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Ex-Assembly and Installation
Manual
T07 enclosure-combinations (U)
ATEX & IECEx
Content
1
Introduction .............................................................................................................. 4
2
General Data ............................................................................................................. 6
3
General Safety Notes ............................................................................................... 6
4
Compliance with Standards .................................................................................... 7
5
Document Overview ................................................................................................. 8
6
Technical Data .......................................................................................................... 9
6.1
Parameters of the explosion protection ............................................................... 9
6.2
Mechanical parameters ....................................................................................... 9
6.3
Chemical Resistance......................................................................................... 12
6.4
Others ............................................................................................................... 12
7
Transportation, Storage, Disposal ........................................................................ 13
8
Installation and Commissioning ........................................................................... 14
8.1
Design of the enclosure-combination ................................................................ 14
8.2
Opening of the Enclosure .................................................................................. 15
8.3
Adaption of a Mounting Adapter ........................................................................ 16
8.4
Drillings of the Cable Glands ............................................................................. 17
8.5
Notification for Installations ............................................................................... 17
8.6
Closing of the Enclosure ................................................................................... 18
8.7
Grounding / Potential Equalization .................................................................... 18
8.8
Installation ......................................................................................................... 18
9
Declaration of confirmity ATEX/ IECEx ................................................................ 19
10
EC Type Examination (TÜV 14 ATEX 7473) ...................................................... 20
11
Certificate of Conformity (IECEx TUR 14.0024U) ............................................. 23
12
Notes .................................................................................................................... 27
Doc.-ID: 131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx, page 2 of 30
Table of Figures and Charts
Figure 1-1: VA1.2 (left) VA2.2 (right) ................................................................................. 5
Figure 8-2: Explosion drawing of the enclosure-combination (rear view) ........................ 14
Chart 8-1.: Connection elements VA1.x enclosure .......................................................... 15
Chart 8-2.: Connection elements VA2.x enclosure .......................................................... 15
Figure 8-3: VA1.x.K1 (standard execution) ...................................................................... 16
Revision history
Product:
Titel:
Doc. -Id.
Author:
Date:
T07 – (VA1.x & VA2.x)
T07 – Ex-Assembly and Installation Manual
131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx
Thiemo Gruber / Steffen Seibert
May 05, 2014
Rev.
Date
Name
Comments
Authorization of ATEX/
IECEx Supervisor
01
02
03
June 02, 2014
July 14, 2014
2014/09/25
T. Gruber
T. Gruber
S.Seibert
Additions and corrections
Supplement warning message for mining area
Adding the certificates
Diverse corrections.
25.09.2014
Doc.-ID: 131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx, page 3 of 30
1
Introduction
The Ex-d enclosure-combinations VA1.x and VA2.x (type 07) have been certified according to ATEX as well as IECEx and are delivered as pressure–resistant components with
the applicable “U-certificate”.
The stainless steel enclosure is available in two sizes; VA1 and VA2, differing in length,
in profile, in the quantity of threaded holes/connecting elements, as well as in blind holes;
however, the characteristic design is identical. The flange located on the enclosure’s front
side disposes of a sight glass (optical adapter); the one situated on the rear side allows
the introduction of one, or several, explosion proof cable glands and/or compatible sealing plugs. The design allows the combination of the applicable enclosure body with different optical flanges (VA1.x.BOR, VA2.x.ZnS etc.) but also with different cable glands
(VA1.x.K1, VA1.x.K2 etc.) in order to meet the requirements of the individual application.
The enclosures are available with and without pins to allow either the installation on a
wall bracket (with pin) or on a sight glass (without pin).
The different enclosure-combinations also allow the usage of non-ex electrical components in gas and/or dust explosion risk atmospheres. Due to the sight glass, the pressure-resistant enclosure is particularly suitable for the installation of a camera module or
an illuminant.
The different combination possibilities of the enclosures guarantee a very high degree of
flexibility, meeting the requirements of the various applications, for example for hazardous areas in the chemical as well as petro-chemical industry, at off-shore installations,
pits at risk of firedamp, and bio-gas plants. The enclosures are suitable for zone 1, 2 as
well as 21 and 22 including the explosion groups IIC/ IIIC where the risk of mechanical
danger is “high” and in mining areas where the risk of mechanical danger is “low”. Using
the empty enclosures in the mining sector with a “high” risk of mechanical hazard, the
presence of a device for protecting light transmitting parts must be ensured.
The enclosures are allowed within atmospheres containing hydrogen or acetylene or in
atmospheres with flammable lint or with conductive dust at occasional risk.
According to the drop and resistance to impact tests (DIN EN 60079:0 2012), the enclosures VA1.x and VA2.x have been certified as stationary as well as mobile components.
Regarding the electrical input, neither limits nor mandatory values have been determined.
Surface temperatures or temperatures inside the enclosure which may be caused by
thermal dissipation have to be evaluated in the course of the equipment approval process.
The ambient as well as operating temperature must range between -60°C and 85°C. The
material specification of the enclosure allows the usage within the temperature classes
T6, T5, T4, and T3 (max. 200°C surface temperature).
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The protection level of the individual enclosure-combination meets the requirements of
IP68 (DIN EN 60529) and is therefore suitable for the permanent immersion in liquid up
to a limited water column.
The metal as well as nonmetal enclosure components dispose of a high resistance concerning environmental and chemical conditions such as sea water corrosion or acid environments. The stainless steel components are, in addition, also available in different
stainless steel executions (MNo.1.4xxx according to DIN EN 10020) to allow meeting
specific application requirements.
Figure 1-1: VA1.2 (left) VA2.2 (right)
Doc.-ID: 131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx, page 5 of 30
2
General Data
SAMCON Prozessleittechnik GmbH
Schillerstrasse 5a/ 17
D-35102 Lohra-Altenvers
Telephone: +49 6426 9231-0
Telefax:
+49 6426 9231-31
Internet:
www.samcon.eu
3
General Safety Notes
Attention!
The enclosures VA1.x and VA2.x must not be used in zone 0 and/or
zone 20. The specific values detailed on the enclosure type plate have
to be observed. Modifications or changes at the enclosure are not allowed. The enclosures are only suitable for the intended use and are
only to be operated when undamaged and in good order and condition.
Attention!
Attention when opening and closing the enclosures. It is mandatory
that specified torques and screw connection values have to be observed. Circular cylindrical surfaces have to be checked for damages
and residues at the fits of the flange and the body as well as at the fine
threads of the cable glands (flame-proof gap).
Attention!
Repairs must only be carried out with original parts of SAMCON
Prozessleittechnik GmbH. Repairs concerning the explosion protection have to be carried out by Samcon Prozessleittechnik GmbH in
accordance with the national rules and regulations.
Attention!
External sources of heat or cold have to be considered prior to installation. The indicated temperature ranges have to be observed!
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4
Compliance with Standards
The enclosure-combination VA1.x and VA2.x complies with the following rules and regulations:
-
-
-
Directive 94/9/EC Equipment and protection systems for the intended use within hazardous areas
IEC 60079-0:2011, modified + Cor.:2012
German version EN 60079-0:2012 - „General Requirements“
IEC 60079-1:2007
German version EN 60079-1:2007 - „Flame-proof enclosure (d)“
IEC 60079-31:2008 + Corrigendum 1:2009
German version EN 60079-31:2009 - „Dust Explosion Protection (t)“
IEC 60529:1989 + A1:1999
German version EN 60529:1991 + A1:2000
- „Protection classes by enclosures (IP-Code)
ISO 286-1:2010
German version EN ISO 286-1:2010 – „Geometrical product specification, l1:
ISO Tolerance System for Fittings“
ISO 468:1982 – Surface roughness
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5
Document Overview
SAMCON enclosure overview
Enclosure
VA & VA2 (ATEX):
- EX Installation manual
- EC Declaration of conformity
- EC type examination
VA
- Data sheet
- Technical drawings
VA2
- Data sheet
- Technical drawings
Enclosure-Combination T07
VA1.x & VA2.x (ATEX, IECEx):
- EX Installation manual
- EC Declaration of conformity
- EC type examination
VA1.x
- Data sheet
- Technical drawings
VA1.2
- Data sheet
- Technical drawings
VA2.x
- Data sheet
- Technical drawings
VA2.2
- Data sheet
- Technical drawings
The present document is marked in red.
Doc.-ID: 131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx, page 8 of 30
6
Technical Data
6.1
Parameters of the explosion protection
Identification marks according to
Directive 94/9/EG:
II 2 G (Zone 1 and 2)
II 2 D (Zone 21 and 22)
I M2 (Mining)
Identification marks according to protection level
„ATEX“ and „IECEx“ (EN 60079-0):
Explosion protection (gas):
Explosion protection (dust):
Explosion protection (mining).
Ex d IIC Gb
Ex tb IIIC Db IP68
Ex d I Mb
EC type examination:
Test log:
IECEx Zertifikat:
IECEx Test Report:
TUV 14 ATEX 7473 U
557/Ex473.00/14
IECEx TUR 14.0024U
DE/TUR/ExTR 14.0024/00
6.2
Mechanical parameters
Housing material:
Stainless steel (according to EN 10027-2)
MNo.: 1.4301 (X5CrNi18-10), AISI 304 (V2A) -(standard)MNo.: 1.4305 (X8CrNiS18-9), AISI 303
MNo.: 1.4401 (X5CrNiMo17-12-2), AISI 316, (V4A)
MNo.: 1.4404 (X2CrNiMo17-12-2), AISI 316L, (V4A)
MNo.: 1.4571 (X6CrNiMoTi17-12-2), AISI 316Ti, (V4A)
Additional materials :
MNo.: 1.0330 (spring steel)
PTFE with glass micro beads (GYLON® Style 3504 blue),
Borosilicate glass (Ilmadur 10 I-420) -(standard)Germanium/ zinc sulphide glass -(optional)Silicone casting compound (Silcoset 105 incl. Cure Agent 28)
VMQ (silicone)
Doc.-ID: 131018-PT07BAU-TG-EX-Installation Manual_en rev.3.docx, page 9 of 30
Housing Dimensions without pin (WxHxD):
VA1.x (K1)
VA1.x (K2)
VA1.1 (K1)
VA1.1 (K2)
VA1.2 (K1)
VA1.2 (K2)
VA2.x (K1)
VA2.x (K2)
VA2.1 (K1)
VA2.1 (K2)
VA2.2 (K1)
VA2.2 (K2)
79.0 x 79.0 x ... [mm]
79.0 x 79.0 x ... [mm]
79.0 x 79.0 x 128.0 [mm]
79.0 x 79.0 x 141.0 [mm]
79.0 x 79.0 x 157.0 [mm]
79.0 x 79.0 x 171.0 [mm]
113.0 x 113.0 x ... [mm]
113.0 x 113.0 x ... [mm]
113.0 x 113.0 x 210.5 [mm]
113.0 x 113.0 x 226.0 [mm]
113.0 x 113.0 x 260.5 [mm]
113.0 x 113.0 x 277.0 [mm]
VA1.x (K1)
VA1.x (K2)
VA1.1 (K1)
VA1.1 (K2)
VA1.2 (K1)
VA1.2 (K2)
VA2.x (K1)
VA2.x (K2)
VA2.1 (K1)
VA2.1 (K2)
VA2.2 (K1)
VA2.2 (K2)
79.0 x 96.0 x ... [mm]
79.0 x 96.0 x ... [mm]
79.0 x 96.0 x 128.0 [mm]
79.0 x 96.0 x 141.0 [mm]
79.0 x 96.0 x 157.0 [mm]
79.0 x 79.0 x 171.0 [mm]
113.0 x 138.5 x ... [mm]
113.0 x 138.5 x ... [mm]
113.0 x 138.5 x 210.5 [mm]
113.0 x 138.5 x 226.0 [mm]
113.0 x 138.5 x 260.5 [mm]
113.0 x 138.5 x 277.0 [mm]
VA1.x (K1)
VA1.x (K2)
VA1.1 (K1)
VA1.1 (K2)
VA1.2 (K1)
VA1.2 (K2)
VA2.x (K1)
VA2.x (K2)
VA2.1 (K1)
VA2.1 (K2)
VA2.2 (K1)
VA2.2 (K2)
= n.a.
= n.a.
= 2000 [g]
= 2500 [g]
= 2200 [g]
= 2900 [g]
= n.a.
= n.a.
= 5100 [g]
= 6100 [g]
= 5800 [g]
= 6500 [g]
Housing Dimensions with pin (WxHxD):
Housing weights:
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Available housing volume of the
pressure resistant chamber:
VA1.x (K1)
VA1.x (K2)
VA1.1 (K1)
VA1.1 (K2)
VA1.2 (K1)
VA1.2 (K2)
VA2.x (K1)
VA2.x (K2)
VA2.1 (K1)
VA2.1 (K2)
VA2.2 (K1)
VA2.2 (K2)
n.a.
n.a.
360 [cm3]
360 [cm3]
480 [cm3]
480 [cm3]
n.a.
n.a.
1520 [cm3]
1520 [cm3]
1960 [cm3]
1960 [cm3]
Maximum quantity of cable glands:
T07-VA1.x (K1):
T07-VA1.x (K2):
T07-VA2.x (K1):
T07-VA2.x (K2):
2x M20x1.5 + 1x M16x1.5
1x M20x1.5 + 1x M16x1.5
2x M25x1.5 + 2x M20x1.5
2x M25x1.5 + 1x M20x1.5
General tolerance of the stainless steel
body and flange components:
„f“ (fine)
„H“
Fitting for the flameproof gap (cylinder)
according to DIN ISO 286-1
T07-VA1.x:
T07-VA2.x:
- Length and angular
measure DIN ISO 2768-1
- Form and position
DIN ISO 2768-2
, nominal diameter: 57mm,
Tolerance: -60...-30 [µm 0...+46 [µm]
Gap length: L1=13.0 [mm], L2=16.2 [mm]
, nominal diameter: 91mm,
Tolerance: -71...-36 [µm 0...+54 [µm]
Gap length: L1=15.0 [mm], L2=23.0 [mm]
Surface of the cylindrical fitting
Average surface finish according to DIN ISO 468
T07-VA1.x:
Ra ≤ 6.3 µm
T07-VA2.x:
Ra ≤ 6.3 µm
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6.3
Chemical Resistance
General:
Acetone, alcohol, acetylene, ammonia, aniline, benzene, butane, chlorine, pressurized water, pressurized
air, ethane, crude oil, fluorine, glycerin, sea water, methane, oils, phosphoric acid, propane etc. …-(excerpt)-
Stainless Steel:
WNr.1.4301:
(Standard)
WNr.1.4401:
WNr.1.4404:
6.4
Water, steam (water), humidity, mild organic
and anorganic acids, optimized corrosion
resistance due to electro-polishing possible
Increased roughness, optimized corrosion
resistance, permanent resistance against sea
water (offshore plants) and aggressive
chemical substances
Resistance against aggressive acids and
also media containing chlorine
(highly acid environments), not suitable for
permanent sea water applications
Others
Ambient temperature range:
-60°C...+85°C
Temperature classes (EX):
T6, T5, T4 and T3 (max. surface temp.: 200°C)
Enclosure protection level:
IP68 (DIN EN 60529)
Testing conditions: 24h, 3m water column, 5°C),
an additional mechanical protection against water jets is recommended
Borosilicate glass (standard) λ=350 2000 [nm]
Germanium glass (optional) λ= 7500–14000 [nm]
Zinc sulfide glass (optional) λ=8000–12000 [nm]
Sight glass material:
Sight glass dimensions and angles:
VA1.x:
VA2.x:
Electrical power:
DxT = 48 x 10 [mm] D1= 40 [mm] (visible)
= 100° (max. aperture angle)
DxT = 80 x 10 [mm] D1= 72 [mm] (visible)
= 120° (max. aperture angle)
n.a.
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7
Transportation, Storage, Disposal
-
Avoid impacts, shocks, and strong vibrations
-
Pay attention to possible damages to the packaging and/or the housing
-
Store the housing under dry and weather-proof conditions either using the original
packaging or suitable storage measures with protection against dirt and weather
influences
-
Avoid exposing the housing to extreme heat or cold
-
Make sure to observe the national regulations when disposing of any components
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8
Installation and Commissioning
8.1
Design of the enclosure-combination
10
0
8
6
4
11
0
12
0
3
2
1
14
0
16
0
13
0
15
0
Figure 8-2: Explosion drawing of the enclosure-combination (rear view)
Components of the pressure resistant enclosure
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Cylinder screws hexagon socket
Spring discs
Optical adapter VA1.x.BOR, VA2.x.BOR, VA2.x.ZnS
Compound (silicone compound)
Sight glass VA1.BOR, VA2.BOR, VA2.GER, VA2.ZnS
Silicone buffer ring
Adjusting washer
Seeger-V-ring
Flat gasket
Enclosure body VA1.1.R, VA1.2.R, VA2.1.R, VA2.2.R
Flat gasket
Cable gland flange VA1.x.K1, VA1.x.K2, VA2.x.K1, VA2.x.K2
Washer
Spring discs
Cylinder screws slit
Cylinder screws hexagon socket
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8.2
1.
Opening of the Enclosure
In order to open the pressure-resistant housings, loosen the cylinder head screws
(DIN 912) which are situated at the flanges by using an Allen-key size 4 (included
in the delivery scope). In order to avoid the unintentional loosening of the screws,
the screw connection disposes of a spring washer (DIN 127 Form A) (q.v. chart 81/2 sec. 1, 2, 14 and 16).
Attention: To avoid the unintentional loosening of the screw connection due to impacts or vibrations etc. as well as to allow for an additional sealing purpose, an
acrylate (LOCTITE® 243™) is applied to the joints. Avoid contact with skin and/or
clothing.
Screw connection of the VA1.x and VA2.x enclosure-combinations
Type
Specification
Quantity
Length
Material
Quality
Directive
Tightening torque
VA1.x.BOR
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
6
10 (14) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
VA1.x.K1
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
6
10 (14) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
VA1.x.K2
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
5
25 (29) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
Chart 8-1.: Connection elements VA1.x enclosure
Type
Specification
Quantity
Length
Material
Quality
Directive
Tightening torque
VA2.x.BOR/ ZnS
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
8
12 (16) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
VA2.x.K1
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
8
12 (16) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
VA2.x.K2
Cylinder screw hexagon socket
M4x0.7 ISO metric
(dextrorotatory)
7
30 (34) mm
1.4301 A2 - 70
6g
DIN 912/ ISO 4762
3 Nm
Chart 8-2.: Connection elements VA2.x enclosure
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2.
Pull out carefully the flange in a straight manner (q.v. Chart 8-1 sec. 3 and Chart 82 sec.12). Due to the under-pressure which will be created when separating the
flanges, additional effort might be required.
Be aware not to tilt the components! It is absolutely mandatory not to damage the
cylindrical surface of the clearance fit (H8f7 – ISO 286) of body and flange components (drilling and arbor) (flame-proof gap – DIN EN 60079-1)!
Attention: At the cylindrical fitting areas of the body and flange components, a
thin lubrication layer (Molykote® P-40) is applied in order to avoid fitting corrosion
and to grant protection against mechanical strain. Avoid contact with skin and/or
clothing.
8.3
Adaption of a Mounting Adapter
1.
The blind holes on the inside of the flange dispose of a thread (M3x0.5 or
M4x0.7) and can be used to freely place installations. Spacing and positions of
the tapped holes at the cable as well as at the inlet flange are flexible and can reflect customary adaptions. Limits for the drilling grid have been determined by
SAMCON GmbH within the explosion protection concept during the ATEX/ IECEx
certification and are mandatory.
Figure 8-3 illustrates the standard execution of the cable gland flange VA1.x.K1.
The minimum remaining wall thickness from thread to thread or from thread to
flame-proof gap respectively, must not be less than 3mm. The maximum depth of
the thread is 8mm.
M3x0.5
M4x0.7
Figure 8-3: VA1.x.K1 (standard execution)
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Via the threaded holes it is possible to adapt the position of sheet metal bending
parts and electrical modules etc. The screw connection of the installation components must not create mechanical overstress to the threads (deformations). In
case of any necessary adaptions, only the screws specified in the installation
manual are allowed to be used. The installations have to be applied in a stationary/fixed manner (immovable) and have to resist potential impacts and vibrations.
Mounting adapters are not included in the delivery scope, however SAMCON
GmbH offer several universal adaptors for cameras as well as illuminants.
Attention: According to DIN EN 60079-1: 2008 Annex [D.3.10], for ex-component
housings of the group I, IIA and IIB it is allowed to install components regardless
of their alignment if it is guaranteed that at least 20% of each cross section area
remain free to allow the unobstructed gas flow so that an explosion can develop
without any restrictions. For ex-component housings of the group IIC, installations
of all types are allowed to be mounted if 40% of each cross section area remains
free to allow the unobstructed gas flow so that an explosion can develop without
any restrictions. The meet the aforementioned values, it is possible to combine individual areas; however, each area has to dispose of a minimum size of 12.5 mm
in each direction.
8.4
Drillings of the Cable Glands
Quantity, specification and position of the fine tapped holes for the pressure resistant cable screw connection at the cable glands are variable (q.v. chapter 6.2 of
the certification). Idle openings have to be covered with suitable blind plugs.
Attention: In case the IIC enclosure-combination exceeds the volume of 500cm3
(q.v. chapter 6.2) the applicable ex-d cable screw connection has to be equipped
with an internal pressure stop (incl. compounding the individual conductors).
8.5
Notification for Installations
Evaluation of batteries and acceptable primary cells according to DIN EN 60079-1:
2008 Tab. [E.1].
Evaluation of temperatures and electric input according to DIN EN 60079-0: 2012
[26.5.1.1]
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8.6
1.
2.
3.
8.7
Closing of the Enclosure
The flanges must not be tilted
The tightening torque of the M4 cylinder head screw is 3 Nm. The screws have to
be tightened diagonally and it has to make sure that the spring washers are in
place
Please make sure that the flat gaskets are not damaged and that they are positioned correctly. The GYLON sealings/hole grid for the optic adapter, are identical
for K1 and K2 flange
Grounding / Potential Equalization
At the specified location, a cable eye or clip has to be applied when manipulating
the enclosures in order to carry out a potential equalization (danger of sparks due
to electrostatic charging). The grounding has to be in accordance with the national
rules and regulations (minimum Q = 4mm2 fixed).
8.8
Installation
---- lateral pin, fixation, possibilities of adaptions at the cable gland flange and at teh optical adapter ---
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9
Declaration of confirmity ATEX/ IECEx
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10
EC Type Examination (TÜV 14 ATEX 7473)
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11
Certificate of Conformity (IECEx TUR 14.0024U)
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Notes
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