Digital Purge Gas Valve 3G - BARTEC

3GOperating instructions

Digital Purge Gas Valve 3G Type: 03-5110-00..

Document no.: 03-5110-7D0001 Version: 01. July 2011/Rev. 0

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 claim for damages.

Operating Instructions

Digital Purge Gas Valve 3G

Type: 03-5110-00..

Document no.: 03-5110-7D0001 Version: 1 July 2011 / Rev. 0

Contents Page

English 1 – 24

Appendix EC Declaration of Conformity EC Type Examination Certificate

Table of Contents Digital Purge Gas Valve 3G Type 03-5110-00..

Technical data subject to change without notice.

1 Safety 1 1.1 This Manual 1 1.1.1 Languages 2 1.2 Handling the Product 2 1.3 Use in Accordance with the Intended Purpose 2 1.3.1 Use Exclusively for the Intended Purpose 2 1.3.2 Improper Use 2 1.4 Owner’s/Managing Operator’s Obligations 2 1.5 Safety Instructions 3 1.5.1 General Safety Instructions 3 1.5.2 Safety Instructions for Operation 3 1.6 Standards Conformed To 4 1.7 Ex Protection Type Marking and Certification 4 1.8 Warranty 5

2 Product Description 6 2.1 Mode of Operation 6 2.2 Configuration 7

3 Installation 8

4 Connections 9 4.1 Directions for Wiring to the Digital Purge Gas Valve 3G 9 4.2 Electrical Connection 10

5 Operating 11

6 Commissioning 12 6.1 Inspections Before Commissioning 12 6.2 Adjusting the Rate of Loss through Leakage 12 6.3 Commissioning 12

7 Operation 13

8 Maintenance and Care 14

9 Malfunctioning and Troubleshooting 15

10 Technical Data Sensor Module 16

11 Order Numbers 17

12 Appendix 18 12.1 Dimensions 18 12.2 Rate of Air Leakage 19

13 Declarations of Conformity and Approvals 20 13.1 EC Declaration of Conformity for the Digital Purge Gas Valve 3G 20

Digital Purge Gas Valve 3G Type 03-5110-00..

Safety

Technical data subject to change without notice. Page 1 of 22

1 Safety

1.1 This Manual

O p e ra t i ng I ns t r u c t i o ns

It is essential to read and observe the contents of this documentation and this chapter

in particular before you install and operate the Purge Gas Valve 3G.

This manual contains the information necessary for using the Purge Gas Valve 3G in

accordance with the intended purpose. It is addressed to technically qualified personnel.

Familiarity with and the technically perfect implementation of the safety instructions and

warnings described in this manual are preconditions for safe installation and

commissioning. The safety notes and warnings given in this documentation are given in

a general way and only qualified personnel will have the necessary specialised know-

how to interpret and implement them correctly in specific cases.

This manual is an integral part of the scope of supply even if for logistical reasons it can be

ordered and delivered separately. If you need any further information, please ask the

BARTEC branch that is near you or responsible for your area.

Particularly important points in this documentation are marked with a warning symbol:

DANG E R

The DANGER sign draws attention to a danger which will lead to death or

serious injury if not avoided.

W AR NI NG

WARNING draws attention to a danger which can lead to death or serious

injury if it is not avoided.

CAUT I O N

CAUTION draws attention to a danger which can lead to an injury if it is not

avoided.

AT T E NT I O N

ATTENTION draws attention to measures to be taken to prevent damage to property.

No t e

Important instructions and information on effective, economical and

environmentally compatible handling.

Safety Digital Purge Gas Valve 3G Type 03-5110-00..

Page 2 of 22 Technical data subject to change without notice.

1.1.1 Languages

No t e

The original operating instructions were written in German. All other

available languages are translations of the original operating instructions.

The operating instructions are available in various languages. They are enclosed with the

product in the languages German, English, French, Italian, Spanish and Russian. If you

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

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 Purge Gas Valve 3G must be mounted properly and securely onto the Ex p

operating equipment if it is to work perfectly and correctly.

1.3 Use in Accordance with the Intended Purpose

1.3.1 Use Exclusively for the Intended Purpose

The Purge Gas Valve 3G serves exclusively as a purge gas inlet for Ex p operating

equipment and is intended for use in Explosion Group II, Category 3G and Temperature

Class T4.

The permissible operating 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’s/Managing Operator’s Obligations

The owner/managing operator undertakes to restrict permission to work with the Purge

Gas Valve 3G to people who:

are familiar with the basic regulations on safety and accident prevention and have been instructed in the use of the Purge Gas Valve 3G

have read and understood the documentation, the chapter on safety and the warnings.

The owner/managing operator must check that the safety regulations and accident prevention rules valid for the respective application are being observed.


Safety


1.5 Safety Instructions

1.5.1 General Safety Instructions

Take the device out of the hazardous area before wiping it with a dry cloth or cleaning it!

Do not open devices in a hazardous area.

The general statutory regulations or directives relating to safety at work, accident prevention and environmental protection legislation must be observed, e.g. the German industrial health and safety ordinance (BetrSichV) or the applicable national ordinances.

In view of the risk of dangerous electrostatic charging, wear appropriate clothing and footwear.

Avoid the influence of heat that is higher or lower than the specified temperature range.

Keep the devices away from moisture.

1.5.2 Safety Instructions for Operation

Upkeep

For electrical systems the relevant installation and operating regulations must be complied with (e.g. Directive 99/92/EC, Directive 94/9/EC and the national applicable ordinances IEC 60079-14 and the DIN VDE 0100 series)!

The disposal of this equipment must comply with the national regulations on the disposal of waste.

Maintenance

Regular servicing is not necessary if the equipment is operated correctly in accordance with the installation instructions and environmental conditions.

Inspection

Under IEC 60079-19 and EN 60079-17, the owner/managing operator of electrical installations in hazardous areas is obliged to have these installations checked by a qualified electrician to ensure that they are in a proper condition.

Repairs

Repairs on explosion-protected operating equipment may be done only by authorised persons working in accordance with the latest developments in technology and using original spare parts. The applicable regulations must be observed.

Commissioning

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

Safety Digital Purge Gas Valve 3G Type 03-5110-00..


1.6 Standards Conformed To

The sensor module conforms to Directive 94/9/EC for devices and protective systems for

their use to the intended purpose in hazardous areas (ATEX Directive). Pursuant to this

directive, the following standards serve as a basis for the Digital Purge Gas Valve 3G:

Standard Designation

EN 60079-0:2006 Electrical apparatus for explosive gas atmospheres - Part 0: General requirements

EN 60079-15:2005 Explosive atmosphere –

Part 15: Construction, test and marking of type of protection "n" electrical apparatus

DIN VDE 0580:2000 Electromagnetic devices and components - General specifications

EN 60204-1:2004 Safety of machinery- Electrical equipment of machines –

Part 1:General requirements

EN 60529:1991+A1:2000 Degrees of protection provided by enclosures (IP code)

EN 61000-6-2:2005 Electromagnetic Compatibility (EMC) - Part 6-2: Generic standards -

Immunity for industrial environments

1.7 Ex Protection Type Marking and Certification

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

ATEX

II 3G Ex nA II T4


Safety


1.8 Warranty

W AR NI NG

Risk of death or serious injury if the control is modified or converted without the manufacturer’s approval. It can then no longer be assured that the design and production will provide explosion protection, stress tolerance and conformance to safety requirements.

Before making any modifications or implementing any conversions,

contact the manufacturer and obtain written approval.

Use only original spare parts and original expendable parts.

No 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 Digital Purge Gas Valve 3G for a purpose other than that for which it is intended.

incorrect installation, commissioning, operation and maintenance of the Digital Purge Gas Valve 3G.

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

unauthorised structural modifications of the Digital Purge Gas Valve 3G

inadequate monitoring of parts that are subject to wear

repairs done incorrectly.

disasters due to the effects of foreign matter or Act of God (events outside human control).

We guarantee the Digital Purge Gas Valve 3G 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 Digital Purge Gas Valve 3G Type 03-5110-00..


2 Product Description

The Digital Purge Gas Valve 3G is an optional component in a SILAS control. It serves to introduce a purge gas into a pressurised piece of operating equipment in Zone 2. It is actuated by the SILAS controller.

The digital purge gas valve is particularly suitable for neutral media such as inert gases and instrument air.

2.1 Mode of Operation

The digital purge gas valve does not need operating or differential pressure to function.

The valve switches from 0 bar on.

The 2/2-way solenoid valve opens directly by means of the solenoid plunger and is

closed by a compression spring. The sealing plug is raised from the seat by the

magnetic drive alone.

In the de-energised state, the solenoid valve is closed. The special design and geometry

of the parts inside the valve allow gentle closing with only very slight pressure peaks. In

addition, an adjustable bypass, serving to compensate for the leakage in the Ex pz area,

is integrated in the valve body.


Product Description


2.2 Configuration

Item Component

1 Device plug

2 Purge air nozzle, e.g. ø 2.8 or 5.5

3 or purge air nozzle, e.g. ø 3.9 or 7.7

4 Bypass element in the leakage air valve

5 Adjusting screw

6 Valve body

7 Bulkhead union

8 Nozzle

9 Magnet

7

9

1

3 2

4 5 6

8

Installation Digital Purge Gas Valve 3G Type 03-5110-00..


3 Installation

AT T E NT I O N

ATTENTION Damage due to incorrect installation.

Incorrect installation can cause an excessively high pressure to build up inside the Ex

pz operating equipment.

Pay attention during installation to the digital purge gas valve’s direction of flow.

The purge gas must flow into the Ex p operating equipment. The flow direction is

specified on the valve body.

Decide on the mounting position on the wall of the enclosure on the Ex pz operating equipment.

Drill a 17-mm-diameter borehole into the enclosure wall.

Mount the digital purge gas valve in accordance with the following drawing. The mounting parts are included in the scope of supply.

Item Designation

1 Bulkhead union

2 Washers

3 Digital purge gas valve

4 Sealing ring

5 Purge air nozzle

1 2 2 3 4 5


Connections


4 Connections

4.1 Directions for Wiring to the Digital Purge Gas Valve 3G

DANG E R

Death or serious physical injury when the Digital Purge Gas Valve 3G is opened in an explosive atmosphere.

Risk of explosion.

Before opening the lids on the enclosure, check the atmosphere for

any explosive gases.

AT T E NT I O N

Short-circuits due to loose or protruding wires in the SILAS control unit.

The SILAS control can become damaged.

All core wires, including those not required, must be connected to a terminal.

Lay the wires only in the space between the shield bus and the connecting

terminal.

Make sure none of the wires are loose or jut out/protrude.

The following describes the procedure for feeding and connecting cables from the Digital

Purge Gas Valve 3G to the SILAS control unit:

Procedure:

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

Feed the connection cable from the Digital Purge Gas Valve 3G through the cable glands into the Ex e junction box.

Establish the electrical connections in accordance with the terminal assignment. Tighten terminals with 0.4-0.6 Nm.

Put the shields and earthing connections onto the shield bus.

Use the appropriate closures to seal cable glands that are not in use.

Tighten cable glands with 3.0 Nm.

Put the lid onto the SILAS control unit and tighten the 4 fastening screws with 1.4 Nm.

Connections Digital Purge Gas Valve 3G Type 03-5110-00..


4.2 Electrical Connection

DANG E R

Explosion hazard due to the operation of the digital purge gas valve

3G without series fuse

The digital purge gas valve must always be operated with a series fuse.

If the digital purge gas valve is operated in a SILAS control, the

series fuse is mounted in the SILAS control unit.

Check the series fuse’s switching capacity.

Depending on the type of digital purge gas valve, the following fuses must be used:

Valve type Fuse

Digital Purge Gas Valve AC 230 V, 50 Hz T 80 mA

Digital Purge Gas Valve AC 115 V, 50 Hz T 160 mA

Digital Purge Gas Valve DC 24 V T 500 mA

Connect the digital purge gas valve as follows:

The cores have distinguishing colours:

Designation Core colour Terminal

BN Brown 6

BL Blue 9,10 or 11

GN/YE Green/yellow 12 or 13

Fuse

F1 Fuse for Digital Purge Gas Valve 3G

SIL

AS


Operation


5 Operating

Once commissioned and once the rate of air leakage has been set, the digital purge gas

valve is operated automatically by means of the control to which the digital purge valve

is attached.

Commissioning Digital Purge Gas Valve 3G Type 03-5110-00..


6 Commissioning

AT T E NT I O N

ATTENTION Damage due to incorrect commissioning.

Operating errors may occur if the operating instructions for the SILAS control unit are

not observed.

Follow the operating instructions relating to the SILAS control unit.

6.1 Inspections Before Commissioning

Before putting into operation for the first time, check that:

the digital purge gas valve has been installed in compliance with regulations,

the connection has been established properly,

the digital purge gas valve is not damaged,

all screw connections have been tightened securely

6.2 Adjusting the Rate of Loss through Leakage

First close the adjusting screw (1). To do so, use a suitable screwdriver and turn the adjusting screw in the clockwise direction as far as it can go.

Refer to the diagram in Chapter 12.2 to determine the number of complete turns of the adjusting screw needed for the required quantity of leakage air depending on the operating pressure (2 bar or 3 bar).

Use a suitable screwdriver to turn the adjusting screw in an anti-clockwise direction as often as is necessary to set the required quantity of leakage air.

No t e

After this setting the enclosure’s internal pressure should be between 2

mbar and 3 mbar during operation.

6.3 Commissioning

As soon as the SILAS controller is switched on, the digital purge gas valve connected to it starts operation automatically. The digital purge gas valve is not commissioned separately.

1


Operation


7 Operation

The Digital Purge Gas Valve 3G is always operated with a SILAS control unit and for

that reason the operating instructions for the SILAS must be observed when operating

the Digital Purge Gas Valve 3G.

Maintenance and Care Digital Purge Gas Valve 3G Type 03-5110-00..


8 Maintenance and Care

DANG E R

Death or serious physical injury due to inhalation of inert gas.

Risk of suffocation.

Before opening, stop the supply of ignition shield gas.

When opening, make sure the escaping ignition shield gas cannot be

inhaled directly.

DANG E R

Death or serious physical injury due to disconnection in the protective

earth connection.

Explosion hazard.

Before starting maintenance work on the Ex p operating equipment,

make sure the valve is closed and there is no interruption in the

protective earth connection.

AT T E NT I O N

ATTENTION Danger due to lines under pressure.

Valve and pressure reducer are under pressure.

Relieve pressure before beginning maintenance work.

AT T E NT I O N

ATTENTION Damage due to incorrect cleaning.

Do not use any aggressive, abrasive or dissolving detergents.

Use a damp cloth to clean the outside of the digital purge gas valve when

necessary.

The Digital Purge Gas Valve 3G is virtually maintenance-free when operated under the conditions described in these instructions.

Use a damp cloth to clean the outside of the digital purging gas valve when necessary.


Malfunction and Troubleshooting


9 Malfunctioning and Troubleshooting

Before looking for the fault, check that the components are mounted and connected

correctly (see “Installation” Section).

No t e

The following table with descriptions of faults and information on possible

causes presupposes that the components have been mounted and

connected correctly.

Fault Possible Cause Remedy

Digital purge gas valve does not open

No voltage Check voltage supply, cable connection and fuse

Short circuit Find and repair the cause.

Coil defective / interrupted Replace digital purging gas valve

Core area dirty Replace digital purging gas valve

Rate of air leakage is too high

Adapt power to the requirements

Set air leakage rate again

Rate of air leakage is too low


Check equipment’s leak-tightness and extent of loss through leakage.

Purging gas pressure is insufficient

Adapt the pressure to the requirements and if necessary increase the conductor’s cross section.

Insufficient power in the purging gas source


Technical Data Digital Purge Gas Valve 3G Type 03-5110-00..


10 Technical Data Sensor Module

Parameter Specifications

Type 03-5110-00..

Design type Poppet valve

Type of protection Ex nA II T4

Area of use II 3G

Protection class IP 65 with mounted female power connector

Nominal diameter DN 6.0

Installation position Magnet on top

Pressure range 0 to 4 bar

max. flow – at 2 bar – at 3 bar

300 l/min 380 l/min

Enclosure material Brass

Sealing material NBR

Flow media cleaned instrument air (class 543) or inert gas

Temperature of the medium 0 °C to +40 °C

Ambient temperature -10 °C to +40 °C

Valve connection G 3/8“

Installation inside Ex pz operating equipment

Electrical Connection Female power connector (DIN EN 175301-803) with 3-m cable

Voltage / power consumption AC 230 V, 50 Hz, 6.5 VA or AC 115 V, 50 Hz, 5.6 VA, DC 24 V, 6.0 W

Voltage tolerance + 10% in conformance to VDE 0580

Duty cycle 100% DC

Nominal operation Continuous Operation (CO)


Order Numbers


11 Order Numbers

Designation Order number

AC 230 V, T4, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0026

AC 230 V, T4, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0027

AC 115 V T4, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0028

AC 115 V, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0030

DC 24 V, G3/8", nozzle 2.8 and 3.9 mm 03-5110-0029

DC 24 V, G3/8", nozzle 5.5 and 7.7 mm 03-5110-0031

Appendix Digital Purge Gas Valve 3G Type 03-5110-00..


12 Appendix

12.1 Dimensions


Appendix


12.2 Rate of Air Leakage

The following diagram shows the rate of leakage (l/h) depending on the adjusting screw

setting (in complete turns).

Complete turns

3 bar

2 bar

L/h

Notes Digital Purge Gas Valve 3G Type 03-5110-00..


13 Declarations of Conformity and Approvals

13.1 EC Declaration of Conformity for the Digital Purge Gas Valve 3G


Notes


Notes Digital Purge Gas Valve 3G Type 03-5110-00..


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BARTEC protects

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of components,

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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]

Digital Purge Gas Valve 3G - BARTEC

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