical data subject to change without notice.
Safety 1.8 Warranty W A R N I N G Risk of death or serious injury if the control is modified or converted without the manufacturer s approval. It can then no longer be assured that the design and production will provide explosion protection, stress tolerance and conformance to safety requirements. Before making any modifications or implementing any conversions, contact the manufacturer and obtain written approval. Use only original spare parts and original expendable parts. Scope of warranty N o t e The manufacturer grants a complete guarantee only and exclusively for the spare parts ordered from the manufacturer. As a basic rule, our General conditions of Sale and Delivery apply. These are available to the owner/managing operator at the latest on formation of a contract. Guarantee and liability claims for personal injury and damage to property are excluded if they are due to one or more of the following reasons: use of the for a purpose other than that for which it is intended. incorrect installation, commissioning, operation and maintenance of the Digital Purge Gas Valve 3G. non-compliance with the instructions in the manual with respect to transport, storage, assembly, commissioning, operation and maintenance unauthorised structural modifications of the inadequate monitoring of parts that are subject to wear repairs done incorrectly. disasters due to the effects of foreign matter or Act of God (events outside human control). We guarantee the and its accessories for a period of 1 year starting on the date of delivery from the Bad Mergentheim factory. This guarantee covers all parts of the delivery and is restricted to the replacement free of charge or the repair of the defective parts in our Bad Mergentheim factory. As far as possible, the delivery packaging should be kept for this purpose. In the event of such a claim, the goods must be returned to us after written arrangement. The customer cannot claim to have the repairs done at the site of installation. Technical data subject to change without notice. Page 5 of 22
Product Description 2 Product Description 2.1 Mode of Operation The is an optional component in a SILAS control. It serves to introduce a purge gas into a pressurised piece of operating equipment in Zone 2. It is actuated by the SILAS controller. The digital purge gas valve is particularly suitable for neutral media such as inert gases and instrument air. The digital purge gas valve does not need operating or differential pressure to function. The valve switches from 0 bar on. The 2/2-way solenoid valve opens directly by means of the solenoid plunger and is closed by a compression spring. The sealing plug is raised from the seat by the magnetic drive alone. In the de-energised state, the solenoid valve is closed. The special design and geometry of the parts inside the valve allow gentle closing with only very slight pressure peaks. In addition, an adjustable bypass, serving to compensate for the leakage in the Ex pz area, is integrated in the valve body. Page 6 of 22 Technical data subject to change without notice.
Product Description 2.2 Configuration 1 9 8 3 2 7 6 5 4 Item Component 1 Device plug 2 Purge air nozzle, e.g. ø 2.8 or 5.5 3 or purge air nozzle, e.g. ø 3.9 or 7.7 4 Bypass element in the leakage air valve 5 Adjusting screw 6 Valve body 7 Bulkhead union 8 Nozzle 9 Magnet Technical data subject to change without notice. Page 7 of 22
Installation 3 Installation A T T E N T I O N ATTENTION Damage due to incorrect installation. Incorrect installation can cause an excessively high pressure to build up inside the Ex pz operating equipment. Pay attention during installation to the digital purge gas valve s direction of flow. The purge gas must flow into the Ex p operating equipment. The flow direction is specified on the valve body. Decide on the mounting position on the wall of the enclosure on the Ex pz operating equipment. Drill a 17-mm-diameter borehole into the enclosure wall. Mount the digital purge gas valve in accordance with the following drawing. The mounting parts are included in the scope of supply. 5 4 3 2 2 1 Item Designation 1 Bulkhead union 2 Washers 3 Digital purge gas valve 4 Sealing ring 5 Purge air nozzle Page 8 of 22 Technical data subject to change without notice.
Connections 4 Connections 4.1 Directions for Wiring to the D A N G E R Death or serious physical injury when the is opened in an explosive atmosphere. Risk of explosion. Before opening the lids on the enclosure, check the atmosphere for any explosive gases. A T T E N T I O N Short-circuits due to loose or protruding wires in the SILAS control unit. The SILAS control can become damaged. All core wires, including those not required, must be connected to a terminal. Lay the wires only in the space between the shield bus and the connecting terminal. Make sure none of the wires are loose or jut out/protrude. The following describes the procedure for feeding and connecting cables from the Digital Purge Gas Valve 3G to the SILAS control unit: Procedure: Loosen the 4 fastening screws in the lid on the SILAS control unit and take off the lid. Feed the connection cable from the through the cable glands into the Ex e junction box. Establish the electrical connections in accordance with the terminal assignment. Tighten terminals with 0.4-0.6 Nm. Put the shields and earthing connections onto the shield bus. Use the appropriate closures to seal cable glands that are not in use. Tighten cable glands with 3.0 Nm. Put the lid onto the SILAS control unit and tighten the 4 fastening screws with 1.4 Nm. Technical data subject to change without notice. Page 9 of 22
SILAS Connections 4.2 Electrical Connection D A N G E R Explosion hazard due to the operation of the digital purge gas valve 3G without series fuse The digital purge gas valve must always be operated with a series fuse. If the digital purge gas valve is operated in a SILAS control, the series fuse is mounted in the SILAS control unit. Check the series fuse s switching capacity. Depending on the type of digital purge gas valve, the following fuses must be used: Valve type Digital Purge Gas Valve AC 230 V, 50 Hz Digital Purge Gas Valve AC 115 V, 50 Hz Digital Purge Gas Valve DC 24 V Connect the digital purge gas valve as follows: Fuse T 80 ma T 160 ma T 500 ma The cores have distinguishing colours: Designation Core colour Terminal BN Brown 6 BL Blue 9,10 or 11 GN/YE Green/yellow 12 or 13 Fuse F1 Fuse for Page 10 of 22 Technical data subject to change without notice.
Operation 5 Operating Once commissioned and once the rate of air leakage has been set, the digital purge gas valve is operated automatically by means of the control to which the digital purge valve is attached. Technical data subject to change without notice. Page 11 of 22
Commissioning 6 Commissioning A T T E N T I O N ATTENTION Damage due to incorrect commissioning. 6.1 Inspections Before Commissioning Operating errors may occur if the operating instructions for the SILAS control unit are not observed. Follow the operating instructions relating to the SILAS control unit. Before putting into operation for the first time, check that: the digital purge gas valve has been installed in compliance with regulations, the connection has been established properly, the digital purge gas valve is not damaged, all screw connections have been tightened securely 6.2 Adjusting the Rate of Loss through Leakage First close the adjusting screw (1). To do so, use a suitable screwdriver and turn the adjusting screw in the clockwise direction as far as it can go. Refer to the diagram in Chapter 12.2 to determine the number of complete turns of the adjusting screw needed for the required quantity of leakage air depending on the operating pressure (2 bar or 3 bar). Use a suitable screwdriver to turn the adjusting screw in an anti-clockwise direction as often as is necessary to set the required quantity of leakage air. N o t e After this setting the enclosure s internal pressure should be between 2 mbar and 3 mbar during operation. 6.3 Commissioning 1 As soon as the SILAS controller is switched on, the digital purge gas valve connected to it starts operation automatically. The digital purge gas valve is not commissioned separately. Page 12 of 22 Technical data subject to change without notice.
Operation 7 Operation The is always operated with a SILAS control unit and for that reason the operating instructions for the SILAS must be observed when operating the. Technical data subject to change without notice. Page 13 of 22
Maintenance and Care 8 Maintenance and Care D A N G E R Death or serious physical injury due to inhalation of inert gas. Risk of suffocation. Before opening, stop the supply of ignition shield gas. When opening, make sure the escaping ignition shield gas cannot be inhaled directly. D A N G E R Death or serious physical injury due to disconnection in the protective earth connection. Explosion hazard. Before starting maintenance work on the Ex p operating equipment, make sure the valve is closed and there is no interruption in the protective earth connection. A T T E N T I O N ATTENTION Danger due to lines under pressure. Valve and pressure reducer are under pressure. Relieve pressure before beginning maintenance work. A T T E N T I O N ATTENTION Damage due to incorrect cleaning. Do not use any aggressive, abrasive or dissolving detergents. Use a damp cloth to clean the outside of the digital purge gas valve when necessary. The is virtually maintenance-free when operated under the conditions described in these instructions. Use a damp cloth to clean the outside of the digital purging gas valve when necessary. Page 14 of 22 Technical data subject to change without notice.
Malfunction and Troubleshooting 9 Malfunctioning and Troubleshooting Before looking for the fault, check that the components are mounted and connected correctly (see Installation Section). N o t e The following table with descriptions of faults and information on possible causes presupposes that the components have been mounted and connected correctly. Fault Possible Cause Remedy Digital purge gas valve does not open Rate of air leakage is too high Rate of air leakage is too low No voltage Short circuit Coil defective / interrupted Core area dirty Adapt power to the requirements Adapt power to the requirements Purging gas pressure is insufficient Insufficient power in the purging gas source Check voltage supply, cable connection and fuse Find and repair the cause. Replace digital purging gas valve Replace digital purging gas valve Set air leakage rate again Check equipment s leaktightness and extent of loss through leakage. Adapt the pressure to the requirements and if necessary increase the conductor s cross section. Adapt power to the requirements Technical data subject to change without notice. Page 15 of 22
Technical Data 10 Technical Data Sensor Module Parameter Specifications Design type Type of protection Area of use Protection class Poppet valve Ex na II T4 II 3G Nominal diameter DN 6.0 Installation position Pressure range max. flow at 2 bar at 3 bar Enclosure material Sealing material Flow media IP 65 with mounted female power connector Magnet on top 0 to 4 bar 300 l/min 380 l/min Brass NBR Temperature of the medium 0 C to +40 C Ambient temperature -10 C to +40 C Valve connection G 3/8 Installation Electrical Connection Voltage / power consumption cleaned instrument air (class 543) or inert gas inside Ex pz operating equipment Female power connector (DIN EN 175301-803) with 3-m cable AC 230 V, 50 Hz, 6.5 VA or AC 115 V, 50 Hz, 5.6 VA, DC 24 V, 6.0 W Voltage tolerance + 10% in conformance to VDE 0580 Duty cycle Nominal operation 100% DC Continuous Operation (CO) Page 16 of 22 Technical data subject to change without notice.
Order Numbers 11 Order Numbers Designation Order number AC 230 V, T4, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0026 AC 230 V, T4, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0027 AC 115 V T4, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0028 AC 115 V, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0030 DC 24 V, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0029 DC 24 V, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0031 Technical data subject to change without notice. Page 17 of 22
Appendix 12 Appendix 12.1 Dimensions Page 18 of 22 Technical data subject to change without notice.
L/h Appendix 12.2 Rate of Air Leakage The following diagram shows the rate of leakage (l/h) depending on the adjusting screw setting (in complete turns). 3 bar 2 bar Complete turns Technical data subject to change without notice. Page 19 of 22
Notes 13 Declarations of Conformity and Approvals 13.1 EC Declaration of Conformity for the Page 20 of 22 Technical data subject to change without notice.
Notes Technical data subject to change without notice. Page 21 of 22
Notes Page 22 of 22 Technical data subject to change without notice.
BARTEC protects p e o p l e a n d the environment b y t h e s a f e t y of components, s y s t e m s and plants. BARTEC GmbH Germany Max-Eyth-Straße 16 97980 Bad Mergentheim Phone: +49 7931 597-0 Fax: +49 7931 597-119 info@bartec.de www.bartec-group.com 03-5110-7D0001-08/11-BARTEC WerbeAgentur-294287