The world leader in serving science Antaris EX and Hazardous Locations Overview Matt Ebersole August...

The world leader in serving science

Antaris EX and Hazardous Locations

Overview

Matt Ebersole

August 13, 2007

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Hazardous Locations Defined

The National Electrical Code (NEC) defines hazardous locations as those areas "where fire or explosion hazards may exist due to flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or flyings."

These areas are also called:• Classified Locations• Explosive Atmospheres (ATEX)• HazLoc

NEC gives as an example: “drying rooms for the evaporation of flammable solvents” (Article 500). Pharmaceutical Dryer

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Hazardous Locations Defined

Equipment for these locations are referred to as:

• Listed• Classified• Labeled

Why talk about this?• Some models of the Antaris EX are rated for

hazardous locations• Antaris Target Blend Analyzer is being tested for

future hazardous locations ratings

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Worldwide Standards

The governing codes are: United States

• National Electric Code (NFPA 70) Article 500

• National Electric Code (NFPA 70) Article 505, since 1996

• NFPA codes Canada

• Canadian Electric Code

(CEC)

• CSA 60079 Europe – Directive 94/9/EC

• EN 60079 Other –

• IECEx Scheme, slowly being • accepted• May accept US or European rating

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Hazardous Area Classification

These areas are divided into three classes:• Class I: Flammable Gases or Vapors

• Pharmaceutical plants• Refineries and chemical plants• Some food processing• Gas stations, aircraft hangers and fueling, paint/spray areas, sewage treatment facilities,

natural gas handling, printing presses• Class II: Combustible Dusts

• Grain storage, flour and feed mills, metal grinding, pharmaceutical plants, producers of: plastics, fireworks, starch, candies, sugar, cocoa, spices, coal

• Class III: Ignitable Fibers & Flyings• Textile, mattress, cotton mills, wool processing, wood cutting

Antaris EX-Z1 & EX-Z2

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European standards (94/9/EC) instead divide hazardous locations into:

• Group• Group I: Mining, underground, firedamp• Group II: All other installations

• Type of hazard• G: gases, vapors, or mists• D: dusts• Both



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Divisions, Zones, and Categories• NEC Code 500

• Division 1 exists under normal operating conditions or may exist frequently due to repair, maintenance, or leakage

• Division 2 only in accidental rupture or breakdown or abnormal operation only in breakdown of ventilation system adjacent to C1D1 location

Antaris EX-Z1

Antaris EX-Z2

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NEC Code 505 – since 1996, and IEC60079• Zone 0

gases present continuously or for long periods of time• Zone 1

gases likely to exist under normal conditions or frequently for maintenance or leakage adjacent to Zone 0

• Zone 2 gases not likely to exist in normal operation, and if they do only for a short time only due to breakdown or abnormal operation only due to ventilation failure Adjacent to Zone 1

Antaris EX-Z1

Antaris EX-Z2

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Europe 94/9/EC• Category 1

explosive atmosphere present continuously, for long periods, or frequently• Category 2

explosive atmospheres likely to occur occasionally• Category 3

explosive atmospheres unlikely to occur, and if they do, only infrequently and for a short period

Antaris EX-Z1

Antaris EX-Z2

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Class I, or Equipment Group 1 Comparison:

NEC500 Division 1 Division 2 Unrated

NEC505

IECEx

Zone 0 Zone 1 Zone 2 Unrated

Europe 94/9/EC

Category 1 Category 2 Category 3 Unrated

Continuously Occasionally Unlikely Never

More dangerous

EX-IPEX-Z1 North Amer

EX-Z1 Intl

EX-Z2 Intl

EX-Z2 N. Amer

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How would you classify these areas? The mixing tank is open and contains volatile materials. A hood is provided over the tank. There is a valve to empty the tank. Fresh air comes in through the vents. More volatile product is stored in the walled-off, separately ventilated area.

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(2) = Zone 0 (hazard continuously present)

(3) = Zone 1 (only intermittent hazard)

(4) = Zone 2 (only abnormal hazard, such as barrel spill)

(5) = Non-Hazardous

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• Equipment is also classified by groups• Some gases, such as Hydrogen, have higher explosive pressures

and are harder to contain.

• Antaris EX-Z2 North America covers groups A, B, C, and D.

• Antaris EX-Z2 International covers group IIC (and all lesser groups).

• Antaris EX-Z1 North America covers groups C and D.

• Check labeling of system to be sure.

Moredangerous

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Temperature Class• Equipment is rated by the

hottest surface temperature on or in the enclosure.

• This must be less than the ignition temperature of the gas the area is rated for.

• Antaris EX-Z2 and EX-Z1 are rated T4. Check labeling of system to be sure.

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Ambient Temperature• Standard operating

temperature range for equipment in hazardous locations is -20°C to 40°C.

• All versions of the Antaris EX are rated for -20°C to 40°C.

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Markings

A note about different standards:• Factory Mutual Approval

• We do not carry FM approval. They are a certification body, just like UL, or others. We use Intertek, which is a notified body in Europe and an OSHA approved NRTL for the US.

• CENELEC Approval• “CENELEC approved” is the old term for ATEX. The ATEX directive, 94/9/EC, became

mandatory July 1, 2003, repealing the old method (76/117/EEC, 79/196/EEC, and 82/130/EEC). While the CENELEC standards body still creates the standards used for all European regulatory approvals, ATEX is the new approval method.

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Working in Hazardous Locations

Some review on working in Hazardous Locations:• Static electricity: sparks can set off explosions. Typically, ESD protection is

used (straps, jackets, etc).

• Ordinary location electrical equipment is not allowed in the hazardous location (e.g. cell phones, meters, oscilloscopes, laptop computers, etc). Also, the enclosures cannot be opened to access the equipment being serviced while it is powered up.

• The above can often be overcome with a “hot work permit” or “safe work permit”. In Zone 1 and 2, where the hazard is intermittent, the atmosphere can be tested for the hazard, and then work can commence.

• The safe environment window for service can be very specific and very small.

• There may be on-site training required before you can enter.

• Always consult the local facility’s safety engineer or officer and strictly comply with his or her guidance and all local safety rules.

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Protection Techniques

The equipment needs to use one or more of the defined protection techniques.

Antaris EX-Z1 and EX-Z2 use a combination of some of these, but primarily type ‘p,’ purged and pressurized.

Protection Technique Principle

Intrinsic Safety (ia) Limit Energy

Flameproof (d) Contain the Explosion

Purged and Pressurized (p) Keep Flammable Gas Out

Oil Immersion (o) Keep Flammable Gas Out

Increased Safety (e) No arcs, sparks, or hot surfaces

Encapsulation (m) Keep Flammable Gas Out

Powder Filling (q) Contain the Explosion

Type ‘n’, non-sparking (nA, nC, nR) No arcs, sparks, or hot surfaces

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Antaris EX Product Overview

Common Specifications:• Antaris FT-NIR Fiber Optic Analyzer

• A rated enclosure containing essentially an Antaris MX spectrometer• 4 channels with internal reference, sampled simultaneously

• Hose washable, corrosion resistant, stainless steel

• Optional Integrated Computer with full-size keyboard and pointing device

• Optional PLC Accessory

• Ambient Temperature of -20°C to 40°C

• Humidity of 0 to 100% condensing

• Able to be wall mounted or stand mounted. EX-IP able to be cart mounted.

• All of the enclosure models are very heavy. They require mechanical lifting. They must be anchored securely according to the instruction manual.

• Key access to enclosure for safety reasons.

• Foam insulated for stability, noise, and temperature reasons.

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8 different systems:• EX-IP Integrated Computer

• EX-IP Remote Computer

• EX-Z2 North America Integrated Computer

• EX-Z2 North America Remote Computer

• EX-Z2 International Remote Computer

• EX-Z1 North America Integrated Computer

• EX-Z1 North America Remote Computer

• EX-Z1 International Remote Computer

• Note: No integrated computer available internationally for EX-Z1 or EX-Z2

• Note: North America system is approved for US and Canada. It can be sold outside of Europe to any country accepting the ETL mark. International is approved for Europe. It can be sold to any country accepting the European ATEX certification.

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Antaris EX-IP• Rated IP65 per IEC 60529• Hose down environment• Also protected against dust• Thermo Electric Cooler (runs from

electrical supply) with closed loop control

• Can be purged, but not necessary (similar to standard Antaris)

• 110V OR 220V• Only this system has a cart option.• This system allows you to take an

Antaris MX into an industrial environment. It is well suited for a loading dock where the temperature can be more extreme, or an area where there is dripping of material.

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Antaris EX-IP Concerns• Use caution when rolling cart down ramps.• Use caution when working inside the enclosure as there is hazardous voltage

present.• The enclosure may be purged with Nitrogen. Use caution when opening.

Turn off the Nitrogen and allow the air to clear before putting your head inside.

• Power plug must be into an outlet rated for the area. The power cord comes with a normal plug on the end. If the area is washed down then the cord should go through a gland into an outlet box. The plug can also be removed for direct wiring into a junction box.

• Keep vents of cooler clear.• System is not universal voltage. It is ordered for 110V or 220V based on the

power cord selected. The cooler is the only part that is voltage specific.• If the system is to be installed on a cart, then the service engineer may be

unpacking the enclosure for installation.• Keep all 4 door latches closed.

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Antaris EX-Z2• Rated for Division 2 or Zone 2

• Must be ordered for North America or International

• Hose down environment

• Vortex Cooler (runs from purge supply) with closed loop control

• Universal input voltage

• Type ‘Z’ purge system

• Tested to NFPA 496 or IEC 60079-0 and 60079-2

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Antaris EX-Z2 Theory of Operation• The enclosure is sealed, but because the sealing is not perfect the enclosure

is pressurized at least 0.1 inches of water above ambient to keep out dangerous gases.

• After the door has been opened or the purge gas has been off, the enclosure must go through a purge cycle. A high flow of gas is pushed through for a certain amount of time to clear out any dangerous gases. Only after this is complete can the enclosure be powered on.

• The timing of the purge cycle is done manually. Connecting and disconnecting power is done manually.

• The system has an alarm available. These are contacts that open when the system is not pressurized.

• Because of hot components inside (source, etc.) that could ignite gases, it is not necessarily safe to open the door when the power is off. Only open the door if the area is known to be non-hazardous.

• If present, the keyboard is protected by “non-incendiary” design. It is certified to not product sparks that could ignite gases.

• See the manual for operating instructions. Read the warning labels.

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Antaris EX-Z2 Concerns• Cooler is loud.• Outside of cooler is very hot. • Use caution when working inside the enclosure as there is hazardous voltage present.• The enclosure may be purged with Nitrogen. Use caution when opening. Turn off the

Nitrogen and allow the air to clear before putting your head inside.• Do not open door unless the area is known to be non-hazardous.• Do not power up system unless the purge cycle has been completed.• Ordinary plant compressed air is not suitable as purge gas due to contaminants. We

specify our usual purge gas guidelines.• Electrical wiring inside enclosure will be required. Customer must supply means to

cycle power to the system.• Purge must be filtered well.• Keep relief valve area clear.• Keep all 4 door latches closed.• Test the purge system after every service procedure.

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Antaris EX-Z1• Rated for Division 1 or Zone 1

• Must be ordered for North America or International

• Hose down environment

• Vortex Cooler (runs from purge supply) with closed loop control

• Universal input voltage

• Type ‘X’ purge system

• Tested to NFPA 496 or IEC 60079-0 and 60079-2

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Antaris EX-Z1 Theory of Operation• The enclosure is sealed, but because the sealing is not perfect the enclosure

is pressurized at least 0.2 inches of water above ambient to keep out dangerous gases (higher pressure than Z2).

• After the door has been opened or the purge gas has been off, the enclosure must go through a purge cycle. A high flow of gas is pushed through for a certain amount of time to clear out any dangerous gases. Only after this is completed is the enclosure powered on.

• The timing of the purge cycle is automatic. Connecting and disconnecting power is automatic. When the pressure falls, all power and I/O signals are cut.

• There is a service bypass that will bypass the purge system and apply power immediately. It is designed so that it cannot accidentally be left in the system.

• The switches to cut the power are located inside an explosion proof box on top of the enclosure. This is designed to keep out that gases, but if there is a leak it will contain any explosion that may occur.

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Antaris EX-Z1 Theory of Operation• The system has an alarm available. These are contacts that open when the

system is not pressurized.

• Because of hot components inside (source, etc.) that could ignite gases, it is not necessarily safe to open the door when the power is off. Only open the door if the area is known to be non-hazardous.

• If present, the keyboard is protected by “intrinsically safe” design. “Barriers” inside the enclosure limit current and voltage to prevent energy that is large enough to ignite gases from passing out to the keyboard.

• See the manual for operating instructions. Read the warning labels.

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Antaris EX-Z1 Concerns• Cooler is loud.

• Outside of cooler is very hot.

• Use caution when working inside the enclosure as there is hazardous voltage present.

• The enclosure may be purged with Nitrogen. Use caution when opening. Turn off the Nitrogen and allow the air to clear before putting your head inside.

• Do not open door unless the area is known to be non-hazardous.

• Do not power up system unless the purge cycle has been completed.

• Do not open the explosion proof box unless the area is known to be non-hazardous.

• Make sure the explosion proof box is sealed correctly and all of its ports are plugged.

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Antaris EX-Z1 Concerns• Ordinary plant compressed air is not suitable as purge gas due to

contaminants. We specify our usual purge gas guidelines.

• Electrical wiring inside enclosure will be required. Customer must supply means to cycle power to the system.

• Purge must be filtered well.

• Keep relief valve area clear.

• Keep all 4 door latches closed.

• Test the purge system after every service procedure.

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Antaris EX Vents• The spectrometer has vents in its sidewalls on 3 sides.

• In the EX-Z1 and EX-Z2, these prevent pockets of gas from forming inside the spectrometer. They must not be covered up!

• In the EX-IP, these vents are covered up to improve spectrometer stability.

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Antaris EX Installation Process

2 Palettes, one with enclosure, one with spectrometer• “Do not open” sticker on spectrometer box

Simple Antaris EX-IP installations (cart or table top mounting, not direct wired but plugged into wall outlet)

• Service engineer will install entire system

• Customer will need to help with moving the heavy enclosure into place All other installations:

• Service engineer will:• Check mounting, wiring, fiber optic routing• Complete wiring connections inside enclosure• Unpack spectrometer• Install spectrometer• Complete fiber optic connections inside enclosure• Test spectrometer• Help customer with I/O connections• Test purge system (EX-Z1 and EX-Z2 only)

• Customer will:• Unpack enclosure• Mount enclosure• Connect power into enclosure• Run fiber optics into enclosure• Connect purge supplies to enclosure• Complete pre-commissioning form

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Documentation

Our systems will include:• Antaris EX Site, Safety and Installation Manual• Schematic Packet specific to the system (5 different versions: EX-

IP, EX-Z2 NA, EX-Z2 Intl, EX-Z1 NA, EX-Z1 Intl)• Customer Installation Drawing

Shows mounting information, locations for connections• Block Diagram

Informational only• Enclosure Wiring Diagram (EX-Z2, EX-Z1)

Shows DIN rail wiring connections with options• Purge Interface Unit Wiring Diagram (EX-Z1)• Declaration of Conformity (EX-IP, EX-Z2 Intl, EX-Z1 Intl)• ATEX Certificate (EX-Z2 Intl, EX-Z1 Intl)• Schedule drawing showing all regulatory items (EX-Z2, EX-Z1)

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Antaris EX I/O Options

Antaris EX-IP with Integrated Computer• Power in

• 2 USB ports to computer (for USB key, drives, printer, etc.)

• Ethernet to computer

• Ethernet to optional PLC

• 2 gland holes for customer connections to optional PLC• Holes come with removable plugs• 2 glands provided with system• Make connections directly into PLC

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Antaris EX-IP with Remote Computer• Power in

• No USB ports provided

• CAT-5 plug for spectrometer connection• This must be a dedicated CAT-5 cable that goes straight to the receiver at the controlling computer• The receiver at the computer requires AC power. It connects to the computer through the provided

USB cable.• 50 meters maximum

• Ethernet to optional PLC

• 2 gland holes for customer connections to optional PLC• Holes come with removable plugs• 2 glands provided with system• Make connections directly into PLC

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Antaris EX-Z2 wiring connections• All wiring must be through conduit or armored cable. If using cable, then

glands are required that are RATED for the hazardous environment and installed according to the manufacturer’s directions. The gland or the conduit entries will have epoxy packed around the wires to prevent gas from traveling through the cable.

• 5 holes with removable plugs are provided• No glands provided with system• Make connections to DIN rail terminal blocks or directly to optional PLC• One Ethernet interface is provided on the DIN rail. • 8 I/O wires plus ground are provided on the DIN rail. They can be connected to the

optional PLC I/Os.• See more information below

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Antaris EX-Z2 with Integrated Computer• Power in

• Connect to DIN rail terminal blocks• Ethernet to computer

• Connect to DIN rail terminal blocks, plug Ethernet cable into computer• Ethernet to optional PLC

• Connect to DIN rail terminal blocks, plug Ethernet cable into PLC. If both Ethernets are required, plug Ethernet cable into computer and run an additional Ethernet directly to the PLC, bypassing the terminal blocks.

• Customer connections to optional PLC• Connect to DIN rail terminal blocks. Make appropriate connections at the PLC. If additional I/O lines

are required, connect directly to the PLC, bypassing the terminal blocks.

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Antaris EX-Z2 with Remote Computer• Power in• CAT-5 wiring for spectrometer connection

• This must be a dedicated CAT-5 cable that goes straight to the receiver at the controlling computer• The receiver at the computer requires AC power. It connects to the computer through the provided

USB cable.• The receiver must be located in the non-hazardous area.• 50 meters maximum• Connect to DIN rail terminal blocks. Leave Ethernet cable plugged into USB receiver.

• Ethernet to optional PLC• Connect Ethernet directly to the PLC, bypassing the terminal blocks.

• Customer connections to optional PLC• Connect to DIN rail terminal blocks. Make appropriate connections at the PLC. If additional I/O lines

are required, connect directly to the PLC, bypassing the terminal blocks.

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Antaris EX-Z1 wiring connections• All wiring must be through conduit or armored cable. If using cable, then

glands are required that are RATED for the hazardous environment and installed according to the manufacturer’s directions. The gland or the conduit entries will have epoxy packed around the wires to prevent gas from traveling through the cable.

• All power and I/O wiring must be disconnected automatically when the pressure inside the enclosure falls.

• All connections are to the explosion-proof box, not to the enclosure• Five holes with removable plugs are provided• No glands provided with system• Make connections to relay terminals.• Only 8 I/O wires are available• See more information below

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Antaris EX-Z1 with Integrated Computer• Power in

• Connect to large relay• There are only 8 wires so options are limited (each Ethernet is 4 wires, the

PLC is an option):• Computer Ethernet, PLC Ethernet – connect Ethernet to computer, I/O cable to PLC Ethernet• Computer Ethernet, 4 PLC I/Os – connect Ethernet to computer, I/O cable to PLC I/Os• PLC Ethernet, 4 PLC I/Os - connect Ethernet to PLC, I/O cable to PLC I/Os• 8 PLC I/Os – connect I/O cable to PLC I/Os• Make connections to relay terminals. Connect wires inside enclosure as stated above.• Connect 8-wire cable from explosion-proof box to appropriate terminal blocks on the DIN rail

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Antaris EX-Z1 with Remote Computer• Power in

• Connect to large relay• The PLC is not an option on this system. All 8 wires are used for

spectrometer communication. • Make connections to relay terminals. Inside enclosure, leave all 8 wires connected to the Ethernet

terminal blocks on the DIN rail. Leave Ethernet cable connected to the USB receiver.• Connect a dedicated CAT-5 cable from the relay terminals inside the explosion-proof box straight to

the receiver at the controlling computer• The receiver at the computer requires AC power. It connects to the computer through the provided

USB cable.• The receiver must be located in the non-hazardous area.• 50 meters maximum

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Antaris EX Fiber Optic Installation

Fiber optic probes require SMA connectors on the end. Leave 1m of fiber inside enclosure for connection. EX-IP

• Install through 2 existing holes, or add additional holes in gland plate. EX-Z2

• Install through 5 existing holes, or add additional holes in gland plate. EX-Z1 North America

• Install through 3 existing holes, or add additional holes in gland plate EX-Z1 International

• Install through 3 existing holes, or add additional holes in gland plate Glands are required that maintain the waterproof nature of the

enclosure. For fiber optics with metal sheathing installed into hazardous locations,

then glands are required that are RATED for the hazardous environment and installed according to the manufacturer’s directions. The gland or the conduit entries will have epoxy packed around the fiber optic to prevent gas from traveling through the cable.

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Wrap Up

The EX is a complicated mix of certification options. There are important safety considerations throughout the sales,

installation, commissioning, and servicing process. Think carefully about how your actions affect safety. Is it safe to open

the enclosure now?

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Questions

Time for questions!

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