20140321 01-3711-7D0001 BA APEX2003 EN B

APEX 2003Control unit APEX 2003, Type 07-3711-12../....; Type 07-3711-22../....

Document No. 01-3711-7D0001 Version: 21.03.2014/Rev. B

Operating instructions

BARTEC GmbH Tel.: +49 7931 597-0 [email protected] 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 claims for damages.

Operating Instructions

APEX 2003 Control Unit

Type: 07-3711-12../….

07-3711-22../….

Document no.: 01-3711-7D0001 Version: 21 March 2014 / Rev. B

Contents Page English 1 - 96

Appendix EC Declaration of Conformity EC Type Examination Certificate

APEX 2003 Control Unit Type 07-3711-.2../....

Technical data subject to change without notice.

- EMPTY SHEET -


Table of Contents


1 Safety 6 1.1 This Manual 6 1.1.1 Languages 7 1.2 Handling the Product 7 1.3 Use in Accordance with the Intended Purpose 7 1.3.1 Exclusive Purpose 7 1.3.2 Improper Use 7 1.4 Owner/Managing Operator’s Obligations 7 1.5 Safety Instructions 8 1.5.1 General Safety Instructions 8 1.5.2 Safety Instructions for Operation 8 1.6 Standards Conformed to 9 1.7 Ex Protection Type and Certification 10 1.8 Warranty 10 2 Product Description 11 2.1 APEX Control Unit 11 2.2 “Pressurized Enclosure” Type of Protection 11 2.3 Schematic Diagram of an Ex p Control 12 2.4 APEX 2003 Control Unit 13 2.4.1 APEX 2003.00I 13 2.4.2 APEX 2003.00 (S) 14 2.4.3 APEX 2003.002x (S) 15 2.4.4 APEX 2003.MV (S) 16 2.5 Sensor-Module 17 2.6 Pressure Monitor 17 2.7 Adjustment Device 17 2.8 Purging Gas Valves 18 2.8.1 Digital Purging Gas Valve 18 2.8.2 Proportional Purging Gas Valve 18 2.9 Pressure Reducer with Pressure Gauge 19 2.10 Purging Gas Nozzle 19 2.11 Rain Protection Cap 20 2.12 Rain Protection Roof 20 3 Installation 21 3.1 APEX 2003.00I Control unit 21 3.1.1 Control configuration 21 3.1.2 Installation of the Control Unit 22 3.1.3 Installation of the Pressure Monitor 23 3.1.4 Installation of the Atmosphere Measuring Point 24 3.1.5 Installation of the Sensor Module 25 3.2 APEX 2003.00 Control Unit 26 3.2.1 Configuration Control 26 3.2.2 Installation of the Control Unit 27 3.3 Purging Gas Supply 28 3.3.1 Installation of the G1/4″ Purging Gas Supply 29 3.3.2 Installation of the G1/2″ Purging Gas Supply 30 3.4 APEX 2003.MV control unit 31 3.4.1 Configuration control 31 3.4.2 Installation of the Control Unit 32 3.5 Mounting the Rain Protection Cap 33 3.6 Installation of the Rain Protection Roof 33 4 Connections 34 4.1 Pneumatic Connections 34 4.1.1 APEX 2003.00I Control Unit with a Pressure Monitor 34 4.1.2 APEX 2003.00I Control Unit with two Pressure Monitors 35 4.2 Electrical Connections 36 4.2.1 Safety Instructions for the Electrical System 36

Table of Contents APEX 2003 Control Unit Type 07-3711-.2../....


4.2.2 Directions for Wiring the APEX 2003 Control Unit 36 4.2.3 Electrical Connections to the APEX 2003 Control Unit 37 4.2.4 Sensor Module 38 4.2.5 Bypass Key Switch 39 4.2.6 Temperature Switch 40 4.2.7 Separate ON/OFF Switch 40 4.2.8 Thermal Overload Disconnection 41 4.2.9 Programming Bridge 41 4.2.10 Supply Voltage 42 4.2.11 Purging Gas Valve 42 4.2.12 Enabling the Pressurized Enclosure 43 4.2.13 Floating Contacts 43 4.2.14 RS485 Interface 44 4.3 Purging Gas Supply 44 5 Operation 45 5.1 Setting of Parameters 45 5.2 Operation of the Sensor Module 46 5.3 Display on the Sensor Module 46 5.4 Changing of Values 46 5.5 Indicators on the control module 47 5.5.1 “DIFF A” and “DIFF B” Indicators 47 5.5.2 “MIN A” and “MIN B” Indicators 47 5.5.3 “MAX” Indicator 47 5.5.4 “Operate” Indicator 47 5.5.5 “Purge time” Indicator 47 5.6 S1 Rotary Switch for “Display” 48 5.7 Rotary Switches S2 to S4 “Purge time” 48 5.8 S5 “ON/OFF” Rotary Switch 49 5.9 K4 and K5 Relays 49 6 Commissioning 50 6.1 Calculation of the Differential Pressure 51 6.2 Setting the Positive Operating Pressure 52 6.3 Adjusting the Leakage Air Needle 53 6.4 Calculation of Purge Time 54 6.4.1 Example of a Purging Gas Calculation 55 6.5 Checking the Purging Phase 56 6.6 Checking the Operating Phase 56 7 Operation 57 7.1 Safety during Operation 57 7.2 Types of Purging Gas 57 7.3 Operating Phases in the Pressurized Enclosure 58 7.3.1 Flow Diagram for the Operating Phases 58 7.3.2 Preparatory Phase 58 7.3.3 Purging Phase 59 7.3.4 Operating Phase 59 7.4 Bypass Operation 60 8 Maintenance and Care 61 8.1 Inspection Table for Commissioning and Maintenance 62 9 Malfunctioning and Troubleshooting 63 9.1 Fault Table 63 9.2 Error Code Table 65 10 Technical Data 66 10.1 Aid for the Selection of the APEX Control Unit 66 10.2 General Technical Data for the APEX Control Unit 67 10.3 Supplementary Technical Data APEX 2003.00I Control Unit 67 10.4 Supplementary Technical Data APEX 2003.00 Control Unit 68


Table of Contents


10.5 Supplementary Technical Data APEX 2003.002x Control Unit 68 10.6 Supplementary Technical Data APEX 2003.MV control Unit 69 10.7 Technical Data for the Sensor Module 70 10.8 Technical Data for the Purging Gas Valve 70 10.8.1 Technical Data for the Digital Purging Gas Valve 70 10.8.2 Technical Data for the Proportional Purging Gas Valve 71 10.9 Technical Data for the Rain Protection Cap 71 10.10 Technical Data for the Rain Protection Roof 71 10.11 Technical Requirement for the Purging Gas 72 11 Order Numbers 73 11.1 APEX Control Units 73 11.1.1 APEX 2003.00I Control Units 73 11.1.2 APEX 2003.00 Control Units 73 11.1.3 APEX 2003.00S Control Units 74 11.1.4 APEX 2003.002x Control Units 74 11.1.5 APEX 2003.002xS Control Units 74 11.1.6 APEX 2003.MV Control Units 74 11.1.7 APEX 2003.MVS Control Units 75 11.2 Accessories and Spare Parts 75 11.2.1 Pressure Monitor 75 11.2.2 Sensor Module 75 11.2.3 Digital Purging Gas Valve with Leakage Air Needle and 3 m Connection Cable 76 11.2.4 Digital Purging Gas Valve with Leakage Air Needle and Connection Box without Purging Gas Nozzle 76 11.2.5 Proportional Purging Gas Valve 76 11.2.6 Pressure Reducer 76 11.2.7 Accessories 76 11.2.8 Control Module 76 12 Appendix 77 12.1 Purging Gas Diagrams for the APEX Control Unit 77 12.1.1 Purging gas diagram for the APEX 2003.00 control unit 77 12.1.2 Purging Gas Diagram for the APEX 2003.002x Control Unit 77 12.1.3 Purging Gas Diagram for the APEX 2003.MV Control Unit 78 12.2 Dimensions 79 12.2.1 APEX 2003.00I 79 12.2.2 APEX 2003.00 79 12.2.3 APEX 2003.00S 80 12.2.4 APEX 2003.002x / APEX 2003.002xS 80 12.2.5 APEX 2003.MV / APEX 2003.MVS 81 12.3 Borehole Patterns 81 12.3.1 APEX 2003.00 Control Unit 81 12.3.2 APEX 2003.00 Control Unit2x 82 12.3.3 Sensor Module 82 12.3.4 Roof as Protection Against Rain 82 12.4 Test and Assessment Report Form 83 13 Declaration of Conformity and Approvals 85 13.1 EC Declaration of Conformity for the APEX Control unit 85 13.2 EC Type Examination Certificate for the APEX Control Unit 86 13.3 IECEx Certificate of Conformity Control Unit APEX 91

Safety APEX 2003 Control Unit Type 07-3711-.2../....

EN 6/96 Technical data subject to change without notice.

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 APEX control unit.

This manual contains the information required for using the control unit in accordance with its 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 in this documentation are given in a general way and only qualified personnel will have the necessary specialised know-how to interpret and implement them correctly in specific individual 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.


Safety

Technical data subject to change without notice. EN 7/96

1.1.1 Languages

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 need any other languages, please ask BARTEC or request them when placing the order.

1.2 Handling the Product 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 APEX control unit must be mounted properly and securely onto the pressurized enclosure if it is to work perfectly and correctly.

1.3 Use in Accordance with the Intended Purpose

1.3.1 Exclusive Purpose

The APEX control unit serves exclusively as a controlling and monitoring device for a pressurized enclosure and is intended for use in Explosion Group II, Category 2G and Temperature Classes T4 and T6.

The permissible operational data for the device being used must be observed.

1.3.2 Improper Use

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/Managing Operator’s Obligations

The owner/managing operator undertakes to restrict permission to work on the APEX control unit to people who:

are familiar with the basic regulations on safety and accident prevention and have been instructed in the use of the APEX control unit;

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 observed.



1.5 Safety Instructions

1.5.1 General Safety Instructions

Do not wipe devices with a dry cloth or clean them in a hazardous area!

Do not open devices in a hazardous area.

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, appropriate clothing and footwear should be worn.

Avoid the influence of heat that is higher or lower than the specified temperature range (see Chapter 10.2 “General Technical Data”).

Keep the devices away from moisture.

1.5.2 Safety Instructions for Operation

When setting up or operating explosion-resistant electrical systems, the IEC/EN 60079-14 (NEC for USA/CEC for Canada) and all relevant installation and operating regulations must be observed.

Upkeep

For electrical systems the relevant installation and operating regulations must be complied with (e.g. Directive 99/92/EC, Directive 94/9/EC, German industrial health and safety ordinance (BetrSichV), the applicable national 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 maintenance is not necessary if the device is operated correctly, in accordance with the installation instructions and environmental conditions. See Chapter 8.

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 relevant regulations must be observed.

Commissioning

Before commissioning, check that all components and documents are there.


Safety


1.6 Standards Conformed to

The APEX control unit conforms to directive 94/9/EC for devices and protective systems for use to their intended purpose in hazardous areas (ATEX Directive). Pursuant to this directive, the following standards serve as a basis for the APEX control unit:

Standard Designation

EN 60079-0:2012 IEC 60079-0:2011 Ed. 6.0

Electrical apparatus for explosive gas atmospheres -

Part 0: General Requirements

EN 60079-1:2007 IEC 60079-1:2007-04 Ed. 6

Explosive atmospheres -

Part 1: Equipment protection by flameproof enclosures “d”

EN 60079-2:2007 IEC 60079-2:2007-02 Ed. 5


Part 2: Equipment protection by pressurized enclosure “p”

EN 60079-7:2007 IEC 60079-7:2006-07 Ed. 4


Part 7: Equipment protection by increased safety “e”

EN 60079-11:2012


Part 11: Equipment protection by intrinsic safety “i”

EN 60079-26:2007 IEC 60079-26:2006 Ed. 2


Part 26: Equipment with equipment protection level (EPL) Ga

DIN EN ISO 61511-1:2005 Functional Safety - Safety instrumented systems for the process industry sector- Part 1:

Framework, definitions, system, hardware and software requirements

DIN EN ISO 61511-2:2005 Functional Safety - Safety instrumented systems for the process industry sector - Part 2:

Guidelines for the application of part 1

EN 61000-6-2:2005 IEC 61000-6-2:2005-1 Ed. 2

Electromagnetic Compatibility (EMC) -

Part 6-2: Generic Standards - Immunity for industrial environments

EN 61000-6-4:2007 + A1:2011 IEC 61000-6-4:2006-7 Ed. 2

Electromagnetic Compatibility (EMC) -

Part 6-4: Generic Standards - Emission standard for industrial environments

EN 60529:1991 + A1:2000 IEC 60529 Ed. 2.1

Degrees of protection provided by enclosures (IP code)



1.7 Ex Protection Type and Certification

The following markings showing Ex protection and certification are affixed to the device:

ATEX IECEx II 2(1) G Ex de ib [ia Ga px] IIC T4/T6 Gb

II 2(1) G Ex de [ia Ga px] IIC T6 Gb Ex de ib [ia Ga px] IIC T4/T6 Gb

Ex de [ia Ga px] IIC T6 Gb DMT 99 ATEX E 082 IECEx BVS 13.0039

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.

Explosion protection and the necessary stress tolerance and conformance to safety requirements of the design and production are no longer assured then.

Before making any modifications or implementing any conversions, contact the manufacturer and obtain written approval.

Use only original spare parts and original expendable parts.

N o t e

Scope of warranty

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 APEX control unit for a purpose other than that for which it is intended.

incorrect installation, commissioning, operation and maintenance of the APEX control unit.

non-compliance with the instructions in the manual with respect to transport, storage, assembly, commissioning, operation and maintenance.

structural modifications to the APEX control unit without our prior authorisation.

inadequate monitoring of components that are subject to wear.

repairs done incorrectly.

disasters due to the effects of foreign matter or force majeure.

We guarantee the APEX control unit 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.


Product Description


2 Product Description

2.1 APEX Control Unit

The APEX control unit with its system components is an automatic control for monitoring, controlling and regulating pressurized enclosures in the hazardous areas of Zones 1 and 2.

The APEX control unit is suitable for all standard applications for pressurized enclosures.

The electrical installed parts inside the pressurized enclosure are enabled by the APEX control unit directly or by an additional switching device.

Once the APEX control unit and the purging gas valve have been mounted on the pressurized enclosure and the mains voltage and purging gas have been connected, the pressurized system starts automatically.

The APEX control unit regulates the purging gas flow and the pressure inside the enclosure during the purging phase.

When the operating phase is initiated, the components mounted in the pressurized enclosures are automatically activated by the APEX control unit. The pressure inside the pressurized enclosure is maintained automatically during the operating phase and any leakage losses are compensated.

2.2 “Pressurized Enclosure” Type of Protection

The Ex p type of protection, referred to as “pressurized enclosure”, is based on the measure of purging out any explosive gases that are in a closed enclosure and then generating and maintaining a level of pressure that is higher than that of the ambient atmosphere. As the pressure inside the cabinet is higher than the atmospheric pressure, it is not possible at any time for explosive gases to penetrate the inside of the enclosure. This creates an Ex-free area in which electrical devices that are not themselves explosion-proof can be mounted and operated.

The APEX control unit described in these operating instructions functions in “pressurized enclosure with leakage loss compensation” technology. Specifically this means that the positive pressure in an enclosure is maintained by the addition of purging gas to compensate for the leakage losses from the enclosure.

To ensure that an explosive atmosphere that has penetrated during downtimes cannot become a danger, the enclosure must be flushed with purging gas (compressed air or inert gas) before it is commissioned. The quantity depends on the inspection during first-time operation. The rate of flow is measured or determined at the pressurized enclosure’s outlet.

Since a safe condition in the enclosure is only reached when the operating phase is started, it is necessary to use explosion-proof versions of the APEX control unit and its system components such as sensor module, control module, pressure monitor and purging gas valve.

Product Description APEX 2003 Control Unit Type 07-3711-.2../....


2.3 Schematic Diagram of an Ex p Control

Item Designation

Purging gas flow

Pressurized enclosure

APEX control unit consisting of the components:

pressure monitor module with measuring orifice, spring

valve and flying spark barrier

sensor module with display and pressure measurement

control module

Purging gas valve with purging gas nozzle (purging flow restriction)

Pressure reducer with pressure gauge


Product Description


2.4 APEX 2003 Control Unit

N o t e

Versions other than those listed here are available on request. These include e.g. stainless enclosures.

2.4.1 APEX 2003.00I

The APEX 2003.00I control unit is intended for mounting inside the pressurized enclosure (e.g. on an internal mounting plate).

The sensor module for operating and displaying the system parameters is installed in the pressurized enclosure by means of a mounting frame (e.g. control cabinet door).

The pressure monitor for measuring the purging gas flow is mounted in the wall of the pressurized enclosure.

Construction:

Item Designation Function

Control module Control unit

PE bar Earthing connection

M20 cable gland, black Cable entry

M20 cable gland, blue Cable entry Ex i

N o t e

The sensor module and pressure monitor are not included in the scope of supply.



2.4.2 APEX 2003.00 (S)

The APEX 2003.00 (S) control unit is intended for mounting onto a pressurized enclosure (e.g. on the outer side wall).

The sensor module and the pressure monitor for operating, displaying the system parameters and measuring the system pressure levels are integrated inside the control unit.

The APEX 2003.00S control unit with additionally integrated bypass key switch makes it possible for the pressurized enclosure to open without switching off the installed parts. With respect to operating the pressurized enclosure in the bypass, observe the points in Chapter 4.2.5 “Bypass Key Switch”.

Construction APEX 2003.00: Construction APEX 2003.0S:



Sensor module Measurement and display unit

Pressure monitor Functional unit positive pressure


M20 cable gland Cable entry

Breather Condensation prevention

Bypass key switch Activation bypass operation


Product Description


2.4.3 APEX 2003.002x (S)

The APEX 2003.002x (S) control unit is intended for mounting onto a pressurised enclosure (e.g. on the outer side wall).


The integration of two pressure monitors allows large pressurised enclosures to be purged in a short time.

The APEX 2003.002xS control unit with additionally integrated bypass key switch makes it possible for the pressurized enclosure to open without switching off the installed parts. With respect to operating the pressurized enclosure in the bypass, observe the points in Chapter 4.2.5 “Bypass Key Switch”.

Construction APEX 2003.002x: Construction APEX 2003.002xS:






M20 cable gland Cable entry





2.4.4 APEX 2003.MV (S)

The APEX 2003.MV (S) control unit is intended for remote mounting, at a distance from the pressurized enclosure.


Due to the remote mounting of the control unit it is possible to purge the pressurized enclosure up to a volume of 70 litres and at a distance of up to 10 metres.

The APEX 2003.MVS control unit with additionally integrated bypass key switch makes it possible for the pressurized enclosure to open without switching off the installed parts. With respect to operating the pressurized enclosure in the bypass, observe the points in Chapter 4.2.5 “Bypass Key Switch”.

Construction APEX 2003.MV: Construction APEX 2003.MVS:






M20 cable glands Cable entry


Purging gas valve Purging gas regulation

Purging gas input Purging gas supply

Purging gas connections Purging gas supply



Product Description


2.5 Sensor-Module

The sensor module is designed for use in APEX controls.

It takes over the measuring functions for the system-specific pressure levels and the display of parameters and pressure levels.

Further technical data can be found in the data sheet.

The sensor module is connected directly to an APEX control unit, which provides it with the necessary intrinsically safe voltage. The signals measured are passed onto the control module with intrinsic safety.

Along with the APEX 2003.00I control unit, the sensor module must be connected to a control module by means of the 12-wire sheathed lead.

In all other versions of the APEX control unit, the sensor module is integrated and wired inside the control unit as standard.

2.6 Pressure Monitor

The pressure monitor has two functions inside the control. Firstly, it serves as a pressure control valve, which opens if the internal pressure is too high and reduces the excess pressure. Secondly, an orifice is integrated in the pressure monitor through which the differential pressure is measured by means of the sensors integrated in the sensor module.

In conjunction with the APEX 2003.00I control unit, this must be mounted separately in the pressurized enclosure. It is also necessary to connect measuring hoses between the pressure monitor and sensor.

In all other versions of the APEX control unit the pressure monitor is integrated and wired inside the control unit as standard.

2.7 Adjustment Device

To change parameters and switching levels, the adjustment device must be connected to the control module.

Values which are changed without a connected programming bridge are not accepted by the APEX control unit.



2.8 Purging Gas Valves

W A R N I N G

Death or risk of injury when the purging gas valve is operated with an APEX control unit that has inadequate fusing.

The control module can be destroyed. The explosion protection is no longer assured.

Operate the G1/4″ digital purging gas valve and proportional purging gas valve only with a 9-W control unit.

Operate the G3/8″ proportional purging gas valve only with a 15-W control unit.

Check the compatibility of the purging gas valve and the control module.

2.8.1 Digital Purging Gas Valve

The digital purging gas valve controls the purging gas supply.

This is a servo-assisted solenoid valve and its function is to introduce purging gas into a pressurized enclosure for Zone 1 or Zone 2.

Here, the digital purging gas valve is controlled by the APEX control unit to allow the purging gas valve to open to purge the pressurized enclosure and close again when the purging is finished. The integrated, adjustable leakage air needle compensates for the loss through leakage in the pressurized enclosure.

The leakage air needle can be integrated or it is located laterally at the valve body.

The necessary fusing for the purging gas valve is mounted inside the control module.

The relevant technical data can be found in the data sheet.

2.8.2 Proportional Purging Gas Valve

The proportional purging gas valve controls the purging gas feed.

This is a direct-action proportional solenoid valve and it is used to introduce purging gas into a pressurized enclosure in Zone 1 or Zone 2.

Here, the proportional purging gas valve is controlled by the APEX control unit to allow the purging gas valve to open to purge the pressurized enclosure and close again when the purging is finished. Any loss occurring through leakage is compensated by the purging gas valve opening and closing to a slight degree.

The proportional valve technology compensates for the actual loss through leakage in the pressurized enclosure.

The necessary fusing for the purging gas valve is mounted inside the control module.



Product Description


2.9 Pressure Reducer with Pressure Gauge

A T T E N T I O N

Damage to property when the maximum permissible internal pressure is exceeded in the pressurized enclosure.

If the supply pressure is set at too high a level, there is a risk of destroying the pressurized enclosure.

Mark the supply pressure on the pressure gauge.

The supply pressure setting on the pressure gauge must be checked regularly.

Lock the pressure reducer.

The upstream pressure reducer is a diaphragm pressure regulator with secondary venting for lowering the pressure of externally supplied purging air .

The levels for the pressure reducer are set by means of a hand wheel and can be read on the pressure gauge.

Pressure reducers are available in sizes G1/4″ and G1/2″ for the supply to the pressurized enclosure.


To select the pressure reducer, see Chapter 3.3 “Purging Gas Supply”.

2.10 Purging Gas Nozzle

A T T E N T I O N

Damage to property caused by the absence of a purging gas nozzle.

The build-up of internal pressure can give rise to the risk of excessive stress on the pressurized enclosure.

Make sure there is a purging gas nozzle there.

The purging gas nozzle serves to mechanically restrict the maximum flow.

This is necessary to restrict the maximum flow if the purging gas valve is defective.



2.11 Rain Protection Cap

A T T E N T I O N

Malfunctioning when a rain protection cap is used on APEX control units that have an orifice larger than 15 mm.

The rain protection cap may be mounted only on APEX control units with an orifice of up to 15 mm. Using this cap on APEX control units with an orifice larger than 15 mm can impair functioning.

If the orifice size is larger than 15 mm, a roof must be mounted instead of a cap to protect the pressure monitor outlets against rain.

The rain protection cap is a screw-on protection for the flying spark barrier against dust and drops.

The rain protection cap is made of plastic (PVC black) and can be mounted onto the pressure monitor on the APEX control unit.

The rain protection cap can be used on control units and pressure monitors with an internal orifice of up to 15 mm.

2.12 Rain Protection Roof

The rain protection roof provides additional protection against rain drops for APEX control units.

It is mounted at a distance of ca. 10 mm from the pressure monitor outlet above the control unit on the pressurized enclosure.


Installation


3 Installation

3.1 APEX 2003.00I Control unit

3.1.1 Control configuration

D A N G E R

Death or serious physical injury if the purging gas supply and the pressure monitor outlet are installed incorrectly.

This interferes with the purging action in the pressurized enclosure. Gas bubbles can form inside the pressurized enclosure and lead to an explosion when the installed parts are activated.

The purging gas valve and the pressure monitor must not be mounted exactly opposite.

For opposite mounting, use angled pieces or other mechanical aids to direct the flow of purging gas to allow smooth purging.

Item. Designation Function

Pressurized enclosure Ex p operating equipment

APEX 2003.00I control unit Ex p control


Pressure monitor Functional unit positive

Atmosphere measuring point Measurement of atmospheric

Pressure measuring lines System hoses

Purging gas valve Purging gas feed

Pressure reducer Setting for purging gas

Installation APEX 2003 Control Unit Type 07-3711-.2../....


3.1.2 Installation of the Control Unit

To install the APEX2003.00I control unit inside the pressurized enclosure, the top lid must be removed. The APEX control unit can be screwed to the mounting plate in the pressurized enclosure using the mounting holes provided for that purpose.

Assembly drawing:

Mounting material required when mounting using threaded holes:

Quantity Material

4 Screw M6 x 30

Quantity Material

4 Screw M6 x 35

4 Washer M6

4 Retaining ring M6

4 Nut M6

N o t e

- The relevant borehole pattern for affixing the APEX control unit can be found in the appendix to these operating instructions.

- The mounting material for the APEX control unit is not included in the scope of supply.


Installation


3.1.3 Installation of the Pressure Monitor

W A R N I N G

Death or risk of injury due to excessive internal pressure in the pressurized enclosure.

The enclosures can be destroyed.

Make sure the outlet threaded connection is not covered from the outside.

Check if the direction of flow in the pressure monitor is from the inside to the outside.

A through hole of 37 mm in the wall of the pressurized enclosure is required for mounting the pressure control device. The outlet threaded connection is used to facilitate the attachment.

Procedure:

Make a 37-mm-diameter borehole at the mounting position provided for that purpose in the pressurized enclosure.

Unscrew the outlet threaded connection out of the pressure monitor enclosure.

Installation step

Put the pressure monitor enclosure on, positioning it so that the air in the pressurized enclosure can flow outwards.

Installation step

Screw the pressure monitor module together. Tighten the outlet threaded connection and the pressure monitor enclosure so that the pressure monitor module is positioned securely.



3.1.4 Installation of the Atmosphere Measuring Point

A T T E N T I O N

Faulty measurement of the operating pressure levels due to dirt on the atmosphere measuring point.

The pressurized enclosure is then deactivated.

Check the atmosphere measuring point at regular intervals for dirt.

In order for the APEX2003.00I control unit to be able to measure the operating pressure levels correctly, an atmosphere measuring point must be set. The scope of supply for the sensor module contains all the parts required for this.

Procedure:

Make a Ø 9.6-mm-diameter borehole at the mounting position provided for that

purpose in the pressurized enclosure.

Put the screw plug () with a 1-mm-diameter borehole and the sealing ring () through the borehole.

Put the second sealing ring () on the inside over the threading projecting out of the hole.

Screw the sleeve () onto the threading.

Screw the quick plug-in connector () into the sleeve ().

The following diagram is intended to clarify the installation procedure:


Installation


3.1.5 Installation of the Sensor Module

In order for the APEX control unit to be able to measure and display the operating pressure levels, the sensor module has to be installed in the pressurized enclosure. The sensor module also serves to operate the control module.

Procedure:

Make a cut-out at the mounting location provided for that purpose as shown in

Chapter 12.3.3 “Sensor Module“.

Put the sensor module () into the cut-out.

Use 4 nuts (M4) () with Schnorr® safety washers to fasten the sensor module.

Earth the sensor module by means of the threaded bolts () and the centre threaded bolt ().

The following diagram is intended to clarify the installation procedure:



3.2 APEX 2003.00 Control Unit

3.2.1 Configuration Control

D A N G E R







APEX 2003.00 control unit Ex p control

Purging gas valve Purging gas feed

Pressure reducer Setting for purging gas

The APEX control unit for external mounting is mounted on an external side of the pressurized enclosure. The sensor module and the pressure monitor are mounted inside the APEX control unit and they therefore do not need to be mounted separately.


Installation



The APEX2003.00 control unit is intended for mounting onto the outside of the pressurized enclosure. For this purpose the APEX control unit is mounted onto the pressure monitor by means of the outlet threaded connection and two M6 screws to prevent twisting.

The borehole patterns for affixing the APEX control unit can be found in the appendix.

Depending on which version of the APEX control is used, one or two 37-mm-diameter holes for the pressure monitor outlets must be bored in the pressurized enclosure.

Quantity Material

2 Screw M6 x 35

2 Washer M6

2 Retaining ring M6

2 Nut M6

N O T E





3.3 Purging Gas Supply

A T T E N T I O N

Not enough purging gas because purging gas supply lines are too small.

The insufficient flow prevents the pressurized enclosure from starting operation.

Adapt the internal diameter of the purging gas supply line to the required flow.

A T T E N T I O N

Damage to property caused by the absence of a purging gas nozzle.

The build-up of internal pressure can give rise to the risk of excessive stress on the pressurized enclosure.

Check the purging gas nozzle.

The purging gas supply is composed of a pressure reducer, a purging gas valve and a purging gas nozzle. Depending on the capacity of the pressurized enclosure, the purging gas supply is available in the sizes G1/4“ or G1/2“.

The purging gas feed must be selected in accordance with the following table.

Capacity Pressure Pressure reducer Purging gas nozzle

< 50 litres 2 bar 1/4″ 2.8 mm

50 to 300 litres

2 bar 1/4″ 3.9 mm

300 to 700 litres

2 bar 1/2″ 4.5 mm

700 to 1,000 litres

3 bar 1/2″ 4.5 mm

From 1,000 litres on

3 bar 1/2″ 5.5 mm

(The levels specified in the table are references values and can vary.)

The pressure reducer to lower the supplied purging gas pressure is mounted on the outside of the pressurized enclosure. The purging gas valve, which releases the purging gas, is mounted inside the pressurized enclosure. The purging gas nozzle restricts the maximum flow of the purging gas and accordingly prevents pressure increasing to the maximum level when a purging gas valve is defective.

The following illustrates the assembly of the purging gas feed. The required mounting material is included in the scope of supply.


Installation


3.3.1 Installation of the G1/4″ Purging Gas Supply

The purging gas feed must be installed carefully. To ensure that the screwed parts are leak-tight, they can be sealed with Teflon® tape.

Care must be taken to prevent the penetration of foreign particles during assembly.

Procedure:

Make a 17-mm-diameter borehole at the mounting position provided for that purpose on the pressurized enclosure ().

Use the reducing sleeve () and the sealing washers () to mount the purging gas valve () on the pressurized enclosure.

Drill the purging gas nozzle according to the table in chapter 3.3.

Screw the purging gas nozzle () in at outlet of the purging gas valve ().

Screw the detachable double threaded nipple () into the reducing sleeve ().

Screw the G1/4″ pressure reducer () onto the detachable double threaded nipple ().

Item Material

Purging gas nozzle with borehole (according to the table in chapter 3.3)

Purging gas valve

Sealing washer


G1/4″i / G3/8″ reducing sleeve

Detachable double threaded nipple G1/4″, both sides

G1/4″ pressure reducer

Borehole dia. 17 mm



3.3.2 Installation of the G1/2″ Purging Gas Supply

The purging gas feed must be installed carefully. To ensure that the screwed parts are leak-tight, they can be sealed with Teflon® tape.

Care must be taken to prevent the penetration of foreign particles during assembly.

Procedure:

Make a 21-mm-diameter borehole at the mounting position provided for that purpose on the pressurized enclosure ().

Use the reducing sleeve ()and the sealing washers ()to mount the G1/2″ pressure reducer () onto the pressurized enclosure.

Screw the detachable double threaded nipple () into the reducing sleeve ().

Screw the purging gas valve () onto the detachable double threaded nipple ().

Drill the purging gas nozzle according to the table in chapter 3.3.

Screw the purging gas nozzle () in at the outlet of the purging gas valve ().

Item Material

Purging gas nozzle with borehole (according to the table in chapter 3.3)

Purging gas valve

Detachable G3/8″ bulkhead nipple

G3/8″i / G1/2″a reducing sleeve

Sealing washer


G1/2″ pressure reducer

Borehole dia. Ø 21 mm


Installation


3.4 APEX 2003.MV control unit

3.4.1 Configuration control

D A N G E R







APEX 2003.MV control unit Control

Purging gas connection Purging gas feed

Pressure reducer Setting for purging gas pressure

The system components in the “Remote Installation of the Control Unit” version should be selected to ensure that the purging gas feed purges the pressurized enclosure well.

The components pressure reducer, purging gas valve and sensor module are integrated in the control unit and they therefore do not need to be mounted separately.

G 1/4″ screw connections with internal thread are attached to the APEX control unit as standard for the purging gas feed and return.

The purging gas lines are to be produced with a hose with an internal diameter of at least 8 mm and a maximum length of 10 m.




To install the APEX2003.MV control unit on a wall or mounting plate, the top lid must be removed and the APEX control unit can be screwed onto a wall or mounting plate by means of the mounting holes provided for that purpose.

Assembly drawing:

Quantity Material

4 Screw M6 x 30

Quantity Material

4 Screw M6 x 35

4 Washer M6

4 Retaining ring M6

4 Nut M6

N o t e




Installation


3.5 Mounting the Rain Protection Cap

A T T E N T I O N

Malfunctioning when the rain protection cap is used on non-approved APEX control units.

The rain protection cap may be mounted only on APEX control units with an orifice of up to 15 mm. Using this cap on APEX control units with an orifice larger than 15 mm can impair functioning.

If the orifice size is larger than 15 mm, a roof must be mounted instead of a cap to protect the pressure monitor outlets against rain.

The rain protection cap prevents the flying spark barrier getting dirty. It can then be mounted onto the APEX control unit’s pressure monitor outlet in accordance with the following instructions.

Step 1:

Put the rain protection cap onto the pressure monitor outlet.

Step 2:

Twist the rain protection cap into the pressure monitor.

3.6 Installation of the Rain Protection Roof

The rain protection roof prevents the penetration of rain drops through the pressure monitor outlet into the pressurized enclosure.

In accordance with the following instructions, the rain protection roof can be mounted above the APEX control unit.

Procedure:

Make two 6.5-mm-diameter boreholes at the mounting position provided for that purpose on the pressurized enclosure as shown in the borehole pattern (see Chapter 12.3.4 “Roof as Protection against Rain“).

Put on the rain protection roof by inserting the fastening bolts into the two boreholes.

Using M6 washers and M6 nuts, screw the bolts securely from the back onto the pressurized enclosure.

Connections APEX 2003 Control Unit Type 07-3711-.2../....


4 Connections

4.1 Pneumatic Connections

When using an APEX 2003.00I control unit, measuring lines must be produced between the atmospheric pressure, the pressure monitor and the sensor module to ensure correct functioning.

These measuring lines are connected as standard in the APEX 2003.00 control unit, APEX 2003.002x and APEX 2003.MV and they therefore do not need to be mounted separately.

4.1.1 APEX 2003.00I Control Unit with a Pressure Monitor

A T T E N T I O N

Faulty measurement of the pressure levels because of bent and squeezed lines.

The APEX control starts to malfunction.

Check that the lines have been laid properly.

Sensor module Target Function

A Atmosphere measuring point Measurement of the environment

H - Measurement of the enclosure

L Pressure monitor “L” Measurement after orifice

Functions in the same way as the APEX 2003.00 control unit.

The “A” connections (atmosphere) must be produced with the atmosphere measuring point in the wall of the pressurized enclosure.

The “L” (low-pressure) connection must be joined to the pressure monitor.

These measuring points allow the sensor module to measure the operating pressure levels and the flow in the pressurized enclosure correctly.

There are quick plug-in connectors available at the sensor module and at the pressure monitor. These must be connected together by means of a measurement hose with an outside diameter of 4 mm as shown in the above diagram.


Connections


4.1.2 APEX 2003.00I Control Unit with two Pressure Monitors

A T T E N T I O N

Faulty measurement of the pressure levels because of bent and squeezed lines.

The APEX control starts to malfunction.

Check that the lines have been laid properly.

Sensor module Target Function

A Atmosphere measuring point Measurement of the environment

H - Measurement of the enclosure

L Pressure monitor “L” Measurement after orifice

Functions in the same way as the APEX 2003.002x control unit.

The “A” connections (atmosphere) must be produced with the atmosphere measuring point in the wall of the pressurized enclosure.

The “L” (low-pressure ) connection must be joined to the pressure monitor. This must be split by means of a T connector.

These measuring points allow the sensor module to measure the operating pressure levels and the flow in the pressurized enclosure correctly.

Marked quick plug-in connectors are available on the sensor module and on the pressure monitor. These must be connected together by means of a measurement hose with an outside diameter of 4 mm, as shown in the above diagram.

N o t e

Only the 18-mm orifices may be used for the version with two pressure monitors.



4.2 Electrical Connections

4.2.1 Safety Instructions for the Electrical System

D A N G E R

Death or serious physical injury due to work on live parts.

Risk of fatal injury from electrical current.

Observe the 5 safety rules for work on electrical systems: disconnect mains; protect against unintended reconnection; verify the absence of voltage; earth and short-circuit; cover or safeguard nearby live parts.

4.2.2 Directions for Wiring the APEX 2003 Control Unit

D A N G E R

Death or serious physical injury when the cover on the APEX control unit is opened in an explosive atmosphere.

Risk of explosion.

Before opening the lid of 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 APEX control unit.

The APEX control can be damaged.

All core wires, including those not required, must be attached 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 to the APEX control unit:

Procedure:

Loosen the 4 fastening screws in the lid on the APEX control unit and take off the lid.

Feed the supply, data and enable line through the cable glands into the Ex e junction box.

Establish the electrical connections in accordance with the terminal assignment.

Screw the terminals in securely 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 APEX control unit and tighten the 4 fastening screws with 1.4 Nm.


Connections


4.2.3 Electrical Connections to the APEX 2003 Control Unit

A T T E N T I O N

Avoid damage to the sealing.

Cancellation of the Ex protection strategy.

Visually check the sealing when closing the APEX control unit (cleanliness, secure fitting and intactness).

Terminal Connection Function

1-12 Sensor module Control

13-14 No function Depending on the variant

15-16 Temperature switch Cooling

17-18 Bypass key switch Bypass operation

19-20 Ext. activation Activation Ex p outlet

21-22 No function Depending on the variant

23-24 Programming bridge Safety module

25-26 Supply voltage Voltage supply

28-29 Outlet valve System-dependent

31-32 Purging gas valve Purging gas supply

34-35 Ex p Enabling

27, 30, 33, 36, 37 PE connection Earthing

38-46 Floating contacts Alert messages

47-48 RS485 interface Only for service



4.2.4 Sensor Module

The sensor module is integrated and connected in the control unit as standard in the APEX 2003.00, APEX 2003.002x and APEX 2003.MV control units. In the “APEX 2003.00I control unit” variant, the sensor module must be connected by the user.

The sensor module for installation in the pressurized enclosure is fitted as standard with a connection cable. The wires are numbered 1 to 12 and must be connected, one by one, to terminals 1 to 12 in the APEX control unit on the control module.

Communication and voltage supply are produced with intrinsic safety.

Connection:

Terminal Connection Function

1 Sensor module Display control



4 Sensor module “SET“ button

5 Sensor module “+” button

6 Sensor module “-“ button

7 Sensor module Supply voltage

8 Sensor module Mass

9 Sensor module “MIN B” pressure measurement

10 Sensor module Mass

11 Sensor module “DIFF A” pressure measurement

12 Sensor module “MIN A” pressure measurement


Connections


4.2.5 Bypass Key Switch

D A N G E R

Death or serious physical injury due to commissioning with bypass key switch in an explosive atmosphere.

Risk of explosion

Have the commissioning with a bypass key switch approved by the factory manager or his appointee. Approval may be given only if it has been ensured that there will not be any explosive atmosphere for the duration of the commissioning or if the necessary precautions have been taken to protect against the risk of explosion (fire permit).

Warning sign informing that the Ex protection will be eliminated if the key switch is activated. Affix near the key switch.

Depending on the variant, the bypass key switch is integrated in the APEX 2003.00, APEX 2003.002xS and APEX 2003.MVS control units or it can be mounted separately in the pressurized enclosure.

The bypass key switch must be marked as shown in the following label and this must be attached in the immediate vicinity of the bypass key switch.

The position of the bypass key switch is queried with intrinsic safety by the control module.

Connection: Terminal Connection Function 5 Bypass key switch (N/O) Activation bypass 8 Bypass key switch (N/O) Activation bypass 17 Bypass key switch (N/O) Activation bypass 18 Bypass key switch (N/O) Activation bypass



4.2.6 Temperature Switch

N o t e

This process is not a safety temperature monitoring procedure in the sense of the standard. If this is required, a safety thermostat that can only be manually reset must be used instead of the normal commercially available thermostat.

A standard commercially available thermostat can be connected to terminals 15 and 16 in the control module.

Once the set temperature (N/O contact) is reached, the purging gas quantity is connected for the duration of the increased temperature. Accordingly, the increased purging gas flow cools the pressurized enclosure.

It is not necessary to program the control module. Terminals 15 and 16 are polled automatically by the control module.

Connection:

Terminal Connection Function 15 Temperature monitoring Cooling Ex p 16 Temperature monitoring Cooling Ex p

4.2.7 Separate ON/OFF Switch

N o t e

The 19/20 input must always be provided with a bridge if no switch is connected. Otherwise the purging will proceed but the application in the pressurized enclosure will not be enabled.

A separately certified switch for manually switching the Ex p enabling on and off can be connected at terminals 19 and 20 instead of the existing bridge.

After activation, the APEX control unit purges the pressurized enclosure and generates the required positive pressure. The internal assembly (control) is not switched on until the separate ON/OFF switch is activated.

Connection:

Terminal Connection Function 19 ON/OFF switch Ext. main switch 20 ON/OFF switch Ext. main switch


Connections


4.2.8 Thermal Overload Disconnection

N o t e

This process is not a safety temperature monitoring procedure in the sense of the standard. If this is required, a safety thermostat that can only be manually reset must be used instead of the normal commercially available thermostat.

With thermostats connected, the terminals 19 and 20 can be used for disconnection purposes in the event of a thermal overload in the pressurized enclosure.

When the set temperature is exceeded, the thermostat contact opens. The opening action cancels and accordingly deactivates the command enabling the pressurized enclosure.

The thermostats are queried with intrinsic safety.

Connection:

Terminal Connection Function 19 ON/OFF switch Thermal overload disconnection 20 ON/OFF switch Thermal overload disconnection

4.2.9 Programming Bridge

N o t e

It is not possible to program the control module.

The programming bridge is necessary when altering system pressure level programming and setting because changes without a programming bridge will not be accepted.

Put on the programming bridge to make changes to the programming and remove it when the programming is finished.

Adjustments to the control module and sensor module will have the effect of altering the overall function. When changes are to be made and saved, the programming bridge included in the scope of supply must be placed at terminals 23 and 24 before the adjustments are made.

To ensure that the programming bridge will not be forgotten after the conclusion of the work on the APEX control unit, it is designed to prevent the lid of the APEX control unit closing

Connection:

Terminal Connection Function 23 Programming bridge Enabling programming 24 Programming bridge Enabling programming



4.2.10 Supply Voltage

A T T E N T I O N

Damage to property due to an incorrect voltage supply.

The control module’s internal fusing is destroyed.

Before activating the supply voltage, compare the supply voltage level with the level printed on the APEX control unit.

The supply voltage specified on the control module must be connected to terminals 25, 26 and 27.

Connection:

Terminal Connection Function 25 L Phase 26 N Neutral conductor 27 PE Earthing

4.2.11 Purging Gas Valve

W A R N I N G

Death or risk of injury when the purging gas valve is operated with an APEX control unit that has inadequate fusing.

The control module can be destroyed. The explosion protection is no longer assured.

Operate the G1/4″ digital purging gas valve and proportional purging gas valve only with a 9-W control unit.

Operate the G3/8″ proportional purging gas valve only with a 15-W control unit.

Check the compatibility of the purging gas valve and the control module.

The purging gas valve in the “digital” or “proportional” version is connected to terminals 31, 32 and 33.

Connection:

Terminal Connection Function 31 L+ Phase 32 N- Neutral conductor 33 PE Earthing


Connections


4.2.12 Enabling the Pressurized Enclosure

A T T E N T I O N

Damage to property due to overcurrent at the control module.

The control module’s internal fusing is destroyed.

The Ex p enabling (relay K2/3; terminals 34 and 35) may be operated only in conjunction with a mains fuse. (max. 5 A, 1.500 A switching capacity, quick-acting).

The application inside the pressurized enclosure is enabled by means of the APEX control unit. There must not be any voltage in the pressurized enclosure when the APEX control is deactivated.

The maximum which the Ex p enabling can switch is a single-phase circuit with neutral conductor and a maximum load of 5 A. If the current load inside the pressurized enclosure is polyphase or more than 5 A, a separately certified Ex d contactor, activated by the APEX control unit, will be required.

Connection:

Terminal Connection Function 34 L Enabling 35 N Enabling 36 PE Enabling

4.2.13 Floating Contacts

Floating contacts are available for processing signals at the APEX control unit. Their functions are freely programmable.

Connection:

Terminal Connection Function 38 Floating contact N/C contact 39 Floating contact N/C, base contact 40 Floating contact N/O contact 41 Floating contact N/O contact 42 Floating contact N/O contact 43 Floating contact N/O contact 44 Floating contact N/O contact 45 Floating contact N/O contact 46 Floating contact N/O contact



4.2.14 RS485 Interface

D A N G E R

Death or serious physical injury due to the use of the RS485 interface in an explosive atmosphere.

Risk of explosion

Only authorised and qualified personnel may use the RS485 interface.

The R-S 485 interface is intended only for servicing and setting work in the factory. The RS485 interface may not be used while the pressurized operating equipment is in use.

4.3 Purging Gas Supply

A purging gas supply providing the required flow quantity must be connected to the pressurized enclosure. The following internal diameters of the purging gas supply line can serve as reference values:

Capacity Internal diameter < 50 litres min. 8 mm 50 to 300 litres min. 10 mm 300 to 700 litres min. 15 mm 700 to 1,000 litres min. 20 mm from 1,000 litres on min. 25 mm


Operation


5 Operation

5.1 Setting of Parameters

N o t e

Alteration of parameters and settings.

Parameter changes are only accepted when the programming bridge is connected to terminals 23 and 24.

To ensure that the altered levels are processed correctly by the APEX control unit, it is recommendable to restart the APEX control unit by means of a reset (S5).

The parameters are set on the control module and the connected sensor module. For this purpose there are five rotary switches on the control module and 3 buttons on the sensor module.

The following sections explain the individual functions of the rotary switches and buttons.

Rotary switch Function

S1 Changing display

S2 10-minute purge time

S3 1-minute purge time

S4 10-second purge time

S5 ON/OFF switch

Operation APEX 2003 Control Unit Type 07-3711-.2../....


5.2 Operation of the Sensor Module

The three (+), (-) and (SET) buttons are used for altering and saving the switching values selected with the S1 rotary switch.

Pressing the “+” or “-“ button once changes the level by 0.1 mbar. The altered value is saved by means of the “SET” button and marked by an “*”.

Setting the S1 rotary switch to position 8 or 9 programs the functions of relays K 4 and K 5.

Button Function

+ Increase the value

- Reduce the value

SET Save the altered value

5.3 Display on the Sensor Module

The sensor module display shows the values selected by means of the “S1” rotary switch. Three lines are shown in the display, whereby each line indicates a certain value.

Line Function

1 Display of the current actual value

2 Display of the purge time

3 Display of the current setpoint value

5.4 Changing of Values

The parameters can be adjusted inside the APEX control unit as follows. This example explains how to change the DP1 internal pressure:

Procedure:

Turn S1 “Display” to item 0.

Connect a programming bridge between terminals 23 and 24.

Press the + or - buttons to alter the DP 1 level.

Press the “SET” button to save the new level. o The change is confirmed by an “*” in the display.

Switch the APEX control unit off and on again by means of the S5 rotary switch.

Remove the programming bridge between terminals 23 and 24.

N o t e

Procedure to change the parameters.

Use the same procedure to change the switching values and functions of DIFF A (item 1) to K 5 (item 9).


Operation


5.5 Indicators on the control module

5.5.1 “DIFF A” and “DIFF B” Indicators

The differential pressure A and differential pressure B indicators light up as long as the differential pressure is equal to or higher than the setpoint value.

Before the set purge time can start to count down, the setpoint value for differential pressure A and differential pressure B must be reached and the associated indicators must light up.

5.5.2 “MIN A” and “MIN B” Indicators

The indicators for minimum pressure A and minimum pressure B light up as long as the pressure is equal to or higher than the setpoint level.

Before the set purge time can start to count down, the setpoint value for minimum pressure A and minimum pressure B must be reached and the associated indicators must light up. The pressure level in the pressurized cabinet must be at least as high as the minimum pressure at all times throughout the operating phase. The indicators show that the right pressure level has been reached.

5.5.3 “MAX” Indicator

The maximum pressure indicator lights up when the “max” setpoint is reached or exceeded in the pressurized cabinet during the purging operation or operating phase.

5.5.4 “Operate” Indicator

The “Operate” indicator lights up once the purging phase has finished and the APEX control unit has enabled the pressurized cabinet.

5.5.5 “Purge time” Indicator

The “Purge time” indicator flashes while the control unit purges the pressurized cabinet with purge air.



5.6 S1 Rotary Switch for “Display”

A T T E N T I O N

Disconnection of the positive pressure regulation due to an incorrect setting of the maximum pressure level inside the enclosure during the purge time.

The ability of the APEX control unit to function is no longer assured.

The MAX 1 switching level (pressure inside the enclosure during the purge time) should not be set higher than the MAX switching level (maximum pressure during operation).

The S1 rotary switch is used to display the different switching levels in the sensor module. S1 switch setting at position:

Position Display Function

0 DP 1 Setpoint level of operating pressure / remaining purge time

1 DIFF A Minimum differential pressure A (purge time)

2 DIFF B Minimum differential pressure B (purge time)

3 MIN A Minimum positive pressure A (switching-off level)

4 MIN B Minimum positive pressure B (switching-off level)

5 MAX Maximum positive pressure (switching-off level operation)

6 MAX 1 Maximum positive pressure (switching-off level purge time)

7 MIN P Pre-alarm

8 K 4 Freely programmable signal relay

9 K 5 Freely programmable signal relay

5.7 Rotary Switches S2 to S4 “Purge time”

The purge time is set with rotary switches S 2 to S 4.

If a purge time of 13 minutes and 40 Seconds is set, rotary switches S2 to S4 must be set as follows:

Procedure:

Turn the “Display” S1 rotary switch to position 0.

Place a programming bridge between terminals 23 and 24.

Turn rotary switch S2 to position 1.



Turn the APEX control unit on and off by means of rotary switch S5.

Remove the programming bridge between terminals 23 and 24.

Switch Function

S2 Minutes in tens

S3 Minutes in units

S4 Seconds in tens


Operation


5.8 S5 “ON/OFF” Rotary Switch

The S5 rotary switch is a reset switch and it is used for re-starting the system when adjustments have been made.

Position Function

0 Off / Reset

1 On

5.9 K4 and K5 Relays

Various functions can be assigned to the K4 and K5 potential-free relays. The following table shows the possible functions for the K4 and K5 relays:

Value Function

0 Switches simultaneously with K 2/3 relays (Ex p enabling)

1 Switches if the “DIFF A” level is exceeded.

2 Switches if the enclosure pressure is greater than “MIN P”.

3 Switches if the enclosure pressure is greater than “MIN A”.

4 Switches if the enclosure pressure is greater than “MAX”.

5 Switches if the enclosure pressure is greater than “MAX 1”.

6 Switches if the purge time is counting.

7 Switches simultaneously with K1

8 Switches if the bypass mode is activated

9 Switches if there is any internal malfunctioning.

Commissioning APEX 2003 Control Unit Type 07-3711-.2../....


6 Commissioning

A T T E N T I O N

- Before switching on for the first time, make sure the operating voltage agrees with the mains voltage.

- An error code will indicate any internal faults that may occur while the APEX control unit is starting up.

If the error code is due to a fault in the purging gas supply, the fault should be eliminated and the APEX control unit reset by switching it on and off..

N o t e

Place a programming bridge when changing parameters

During commissioning and when adjusting parameters in the control module, the programming bridge must be set between terminals 23 and 24.

Procedure for commissioning a pressurized system:

Before commissioning, check the electrical devices installed inside the pressurized enclosure.

Make sure the pressurized enclosure is purged sufficiently.

Check that the pressurized system functions correctly: o It must be ensured that there is no external voltage in the pressurized enclosure

(including data lines) when the control is deactivated.

The relevant safety regulations and rules must be observed.

Determine the differential pressure (see Chapter 6.1).

Set the positive operating pressure (see Chapter 6.2).

Calculate and set the purge time (see Chapter 6.3).

Check the purging phase (see Chapter 6.5).

Check the operating phase (see Chapter 6.6).


Commissioning


6.1 Calculation of the Differential Pressure

To determine the flow using DIFF A and DIFF B, close the pressurized enclosure and start up the APEX control unit.

Procedure:

Set the S5 rotary switch to position “1”.


Use the plus key on the sensor module to increase the DIFF A setpoint and confirm with the “Set” button.

e.g. 15 mbar


Use the plus key on the sensor module to increase the “DIFF B” setpoint and confirm with the “Set” button.

e.g. 15 mbar

Use the S5 rotary switch to reset the control module (Position 0 – 1).

Connect the purging gas and set the input pressure at the pressure reducer. e.g. 2 bar

Set the S1 rotary switch to position “1”. o The APEX control unit starts the purging phase.

Register and note the maximum DIFF A level. e.g. registered value = 6.5 mbar

Use the plus or minus keys on the sensor module to set the DIFF A setpoint level to 6.0 mbar and confirm with the SET key.

e.g. detected value 6.5 mbar – 0.5 mbar = 6.0 mbar


Use the plus or minus keys on the sensor module to set the DIFF B setpoint level to 6.0 mbar and confirm with the SET key.

e.g. detected value 6.5 mbar – 0.5 mbar = 6.0 mbar


Set the trial purge time by means of the rotary switches S2 to S4. e.g. 30 seconds (S5 = 0; S2 = 0; S3 = 0; S4 = 3)

Set the S5 rotary switch to position “1”. o The APEX control unit starts and the purge time begins to count down.

N o t e

Deduction of a safety factor from DIFF A and DIFF B.

On account of the possibility of fluctuations occurring in the flow during the purging operation, a safety factor of 0.5 mbar can be deducted from the DIFF A and DIFF B levels.



6.2 Setting the Positive Operating Pressure

The “DP1” level is the internal positive pressure in the pressurized enclosure. This level is monitored by the APEX control unit and compensated if necessary. As standard, the operating pressure is set to 1.5 mbar in the digital purging gas valve and to 2.5 mbar in the proportional purging gas valve.

APEX control unit with digital purging gas valve

Any losses through leakage in the pressurized enclosure are compensated in the digital purging gas valve by means of an adjustable leakage air needle, which must be adjusted to suit the leakage losses.

If the compensation by the leakage air nozzle is not sufficient and the pressure inside the enclosure falls below the “DP 1” level, the digital purging gas valve is connected for a short time to prevent switching-off due to a loss of pressure.

N o t e

Connection of the digital purging gas valve during the operating phase.

Increased leakage losses.

Re-adjustment of the leakage air needle, see Chapter 6.3 “Adjusting the Leakage Air Needle”.

APEX control unit with proportional purging gas valve

Setting of the operating pressure. The proportional valve regulates the pressure inside the enclosure to the “DP 1” setpoint level. This is done by the control module controlling the proportional purging gas valve in a way that ensures that only the actual leakage losses are compensated. There is no leakage air needle such as there is in the digital purging gas valve.

Procedure for setting the positive operating pressure:



Use the “+” and “-“ buttons to adjust the level.

Use the “SET” button to confirm the level.

Use the S5 rotary switch to reset the control module (position 0 – 1).

Setting of the required input pressure on the pressure reducer. e.g. 2 bar

Do not change the leakage air needle in the purging gas valve.

Close the pressurized enclosure.

Connect the mains voltage and set the S5 rotary switch to position “1”. o After the purging phase, the operating phase is initiated and the pressure falls

to the positive operating pressure level. o The positive operating pressure level is indicated in the sensor module display.

This should be kept at a constant level. If there is a drop in the positive operating pressure, increase the flow at the

leakage air needle. If there is an increase in the positive operating pressure, reduce the flow at

the leakage air needle.


Commissioning


6.3 Adjusting the Leakage Air Needle

The leakage air needle for the digital purging gas valve must be adjusted during commissioning and when altering the leakage air quantity in the pressurized enclosure.

Procedure:



Set the required input pressure on the pressure reducer. e.g. 2 bar

Let the purge time for the APEX control unit run.

Do not alter the leakage air needle on the purging gas valve.

Determine the “DP1” level. If there is a drop in the “DP1”, increase the flow at the leakage air needle. If there is an increase in the “DP1”, reduce the flow at the leakage air needle

Increase the flow at the leakage air needle:

Use a small (2-mm) screwdriver to turn the screw in the leakage air needle in ¼ revolutions in an anti-clockwise direction.

Check the “DP1” level again to determine if the level remains constant, increases or continues to fall. o If the “DP1” level remains constant, the leakage air needle has been adjusted

correctly.

Reduce the flow at the leakage air needle:

Use a small (2-mm) screwdriver to turn the screw in the leakage air needle in ¼ revolutions in an anti-clockwise direction.

Check the “DP1” level again to determine if the level remains constant or drops or continues to increase. o If the “DP1” level remains constant, the leakage air needle has been adjusted

correctly.



6.4 Calculation of Purge Time It is assumed in the following that the volume of purging gas is calculated to suit the capacity of the pressurized enclosure (capacity-dependent purge time).

The flow of purging gas at the outlet of the pressurized enclosure is used to calculate the purge time. The “DIFF A” and “DIFF B” purging gas flow must be calculated as described in Chapter 6.1 “Calculation of the Differential Pressure”.

Procedure:

The orifice is determined by the 10th code number in the type designation: APEX control unit type: 07-3711-x21 x /….

Orifice Diameter [mm]

1 2

2 5

3 8

4 12

5 15

6 18

Using the differential pressure determined in accordance with Chapter 6.1 “Calculation of the Differential Pressure”, read the purging gas flow from the diagram. Diagrams are available in the appendix.

The purge time is calculated in accordance with the following formula:

5

60

Set the calculated purge time by means of the S2 to S4 rotary switches.

N o t e

Deduction of a safety factor from DIFF A and DIFF B.

On account of the possibility of fluctuations occurring in the flow during the purging operation, a safety factor of 0.5 mbar can be deducted from the DIFF A and DIFF B levels.


Commissioning


6.4.1 Example of a Purging Gas Calculation

The following is an example of how the purge time is calculated.

Example:

Capacity of the pressurized enclosure = 200 litres,

Control unit type 07-3711-1215/1000

Procedure:

The orifice is determined by the 10th code number in the type designation: APEX control unit type: 07-3711-121 5 /1000

Orifice Diameter [mm]

5 15

o Based on the table, the diameter of the orifice is 15 mm.

The following level was calculated in accordance with Chapter 6.1 “Calculation of the Differential Pressure”:

o Differential pressure = 6.5 mbar o DIFF A and DIFF B minus 0.5 mbar (safety factor)

o Flow read from the diagram = 11.5 m³ / h

Calculate the purge time in accordance with the formula: o Purge time = 200 l x 5 : 11500 l/h x 60 = 5 minutes 20 seconds

Set the calculated purge time by means of the S2 to S4 rotary switches.

Setting for S2=0; S3=5; S4=2

Switch the APEX control unit off and on again by means of the S5 rotary switch.



6.5 Checking the Purging Phase

N o t e

Safe operation during fluctuations in pressure.

For safe operation (pressure fluctuations), raise the pressure reducer’s setpoint inlet pressure by 0.5 bar.

Check the purge time for the pressurized enclosure as follows:

Set up the pressurized enclosure to be ready for operation.

Activate the APEX control unit.

Activate the purging gas supply. o The “MIN A” and “MIN B” LEDs light up. o The “DIFF A” and “DIFF B” LEDs light up. o The “purge time” LED flashes. o The time shown in the sensor module’s display counts down.

Reduce the purging gas supply by lowering the pressure at the pressure reducer. o The “MIN A” and “MIN B” LEDs go out. o The “DIFF A” and “DIFF B” LEDs go out. o The “purge time” LED is off. o The time shown in the sensor module’s display is reset.

Increase the purging gas supply by raising the pressure at the pressure reducer (max. 3 bar). o The “MIN A” and “MIN B” LEDs go out. o The “DIFF A” and “DIFF B” LEDs light up. o The “purge time” LED flashes. o The time shown in the sensor module’s display counts down. o At the end of the purge time the “OPERATE” LED lights up. o The “DIFF A” and “DIFF B” LEDs go out.

6.6 Checking the Operating Phase

Check the operating phase of the pressurized enclosure as follows:

Set up the pressurized enclosure to be ready for operation.

Activate the APEX control unit.

Activate the purging gas supply.

Let the purging phase run. o The “DIFF A” and “DIFF B” LEDs go out. o The “MIN A” and “MIN B” LEDs light up. o The “OPERATE” LED is on. o Relay K2/3 activates the installed parts.

Reduce the purging gas supply by lowering the pressure at the pressure reducer. o The “MIN A” and “MIN B” LEDs go out. o The “OPERATE” LED goes off. o Relay K2/3 deactivates the installed parts.


Operation


7 Operation

7.1 Safety during Operation

D A N G E R

Death or serious physical injury due to a damaged explosion protection measure. It is no longer possible to operate the control unit without risks.

Risk of explosion

Put the APEX control unit out of operation and protect it against unintended reconnection.

7.2 Types of Purging Gas

D A N G E R

Death or serious physical injury due to purging gas escaping when the pressurized enclosure is opened.

Risk of suffocation

Stop the supply of purging gas when opening the pressurized enclosure and make sure the escaping purging gas cannot be inhaled directly.

Only inert gas (e.g. nitrogen) or cleaned and dry instrument air may be used as a purging gas. In any case, a filter must be placed upstream if the quality with respect to foreign particles is not assured. The following quality features should be filled by the purging gas:

Residual dust: < 40 µm

Residual water: dew point +3 °C

Residual oil content: 1 mg/m³



7.3 Operating Phases in the Pressurized Enclosure

The operation of a piece of pressurized operating equipment can be divided into three phases. The three phases break down into the preparatory, purging and operating phase.

7.3.1 Flow Diagram for the Operating Phases

The APEX control unit is constructed in conformance to the currently applicable directives and standards and fulfils the requirements specified there. The processes in the respective states are listed in the following.

Operating phase Requirements Effect

Preparatory phase Mains voltage connected

Initiation of the purging phase

Internal pressure less than MAX Purge time not ended

Purging phase

Internal pressure greater than MIN A / MIN B

Purge time on Internal pressure less than MAX MIN. differential pressure > DIFF A / DIFF B

Purge time ended

Initiation of the operating phase

Operating phase

Internal pressure greater than MIN A / MIN B

Pressurized enclosure is enabled

Internal pressure less than MAX Purge time ended Bridge 19/20 closed

7.3.2 Preparatory Phase

The preparatory phase begins when the supply voltage for the APEX control unit is switched on and the purging gas supply starts. The purging gas flows through the purging gas valve into the pressurized enclosure.

N o t e

Difference between the proportional and digital purging gas valve

Digital purging gas valve: the digital purging gas valve directs the purging gas through the integrated leakage air needle into the pressurized enclosure. Accordingly, the purging gas valve is closed during the preparatory phase and it opens for the start of the purging phase.

Proportional purging gas valve: the proportional purging gas valve directs purging gas into the pressurized enclosure only when it is open. It is therefore necessary for the proportional purging gas valve to be open during the preparatory phase and the bypass operation.

Preparatory phase sequence:

The influx of purging gas increases the internal pressure in the pressurized enclosure.

The “MIN A” minimum pressure in the enclosure is exceeded.

The purging gas valve is opened by means of the control module.

The next phase, the “purging phase“, is initiated.


Operation


7.3.3 Purging Phase

The pressurized enclosure is purged with purging gas in order to remove any explosive gas-and-air mixture inside or to dilute it to a harmless concentration before the possible sources of ignition are connected in the pressurized enclosure.

This process prepares the pressurized enclosure for the operating phase. The necessary purging volume depends on the free capacity in the pressurized enclosure. The purging process is constantly monitored by the sensors in the sensor module and the pressure monitor.

To prevent the pressure inside the enclosure reaching an excessively high level as a result of an impermissibly high flow resistance at the control device’s pressure monitor, the purging gas pressure is restricted during the purge time to the “MAX 1” level. This means when the “MAX 1” level is exceeded, the purging gas valve is closed for the short time.

Purging phase sequence:

Increase the flow with purging gas.

The plate integrated in the pressure monitor is raised.

The “MIN A”, “MIN B”, “DIFF A” and “DIFF B” switching levels are exceeded.

The “DIFF A” and “DIFF B” LEDs light up.

The purge time in the display counts down and the “purge time” LED flashes.

The purging gas valve closes after the end of the purge time.

The “DIFF A”, “DIFF B” and “Purge time” LEDs go out and the next phase, the “Operating phase”, is initiated.

7.3.4 Operating Phase

The operating phase begins when the purging gas valve closes.

The operating pressure must be maintained during the entire operation of the pressurized enclosure to prevent the penetration of combustible substances. The electrical installed parts in the pressurized enclosure are connected and activated by means of a relay integrated in the control module.

If the enclosure pressure drops below the set minimum levels during the operating phase, all electrical installed parts in the pressurized enclosure which are not themselves explosion-proof, are switched off and the purging process starts again.

Operating phase sequence:

The purge valve closes and the leakage losses are compensated.

The “MIN A” and “MIN B” LEDs light up.

The “Operate” LED lights up.

Relay K2/3 connects and activates the mains voltage.

K4 and K5 relays switch depending on their configuration.

The remaining purge time display goes out and the existing pressure inside the enclosure is displayed on the sensor module.



7.4 Bypass Operation

D A N G E R

Death or serious physical injury due to commissioning with a bypass key switch in an explosive atmosphere.

Risk of explosion

Have the commissioning with a bypass key switch approved by the factory manager or his appointee. Approval may be given only if it has been ensured that there will not be any explosive atmosphere for the duration of the commissioning or if the necessary precautions have been taken to protect against the risk of explosion (fire permit).

A warning sign informing that the Ex protection will be eliminated if the key switch is activated must be affixed near the key switch.

N o t e

Special technical condition for the proportional purging gas valve in bypass mode.

When a proportional purging gas valve is used, it is open during the bypass mode!

During the operating phase it may be necessary to change settings on internally mounted components. The APEX control unit provides the bypass function for this function.

If the bypass mode is activated, it must be ensured that there is no explosive gas in the atmosphere. The concentration of gas in the surrounding atmosphere is determined with a gas detector.

Once the bypass mode is activated, the door of the pressurized enclosure can be opened without interrupting the operation of the internal components. The required settings can be carried out and, once done, the pressurized enclosure must be closed again. The operation of the pressurized enclosure is not interrupted for this duration. The purging phase is not repeated for the pressurized enclosure.

Procedure:

Measure the surrounding atmosphere freely.

Activate the bypass mode. o The display changes to “BYPASS”.

Open the door of the pressurized enclosure o The enabling by relay K2/3 is not reset.

Do the required work inside the pressurized enclosure.

Close the door on the pressurized enclosure.

Deactivate the bypass mode. o The display changes to the standard display.


Maintenance and Care


8 Maintenance and Care

N o t e

Maintenance intervals

Regular maintenance is not necessary if the device is operated appropriately in compliance with the installation instructions and with due consideration to the ambient conditions:

An inspection in conformance to the “Inspection Table for Commissioning and Maintenance” in Chapter 8.1 is recommended once a year.

A T T E N T I O N

Maintenance and Care

- The currently applicable provisions in the national regulations must be observed for the upkeep, maintenance and inspection of the operating equipment!

- Operating and maintenance work may be done by trained specialist personnel only. The statutory regulations and other binding directives on workplace safety, accident prevention and environmental protection must be adhered to.

- Live parts can become exposed when covers are opened or parts removed, except where this is possible by hand. Connection parts may be live too.

The “Inspection Table for Commissioning and Maintenance” in Chapter 8.1 serves as a minimum requirement for the maintenance or commissioning of a pressurized enclosure.

Maintenance and Care APEX 2003 Control Unit Type 07-3711-.2../....


8.1 Inspection Table for Commissioning and Maintenance

Item Test point Commissioning

Mainten-ance

OK OK

1 Visual inspection for damage

2 Attachment of the APEX control unit n/a

3 Diagonal purging of enclosure assured n/a

4 Installed devices attached securely

5 Installed equipment purged sufficiently. n/a

6 Devices with integrated capacitors noted (it may be necessary to affix a sign).

n/a

7 Devices with hot surfaces noted

8 Establishment of equipotential bonding

9 Wiring checked to ensure presence of blue cores or cables in the Ex i area

n/a

10 Wiring checked for conformance to the relevant directives.

n/a

11 Any inspection glasses there are made of safety glass or of plastic

n/a

12 “Key switch…” sign affixed wherever there are any key switches.

13 General state of the mounted elements in the pressurized enclosure (device feet, rain shelter, cable glands)

14 Agreement between mains voltage and the connection voltage for the individual devices

n/a

15 Total power consumption of the devices less than the control unit’s maximum switching capacity

n/a

16 Check separation of any data lines. n/a

17 Maximum surface temperature checked n/a

18 Pressure test with 1.5 x Pmax passed, no permanent deformations in the enclosure

n/a

19 Enclosure capacity determined n/a

20 Purging phase checked

21 Switching levels of the APEX control unit checked.

22 Correct functioning of the APEX control unit tested.

23 Correct functioning of any bypass key switch checked.

24 Sign conforming to EN 60079-2 affixed to enclosure.


Malfunctioning and Troubleshooting


9 Malfunctioning and Troubleshooting

It is assumed here that the connection of all external electrical and mechanical units has been carried out in an orderly fashion. For that reason it should be checked that the electrical units have indeed been set up and connected properly.

9.1 Fault Table

Fault Possible Cause Remedy

Device is not working, “Mains” LED does not light up

No mains voltage. Check mains voltage supply line.

The electric devices are connected and activated without purging phase.

Device defective. Return to manufacturer

Key switch turned on Turn off the key switch

The digital purging gas valve switches off briefly during the purging phase

Excessive quantity of purging gas introduced into the pressurized enclosure

Reduce the purging gas nozzle

The “Purge time on” LED does not flash during the purge time

There is no purging gas Connect purging gas.

Purging gas valve does not open or opens only partially

Check purging gas valve for supply voltage (terminals 31 to 33)

Check purging gas valve for foreign particles in the mechanical part

Insufficient purging gas flow through the Ex p enclosure.

Increase input pressure to setpoint level

Check purging gas nozzle for correct level

Check the control unit’s “DIFF A”, “DIFF B”, “MIN A” and “MIN B” for setpoint levels.

Increase the cross-section in the purging gas supply line

The target pressure for the pressure reducer is not reached.

Purging gas supply too low. Increase the cross-section of the supply line.

The pressure monitor for the control unit is inadmissibly blocked or restricted.

Remove the blockage or take suitable measures to eliminate the restriction.

Enclosure leaks during the purging phase due to an increase in internal pressure.

Use suitable measures to seal the enclosure.




Fault Possible Cause Remedy The digital purging gas valve does not switch over to the small nozzle after the purging phase.

Temperature sensor is connected, internal temperature is too high.

Check purging gas valve for foreign particles in the mechanical part. Wait until the increased flow rate reduces the internal temperature or check the set temperature switching value.

The ON/OFF switch or the bridge at terminals 19 and 20 is not connected.

Turn on the ON/OFF switch and connect the bridge to terminals 19 and 20.

The purging gas valve does not close.

Check the purging gas valve to see if the supply voltage is switched off.

The control unit does not connect the electric devices after the purging phase.

The pressure in the enclosure is higher than the “MAX” switching level.

Reduce the air flow in the air leakage nozzle.

“MAX” switching level too low. Check the “MAX” switching level.

Pressurized enclosure leaks. Turn on the “MIN A” and “MIN B” pressure switches.

Seal the pressurized enclosure.

The control unit switches the electric devices off after the purge time with a 5-second time delay.

The leakage air needle in the digital valve is too low.

Increase the air flow rate in the leakage air needle.

The “MIN A” or “MIN B” switching level is too high.

Check the “MIN A” or “MIN B” switching level.

Configuration of K 4 or K 5 Check the configuration of the K4 or K5.

Relays K4 or K5 do not connect.

The enclosure leaks. The purging gas valve tries to maintain the internal pressure by opening the purging air nozzle.

Seal the enclosure or enlarge the passage in the air leakage nozzle.

The digital purging gas valve connects briefly during the operating phase.

The “DP1” level is too high. Reduce the “DP1” level.

The electrical devices do not switch off when the pressure drops.

Key switch turned on. Turn off the key switch.




9.2 Error Code Table

N o t e

Maintenance intervals’

An error code will indicate any internal faults that may occur while the APEX control unit is starting up.

If the error code is due to a fault in the purging gas supply, the fault should be eliminated and the APEX control unit reset by switching it on and off.

Error code Error Description Remedy

(1) Memory: The cause of the error lies in the memory area.

Use the S5 rotary switch to reset the APEX control unit. If this measure is not successful, send the control unit back to the manufacturer.

(2)

Difference between Min A and Min B: the difference measured between the Min A and Min B pressure levels is too large

Check the measuring leads. They could be bent or dirty (e.g. with oil).

(3)

MUX/AD: The cause of the error lies in the area of the Multiplexer control or the analog/digital conversion.


(4)

SITRANS: The cause of the error lies in the area of the opt. pressure switch connections.

Check the connections.

(5) EEPROM: The cause of the error lies in the area of the internal EEPROM.


(6) RAM: The cause of the error lies in the area of the internal RAM modules.


(7)

MAX 1 less than MIN: The cause of the error lies in the setting of the minimum and maximum levels whereby the maximum level was set lower than the minimum level.

Check the setpoint values.

(8)

P > max in purge time: The internal pressure in the Ex p operating equipment exceeds the maximum setpoint level.

Reduce the supplied purging gas pressure.

Technical Data APEX 2003 Control Unit Type 07-3711-.2../....


10 Technical Data

10.1 Aid for the Selection of the APEX Control Unit

The following table serves as an aid for the selection of the right control unit to suit the capacity of the pressurized enclosure.

Capacity Pressure Pressure -

reducer Purging gas

nozzle Orifice

diameter

< 50 litres 2 bar 1/4″ 2.8 mm 12 mm

50 to 300 litres

2 bar 1/4″ 3.9 mm 15 mm

300 to 700 litres

2 bar 1/2″ 4.5 mm 18 mm

700 to 1.000 litres

3 bar 1/2″ 4.5 mm 18 mm or 2 x 18 mm

From 1,000 litres on

3 bar 1/2″ 5.5 mm 2 x 18 mm

Example:

Parameters:

Capacity of the pressurized enclosure: 250 litres

Supply voltage: AC 230 V

Selection of a control unit with a digital purging gas valve:

APEX 2003 control unit with a 15-mm orifice (9 W)

Type: 07-3711-1215/1000

Digital purging gas valve with a 3.9-mm purging gas nozzle, undrilled

Type: 05-0056-0071

Drill the purging gas valve according to the table above.

Pressure reducer size 1/4″

Type: 05-0056-0007

Selection of a control unit with a proportional purging gas valve:

APEX 2003 control unit with a 15-mm orifice (15 W)

Type: 07-3711-1215/1082

Proportional purging gas valve with a 3.9-mm purging gas nozzle, undrilled

Type: 05-0056-0077

Drill the purging gas valve according to the table above.

Pressure reducer size 1/4″

Type: 05-0056-0007


Technical Data


10.2 General Technical Data for the APEX Control Unit

Parameters Specifications Mains voltage AC 230 V or AC 115 V (depending on the variant)

Rated capacity 9-watt (digital purging gas valve) 15-watt (proportional purging gas valve)

Degree of protection IP 65 Connecting terminals MAX. 2.5 mm², fine-wired Ambient temperature operation -20 °C to +40 °C Ambient temperature storage and transport

-20 °C to +60 °C

Construction Ex e protective enclosure with a viewing window in the lid

Enclosure material glass-reinforced polyester Purging gas medium cleaned industrial compressed air or inert gas Pressure switching levels MIN A / MIN B / MIN P 0 to 25 mbar DP 1 / DIFF A / DIFF B 0 to 25 mbar MAX / MAX 1 0 to 25 mbar Purge time 0 to 99 minutes Relay contacts

Relay K2/3 Switching capacity maximum 5 A at cos φ= 1/AC 250 V; dropout delay 5 seconds; additional fuse required; non-floating (=supply voltage)

K4 and K5 relays Switching capacity maximum 5 A at cos φ= 1/AC 250 V; no dropout delay; floating

Purging gas valve Digital or proportional (depending on the variant)

10.3 Supplementary Technical Data APEX 2003.00I Control Unit

Parameters Specifications Type 07-3711-1200/….

Power supply AC 230 V, AC 115 V or DC 24 V (depending on the variant)

Ex type of protection (ATEX) II 2(1)G Ex de ib [ia Ga px] IIC T6/T4 Gb Certification DMT 99 ATEX E 082 Ex type of protection (IECEx) Ex de ib [ia Ga px] IIC T6/T4 Gb Certification IECEx BVS 13.0039 Dimensions 200 [W] x 250 [H] x 120 [D] mm Dimensions borehole pattern 180 [W] x 200 [H] mm Installation internal Sensor module external Pressure monitor external Bypass key switch external

Cable glands 3 x M20x1.5 blue / 8 x M20x1.5 black / 1 x M16x1.5 black

Clamping area M20: 6-13 mm, M16: 4-9 mm

Rate of flow 0 to 44 m³/h depending on orifice diameter for the pressure monitor



10.4 Supplementary Technical Data APEX 2003.00 Control Unit

Parameters Specifications Type 07-3711-121./….


Ex type of protection (ATEX) II 2(1)G Ex de [ia Ga px] IIC T4 Gb Certification DMT 99 ATEX E 082 Ex type of protection (IECEx) Ex de [ia Ga px] IIC T4 Gb Certification IECEx BVS 13.0039 Dimensions 200 [B] x 250 [H] x 120 [D] mm Dimensions borehole pattern 180 [B] x 200 [H] mm Installation flanged-on Sensor module internal Pressure monitor 1 x pressure monitor Bypass key switch internal, in APEX 2003.00S Cable glands 2 x M20x1.5 blue / 4 x M20x1.5 black Clamping area 6-13 mm

Rate of flow 0 to 22 m³/h depending on the diameter of the orifice on the pressure monitor

10.5 Supplementary Technical Data APEX 2003.002x Control Unit

Parameters Specifications Type 07-3711-1216/….


Ex type of protection (ATEX) II 2(1)G Ex de [ia Ga px] IIC T4 Gb Certification DMT 99 ATEX E 082 Ex type of protection (IECEx) Ex de [ia Ga px] IIC T4 Gb Certification IECEx BVS 13.0039 Dimensions 255 [W] x 250 [H] x 120 [D] mm Dimensions borehole pattern 236 [W] x 200 [H] mm Installation flanged-on Sensor module internal Pressure monitor 2 x pressure monitors Bypass key switch internal, in APEX 2003.002xS Cable glands 2 x M20x1.5 blue / 4 x M20x1.5 black Clamping area 6-13 mm



Technical Data


10.6 Supplementary Technical Data APEX 2003.MV control Unit

Parameters Specifications Type 07-3711-211./…. Power supply AC 230 V or AC 115 V (depending on the variant) Ex type of protection (ATEX) II 2(1)G Ex de [ia Ga px] IIC T4 Gb Certification DMT 99 ATEX E 082 Dimensions 255 [W] x 250 [H] x 120 [D] mm Dimensions borehole pattern 236 [W] x 200 [H] mm Installation remote Sensor module internal Pressure monitor Pressure monitor; internal Purging gas valve Proportional, NW 2 Pressure reducer G 1/4″; 0-6 bar Purging gas connections G 1/4″; internal thread Bypass key switch internal, in APEX 2003.MVS Cable glands 2 x M20x1.5 blue / 4 x M20x1.5 black




10.7 Technical Data for the Sensor Module

Parameters Specifications Type 17-51P2-..00 Ex protection type (ATEX) II 2G Ex ib IIC T4 / T6 Ex protection type (IECEx) Ex ib IIC T4 / T6 ATEX certification DMT 99 ATEX E 108 X IECEx certification IECEx BVS 09.0055X Ambient temperature -20 °C to +60 °C Dimensions

internal 70 [L] x 70 [W] x 60 [H] mm external 95 [L] x 95 ]W] x 85 [H] mm

Installation internal or external (depending on the variant) Weight

internal 0.2 kg external 0.5 kg

Degree of protection MIN. IP 20 after mounting For further technical data, see product data sheet.

10.8 Technical Data for the Purging Gas Valve

10.8.1 Technical Data for the Digital Purging Gas Valve

Parameters Specifications Type 05-0056-00.. Ex protection type (ATEX) II 2G Ex m II T4 Ex protection type (IECEx) Ex m II T4 ATEX certification PTB 00 ATEX 2129X IECEx certification IECEx PTB 07.0021X Supply voltage AC 230V, AC 115 V ± 10% or DC 24 V Pressure range 0 to 16 bar Valve connection G 3/8″ Nominal diameter 13 mm Ambient temperature -30 °C to +60 °C Dimensions 56 [L] x 40 [W] x 100 [D] mm Weight 0.9 kg Degree of protection IP 65 For further technical data, see product data sheet.


Technical Data


10.8.2 Technical Data for the Proportional Purging Gas Valve

Parameters Specifications Type 05-0056-00.. ATEX Ex protection type II 2G Ex m II T4 IECEx Ex protection type Ex m II T4 ATEX certification PTB 00 ATEX 2202X IECEx certification IECEx PTB 13.0011X Supply voltage AC 230 V or AC 115 V ± 10% Pressure range 0 to 4 bar Valve connection G 3/8″ Nominal diameter 6 mm Ambient temperature -10 °C to +55 °C Dimensions 103.4 [L] x 56.6 [W] x 95.3 [H] mm Weight 0.9 kg Degree of protection IP 65 For further technical data, see product data sheet.

10.9 Technical Data for the Rain Protection Cap

Parameters Specifications Type 05-0032-0011 Material PVC, black Dimensions Ø 54 mm x 40 mm Mounting thread M36 Temperature range -20 °C to +60 °C Weight 0.048 kg

Application Protection against rain for the APEX control unit with an orifice of up to 15 mm

10.10 Technical Data for the Rain Protection Roof

Parameters Specifications Type 05-0132-00.. Material Sheet steel, varnished or stainless steel Dimensions

for APEX 2003.00 142 [D] x 220 [B] x 50 [H] mm for APEX 2003.002x 142 [D] x 270 [B] x 50 [H] mm

Mounting thread 2 x M6 Temperature range -20 °C to +60 °C Weight 0.5 kg Application Protection against the rain for the APEX control unit



10.11 Technical Requirement for the Purging Gas

The quality of the purging gas must conform to class 543 in compliance with DIN ISO 8573-1:

Parameters Specifications

Residual dust < 40 µm

Residual water Dew point +3 °C

Residual oil content 1 mg/m³

Temperature Maximum +40 °C


Order Numbers


11 Order Numbers

11.1 APEX Control Units

11.1.1 APEX 2003.00I Control Units

APEX control unit for internal installation

9-W version, AC 230 V 07-3711-1200/1010

9-W version, AC 115 V 07-3711-1200/2010

9-W version, DC 24 V 07-3711-1200/4010

15-W version, AC 230 V 07-3711-1200/1099

15-W version, AC 115 V 07-3711-1200/2099

11.1.2 APEX 2003.00 Control Units

APEX 2003.00 control units, standard (1 x pressure monitor )

9-W version, AC 230 V, 8-mm orifice 07-3711-1213/1000


9-W version, DC 24 V, 8-mm orifice 07-3711-1213/4000















Order Numbers APEX 2003 Control Unit Type 07-3711-.2../....


11.1.3 APEX 2003.00S Control Units APEX 2003.00S control units, standard with a bypass key switch (1 x pressure monitor ) 9-W version, AC 230 V, 12-mm orifice 07-3711-1214/1037















11.1.4 APEX 2003.002x Control Units

APEX 2003.002x control units, standard (2 x pressure monitor )

9-W version, AC 230 V, 2x18-mm orifice 07-3711-1216/1017


9-W version, DC 24 V, 2x18-mm orifice 07-3711-1216/4017


15-W version, AC 115 V, 2x18-mm orifice, 07-3711-1216/2107

11.1.5 APEX 2003.002xS Control Units

APEX 2003.002xS control units, standard with a bypass key switch (2 pressure monitor )



9-W version, DC 24 V, 2x18-mm orifice 07-3711-1216/4025



11.1.6 APEX 2003.MV Control Units

APEX 2003.MV control units, remote control unit

AC 230 V, 3-mm orifice 07-3711-2211/1000

AC 115 V, 3-mm orifice 07-3711-2211/2000

AC 230 V, 5-mm orifice 07-3711-2212/1000

AC 115 V, 5-mm orifice 07-3711-2212/2000

AC 230 V, 8-mm orifice 07-3711-2213/1000

AC 115 V, 8-mm orifice 07-3711-2213/2000


Order Numbers


11.1.7 APEX 2003.MVS Control Units APEX 2003.MVS control units, remote control unit with a bypass key switch

AC 230 V, 3-mm orifice 07-3711-2211/1012

AC 115 V, 3-mm orifice 07-3711-2211/2012

AC 230 V, 5-mm orifice 07-3711-2212/1012

AC 115 V, 5-mm orifice 07-3711-2212/2012

AC 230 V, 8-mm orifice 07-3711-2213/1012

AC 115 V, 8-mm orifice 07-3711-2213/2012

11.2 Accessories and Spare Parts

11.2.1 Pressure Monitor

Pressure Monitor for use with an APEX 2003.00I Control Unit Pressure monitor module in the Ex e enclosure, 12-mm orifice 17-51P3-1402

Pressure monitor module in the Ex e enclosure, 15-mm orifice 17-51P3-1502

Pressure monitor module in the Ex e enclosure, 18-mm orifice 17-51P3-1602

Pressure monitor module in the Ex p enclosure, 12-mm orifice 17-51P3-1403



11.2.2 Sensor Module

Sensor module for use with an APEX 2003.00I Control Unit 0-25 mbar, fitted device 17-51P2-1100

0-25 mbar, mounted device with a stainless steel frame 17-51P2-2100

Order Numbers APEX 2003 Control Unit Type 07-3711-.2../....


11.2.3 Digital Purging Gas Valve with Leakage Air Needle and 3 m Connection Cable Digital purging gas valve with a leakage air needle and a 3 m connection cable

G3/8″, purging gas nozzle, 2 x undrilled, AC 230 V, N/C 05-0056-0071

G3/8″, purging gas nozzle, 2 x undrilled, AC 115 V, NC 05-0056-0072

G3/8″, purging gas nozzle, 2 x undrilled, DC 24 V, NC 05-0056-0073 Note: control module in 9-W version

11.2.4 Digital Purging Gas Valve with Leakage Air Needle and Connection Box without Purging Gas Nozzle

Digital purging gas valve with a leakage air needle and a connection box without a purging gas nozzle G3/8″, purging gas nozzle, 2 x undrilled, AC 230 V, N/C 05-0056-0074

G3/8″, purging gas nozzle, 2 x undrilled, AC 115 V, NC 05-0056-0075

G3/8″, purging gas nozzle, 2 x undrilled, DC 24 V, NC 05-0056-0076

11.2.5 Proportional Purging Gas Valve

Proportional purging gas valve

G3/8″, purging gas nozzle, 2 x undrilled, UC 230 V 05-0056-0022

G3/8″, purging gas nozzle, 2 x undrilled, UC 115 V 05-0056-0024 Note: control module in 15-W version.

11.2.6 Pressure Reducer

Pressure reducer, 0.5-6 bar with an attachment of parts

Pressure reducer 1/4″ 05-0056-0007

Pressure reducer 1/2″ 05-0056-0041

11.2.7 Accessories

Accessories for the APEX Control Unit

Programming bridge 05-0012-0193

Rain protection cap 05-0032-0011

Rain protection roof, sheet steel, RAL 7035, width = 270 mm 05-0132-0017

Rain protection roof, sheet steel, RAL 7035, width = 220 mm 05-0132-0014

Rain protection roof, stainless steel 1.4301, width = 270 mm 05-0132-0016

Rain protection roof, stainless steel 1.4301, width = 220 mm 05-0132-0015

11.2.8 Control Module

Spare parts for the APEX control unit

Ex p control, control module, AC 230 V, 7 W / 9 W 07-7331-8112/1100

Ex p control, control module, AC 115 V, 7 W / 9 W 07-7331-8122/1100

Ex p control, control module, AC 230 V, 15 W 07-7331-8112/3100

Ex p control, control module, AC 115 V, 15 W 07-7331-8122/3100 Note: only available as a spare part, quoting type and serial number of the APEX control unit.


Appendix


12 Appendix

12.1 Purging Gas Diagrams for the APEX Control Unit

12.1.1 Purging gas diagram for the APEX 2003.00 control unit

12.1.2 Purging Gas Diagram for the APEX 2003.002x Control Unit

Appendix APEX 2003 Control Unit Type 07-3711-.2../....


12.1.3 Purging Gas Diagram for the APEX 2003.MV Control Unit


Appendix


12.2 Dimensions

12.2.1 APEX 2003.00I

12.2.2 APEX 2003.00



12.2.3 APEX 2003.00S

12.2.4 APEX 2003.002x / APEX 2003.002xS


Appendix


12.2.5 APEX 2003.MV / APEX 2003.MVS

12.3 Borehole Patterns

12.3.1 APEX 2003.00 Control Unit



12.3.2 APEX 2003.00 Control Unit2x

12.3.3 Sensor Module

12.3.4 Roof as Protection Against Rain

Borehole dimensions Material “A” dimension

05-0132-0014, 05-0132-0015 170 mm

05-0132-0016, 05-0132-0017 220 mm


Appendix


12.4 Test and Assessment Report Form

Product designation :

Customer :

Type :

Order number :

Manufacturing no. :

Input voltage :

Valve type : Digital valve Prop. valve DN2 Prop. valve DN6

Measuring orifice :

Settings

Value S1 rotary switch

Description Code Switching level

DP 1 0 Positive operating pressure level between

enclosure and atmosphere D

DIFF A 1 Minimum differential pressure during the purging phase in the pressure monitor

Q

DIFF B 2 Minimum differential pressure during the

purging phase in the pressure monitor module R

MIN A 3 Minimum positive pressure between enclosure

and atmosphere (disconnection threshold) A

MIN B 4 Minimum positive pressure between enclosure

and atmosphere (disconnection threshold) P

MAX 5 The max. positive pressure between enclosure

and atmosphere (disconnection threshold) B

MAX 1 6 The max. positive pressure between enclosure

and atmosphere during purging C

MIN P 7 Pre-alarm F

Relay S1 rotary

switch Description Code

Switching level

K4 8 Function of the K4 relay N

K5 9 Function of the K5 relay O

Purge time

S2 rotary switch 10-minute steps

S3 rotary switch 1-minute steps

S4 rotary switch 10-second steps

Test for correct functioning

Sensor module Functioning tested

Pressure monitor module Functioning tested

APEX control module Functioning tested



Extended parameters (may be changed only by the manufacturer)

Display Display orientation in the sensor module

1 = Sensor module after 2004 2 = Sensor module to 2004

Version Pressure range for the sensor module 1 = 0-25 mbar 2 = 0-300 mbar

Valve type

0 = Digital valve 1 = Proportional valve

P component Proportional component control valve

I component Integral component control valve

Zero point Valve’s response level

Time delay K2/3 time delay as of the MIN a or MIN b signal

ON / OFF function Function of the terminals 19 and 20

1 = Bridge / switch at terminals 19/20 2 = Printer function

MAX. function Positive pressure disconnection

1 = Error when “MAX” is exceeded

2 = No error when “MAX” is exceeded

Text marking

Date:

Tested by:

Checked by:


Declaration of Conformity and Approvals


13 Declaration of Conformity and Approvals

13.1 EC Declaration of Conformity for the APEX Control unit




13.2 EC Type Examination Certificate for the APEX Control Unit




13.3 IECEx Certificate of Conformity Control Unit APEX


Notes


Notes APEX 2003 Control Unit Type 07-3711-.2../....


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3/20

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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

a n d p l a n t s .

BARTEC GmbH Germany

Max-Eyth-Straße 1697980 Bad Mergentheim

Phone: +49 7931 597-0Fax: +49 7931 597-119

[email protected]

20140321 01-3711-7D0001 BA APEX2003 EN B

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