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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.
Digital Purge Gas Valve 3G Type 03-5110-00..
Safety
Technical data subject to change without notice. Page 3 of 22
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..
Page 4 of 22 Technical data subject to change without notice.
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
Digital Purge Gas Valve 3G Type 03-5110-00..
Safety
Technical data subject to change without notice. Page 5 of 22
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..
Page 6 of 22 Technical data subject to change without notice.
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.
Digital Purge Gas Valve 3G Type 03-5110-00..
Product Description
Technical data subject to change without notice. Page 7 of 22
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..
Page 8 of 22 Technical data subject to change without notice.
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
Digital Purge Gas Valve 3G Type 03-5110-00..
Connections
Technical data subject to change without notice. Page 9 of 22
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..
Page 10 of 22 Technical data subject to change without notice.
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
Digital Purge Gas Valve 3G Type 03-5110-00..
Operation
Technical data subject to change without notice. Page 11 of 22
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..
Page 12 of 22 Technical data subject to change without notice.
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
Digital Purge Gas Valve 3G Type 03-5110-00..
Operation
Technical data subject to change without notice. Page 13 of 22
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..
Page 14 of 22 Technical data subject to change without notice.
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.
Digital Purge Gas Valve 3G Type 03-5110-00..
Malfunction and Troubleshooting
Technical data subject to change without notice. Page 15 of 22
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
Adapt power to the requirements
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
Adapt power to the requirements
Technical Data Digital Purge Gas Valve 3G Type 03-5110-00..
Page 16 of 22 Technical data subject to change without notice.
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)
Digital Purge Gas Valve 3G Type 03-5110-00..
Order Numbers
Technical data subject to change without notice. Page 17 of 22
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..
Page 18 of 22 Technical data subject to change without notice.
12 Appendix
12.1 Dimensions
Digital Purge Gas Valve 3G Type 03-5110-00..
Appendix
Technical data subject to change without notice. Page 19 of 22
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..
Page 20 of 22 Technical data subject to change without notice.
13 Declarations of Conformity and Approvals
13.1 EC Declaration of Conformity for the Digital Purge Gas Valve 3G
Digital Purge Gas Valve 3G Type 03-5110-00..
Notes
Technical data subject to change without notice. Page 21 of 22
Notes Digital Purge Gas Valve 3G Type 03-5110-00..
Page 22 of 22 Technical data subject to change without notice.
03-5
110-
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01-0
8/11
-BAR
TEC
Wer
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entu
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287
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