Siemens Operating Instructions, only the rack-mounted versions of Series 6 (CALOMAT 6E and ULTRAMAT 23)

Continuous gas analysis Rack-mounted analyzers of Series 6 Information pursuant to ATEX for use in hazardous areas Compact Operating Instructions 1 1.1 Introduction Purpose of this documentation These instructions are a brief summary of important features, functions and safety information, and contain all information required for safe use of the device. It is your responsibility to read the instructions carefully prior to installation and commissioning. In order to use the device correctly, first review its principle of operation. The instructions are aimed at persons who mechanically assemble the device, connect it electrically, and start it up. To achieve optimum usage of the device, read the detailed version of the manual on the electronic data medium. 1.2 Notes on warranty The contents of this manual shall not become part of or modify any prior or existing agreement, commitment or legal relationship. The sales contract contains all obligations on the part of Siemens as well as the complete and solely applicable warranty conditions. Any statements regarding device versions described in the manual do not create new warranties or modify the existing warranty. The content reflects the technical status at the time of publishing. Siemens reserves the right to make technical changes in the course of further development. 1.3 Intended use ● This analyzer is used to quantitatively determine components in a gaseous sample. ● This analyzer may only be used for the purposes specified in these instructions and in the associated detailed Operating Instructions. ● Modifications to the analyzer which are not expressly referred to in these instructions and in the associated detailed Operating Instructions therefore result in an application which is not in accordance with the intended use. Such modifications are then the exclusive responsibility of the user. © Siemens AG 2012. All rights reserved A5E03084511-01, 02/2012 1 1.4 Field of application Notes In these Operating Instructions, only the rack-mounted versions of Series 6 (CALOMAT 6E and ULTRAMAT 23) approved for operation in hazardous areas in accordance with the EU directive 94/9/EU (ATEX) are described. All other analyzer versions are not considered in these Operating Instructions. The following table provides an overview of the associated analyzers. Table 1-1 Rack-mounted analyzers of Series 6 approved for operation in hazardous areas Certificate Ex type of protection KEMA 09 ATEX 0027 X Non-sparking TÜV 02 ATEX 1873 X Hermetically sealed and non-sparking II 3 G Ex nA II T4 II 2/3 G Ex nA nC IIC T4 Device MLFB No. ULTRAMAT 23 7MB2335-xxxxx-xAAx 7MB2337 7MB2338 CALOMAT 6E 7MB252x-xxx00-xABx-Z+xxx 7MB252x-xxx01-xABx-Z+xxx It is essential that you also observe the respective "Special conditions" of the certificates referred to in the table. These describe ● the fields of application, ● the requirements for operation in hazardous areas, ● other precautionary measures which are important for operation. The technical specifications in these Operating Instructions may be different to those in the associated Operating Instructions for the analyzers and additional equipment under some circumstances. The technical specifications listed in these Operating Instructions are valid in such cases. 1.5 Checking the consignment 1. Check the packaging and the device for visible damage caused by inappropriate handling during shipping. 2. Report any claims for damages immediately to the shipping company. 3. Retain damaged parts for clarification. 4. Check the scope of delivery by comparing the shipping documents with your order for correctness and completeness. WARNING Using a damaged or incomplete device Danger of explosion in hazardous areas. ● Do not use any damaged or incomplete devices. 2 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 2 Safety notes This device left the factory in good working condition. In order to maintain this status and to ensure safe operation of the device, observe these instructions and all the specifications relevant to safety. Observe the information and symbols on the device. Do not remove any information or symbols from the device. Always keep the information and symbols in a completely legible state. Qualified personnel for hazardous area applications Persons who install, assemble, commission, operate and service the device in a hazardous area must have the following specific qualifications: ● They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media. ● They are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems. ● They are trained or instructed in maintenance and use of appropriate safety equipment according to the pertinent safety regulations. WARNING Improper device modifications Danger to personnel, system and environment can result from modifications to the device, particularly in hazardous areas. ● Only carry out modifications that are described in the instructions for the device. Failure to observe this requirement cancels the manufacturer's warranty and the product approvals. Due to the large number of possible applications, each detail of the described device versions for each possible scenario during commissioning, operation, maintenance or operation in systems cannot be considered in the instructions. If you need additional information not covered by these instructions, contact your local Siemens office or company representative. Note Operation under special ambient conditions We highly recommend that you contact your Siemens representative or our application department before you operate the device under special ambient conditions as can be encountered in nuclear power plants or when the device is used for research and development purposes. Symbol Explanation of the symbols on the device Consult operating instructions Warning of hot surface Warning of dangerous voltage Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 3 2.1 Laws and directives Observe the test certification, provisions and laws applicable in your country during connection, assembly and operation. These include, for example: ● National Electrical Code (NEC - NFPA 70) (USA) ● Canadian Electrical Code (CEC) (Canada) Further provisions for hazardous area applications are for example: ● IEC 60079-14 (international) ● EN 60079-14 (EC) 2.2 Conformity with European directives The CE marking on the device shows the agreement with the regulations of the following European guidelines: EMC 2004/108/EC Directive of the European Parliament and of the Council on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC. Low-voltage directive 2006/95/EC Directive of the European Parliament and of the Council on the harmonisation of the laws of Member States relating to electrical equipment designed for use within certain voltage limits. ATEX 94/9/EC Directive of the European Parliament and the Council on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres. The applied standards and associated versions can be found in the corresponding EC declaration of conformity. 2.3 General directives for explosion protection WARNING Use of an unsuitable device for the hazardous area Danger of explosion if incorrect device for the hazardous area. ● Only use the device within the characteristics specified on the nameplate and in Section Auto-Hotspot for the hazardous area. 2.3.1 Further safety measures The exhaust lines for the sample and reference gases must terminate outside the hazardous area at a harmless position. The sample gas exhaust line can also be returned to the sampling point. The maximum permissible sample gas pressure in the analyzer depends on the type of connected gas, and is described in the Technical data (Page 24) under the point "Sample gas input conditions". Install the ULTRAMAT 23 and CALOMAT 6E gas analyzers in an appropriate enclosure. This enclosure must be suitable for use in Zone 2 and comply with the requirements of EN 60079-15. The enclosure must satisfy IP54 protection and be designed for all ambient conditions which can occur during operation. If the temperature under normal conditions can exceed 70 °C at the inlet of the cable or conduit, or 80 °C at the branching point of the conductors, you must use a cable which is approved for use at these temperatures. Furthermore, you must use appropriate measures to ensure that interferences cannot lead to a deviation from the rated voltage of more than 40%. You must only connect devices which do not generate sparks during operation to non-intrinsically-safe circuits in Zone 2, and these must be suitable for operation in hazardous areas of Zone 2 and the conditions present at the location of use. 4 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 2.3.1.1 CALOMAT 6E DANGER Explosion hazard Frequently or permanently explosive gas mixtures must not be connected. Rarely or occasionally explosive gas mixtures may be connected in accordance with the special conditions specified in the corresponding certificates. When installing in control cabinets, suitable ventilation measures must be provided to guarantee an air change of at least once per hour. If the sample gases can be occasionally potentially explosive, you must install suitable flame arrestors in the sample gas inlet and outlet. A flame arrestor can be omitted at the outlet if the sample gas is routed into a non-hazardous area. Make sure that sample gas pressures higher than 1.1 bar (110 kPa) absolute cannot occur. You must carry out a leak test following installation and maintenance work affecting the containment system. 2.3.1.2 ULTRAMAT 23 DANGER Explosion hazard Gases or gas/air mixtures whose composition is between the lower and upper explosive limits must never be connected to the analyzers! If in doubt, we recommend that you contact our technical department to discuss your planned application. If the sample gas connected to the analyzer could contain flammable components above the upper explosive limit (UEL), the analyzer version 'Gas path in pipe' is required. In analyzers with hoses, flammable or explosive gases/air mixtures must not be connected, not even when below the LEL. NOTICE In the analyzer version 'Gas path in pipe', the internal gas path does not contain a safety filter or condensation trap. Therefore you must always provide correct gas preparation. WARNING External influences The influence of certain chemicals could damage the sealing properties of materials used in the following components: ● Relay on the electronics motherboard: W79052-K5001-C5; manufacturer: Axicom, Part V23026-A1001-B201 ● Infrared source: C79451-A3468-B205 or -B206; manufacturer: SIEMENS Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 5 3 3.1 Assembly/installation/mounting Assembly guidelines Installing the devices Install the explosion-proof analyzer at a location as free from vibration as possible. Further information can be found in Section Technical data (Page 24). Protect the analyzer and the connected devices from direct solar radiation, and ensure that the permissible ambient temperature is observed during operation. ● Secure the analyzer in accordance with the dimensional drawing in Section Dimensions for preparing installation (Page 7) ● Note that all cables must be secured in place! ● If an intervention is necessary inside the enclosure, make sure that this is properly closed again afterwards. ● Pipes must be provided for the sample gas inlet and outlet in areas of Zone 2. Hoses are not permitted in this case. 6 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 3.2 Dimensions for preparing installation ULTRAMAT 23 362 338,5 300 4,5 82 158,5 80 6,5 101,6 37,7 177 M4 14,5 70 9 465 483 51 29 30,5 440 2 1 348 3 377 4 293 5 242 6 25 53,5 82 110,5 139 167,5 196 0 7 *DVFRQQHFWLRQVSLSHFRXSOLQJPPRUGLDPHWHU &DXWLRQ:KHQLQVWDOOLQJLQGHVNWRSKRXVLQJRUFDELQHW RQO\PRXQWRQVXSSRUWLQJUDLOV Figure 3-1 ULTRAMAT 23, dimensions for preparing installation Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 7 CALOMAT 6E &$/20$7 0 411,5 345 320 132 104 0 1 2 4 3 Figure 3-2 8 CALOMAT 6E, dimensions for preparing installation Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 3.3 Further safety instructions WARNING Wetted parts unsuitable for the process media Danger of injury or damage to device. Hot, toxic and corrosive media could be released if the process medium is unsuitable for the wetted parts. ● Ensure that the material of the device parts wetted by the process medium is suitable for the medium. Refer to the information in "Technical data". 3.3.1 Installation location requirements CAUTION Direct sunlight Device damage. The device can overheat or materials become brittle due to UV exposure. ● Protect the device from direct sunlight. ● Make sure that the maximum permissible ambient temperature is not exceeded. Refer to the information in "Technical data". WARNING Insufficient air circulation Risk of fire. The device may overheat or start burning in case of insufficient air circulation. ● Ensure sufficient air circulation in the room. Refer to the information in Chapter Technical data (Page 24). NOTICE Incorrect mounting The device can be damaged, destroyed or its functionality impaired through improper mounting. ● Before installing ensure there is no visible damage present on the device. ● Make sure that process connectors are clean, and suitable gaskets and glands are used. ● Mount the device using suitable tools. Refer to the information in "Technical data" , for example installation torques requirements. Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 9 4 4.1 Connecting Gas connections Gas connections All gas inlets and outlets are pipes with a diameter of 6 mm or 1/4". The materials used must be suitable for the respective measurement. If you wish to exit the sample gas into a common line, please observe the following points: ● The exhaust gas line must be free of rapid changes in pressure. If this is not possible, you must either provide a separate exhaust gas line or fit a damping vessel ( > 1 l) between the analyzer and the exhaust gas line. ● The exhaust gas line should always be routed with a downward gradient since water can condense in it. Gas preparation To prevent contamination of parts through which the sample gas flows, the sample gas must be prepared appropriate to the measurement. We recommend the following minimum configuration: ● Gas sampling unit with filter ● Sample gas cooler ● Analyzer filter (approx. 1-2 μm) Depending on the characteristics of the sample gas it may be necessary to provide additional equipment such as an external gas suction pump, washbottle or pressure reducer. Appropriate components must be used for toxic and/or flammable gases. These components must be approved for the respective application. 4.1.1 Toxic and corrosive gases We recommend that you consult our technical department before connecting toxic or corrosive gases. Please note in particular that the control cabinet housing the analyzer must have a protection rating of at least IP54 and be purged with a suitable purging gas. 10 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 4.2 Electric connections 4.2.1 Safety instructions WARNING Missing PE/ground connection Danger of electric shock. Depending on the device version, connect the power supply as follows: ● Power plug: Ensure that the used socket has a PE/ground conductor connection. Check that the PE/ground conductor connection of the socket and power plug match each other. ● Connecting terminals: Connect the terminals according to the terminal connection diagram. First connect the PE/ground conductor. WARNING Improper laying of shielded cables Danger of explosion through compensating currents between hazardous area and the non-hazardous area. ● Only ground shielded cables that run into the hazardous area at one end. ● If grounding is required at both ends, use an equipotential bonding conductor WARNING Improper power supply Danger of explosion in hazardous areas as result of incorrect power supply, e.g. using direct current instead of alternating current. ● Connect the device in accordance with the specified power supply and signal circuits. The relevant specifications can be found in the certificates, in Chapter "Auto-Hotspot" or on the nameplate. WARNING Lack of equipotential bonding Danger of explosion through compensating currents or ignition currents through lack of equipotential bonding. ● Ensure that the device is potentially equalized. Exception: It may be permissible to omit connection of the equipotential bonding for devices with type of protection "Intrinsic safety Ex i". WARNING Dangerous contact voltage Danger of electric shock in case of incorrect connection. ● For the electrical connection specifications, refer to the information in Chapter "Auto-Hotspot". ● At the mounting location of the device observe the applicable directives and laws for installation of electrical power installations with rated voltages below 1000 V. CAUTION Devices of the protection type "non-sparking" may only be connected and disconnected when in a powered-down state. This also applies to the SUB-D connections. Particular reference is made here to the PROFIBUS DP connection. The bus must be switched off when the plug on the analyzer is connected or disconnected. Please observe the information in Section PROFIBUS DP (Page 12) with regard to the bus connection of PROFIBUS DP. The plug connectors must be mechanically locked. Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 11 4.2.2 Special requirements for Zone 2/22 WARNING Unsuitable devices Only devices which do not generate sparks during operation may be connected to non-energy-limited circuits in Zone 2 or 22, and these must be suitable for operation in hazardous areas of Zone 2 or 22 and the conditions present at the location of use. 4.2.3 PROFIBUS DP 68%');FRQQHFWRU 352),%86'3 9 8 7 6 Figure 4-1 5 '*1' &1751 &1753GLUHFWLRQFRQWURO 5['7['1$ 5['7['3% 4 3 2 1&QRWDVVLJQHG 939 1&QRWDVVLJQHG 1 PROFIBUS DP connection CAUTION Pin 7 is connected to the data line. No consumers must be connected. The cable shield must be connected over a larger surface in the plug housing. Failure to comply with this can result in personal injury or damage to property. Please observe the following for correct operation: ● A mains circuit-breaker must be provided in the building installation. ● Connects the analyzer's enclosure to the equipotential bonding ● Identify the intrinsically-safe lines and route them separately from the non-intrinsically-safe lines. Observe the minimum distances required when doing this. ● Connect the signal lines to the SUB-D plug connectors on the rear of the analyzer. 4.2.4 Power supply The analyzer comes with an appliance plug which must only be connected to the mains supply line by qualified personnel (see Section 1.5). If the supplied power cord cannot be used, use a flexible cable suitable for power supply connections. This cable must meet the following requirements: ● Each conductor must have a cross-section ≥1 mm2. The cross-section of the PE conductor must not be smaller than that of the L and N conductors. You must connect the phase conductor to the marked position in the plug. ● The cable must at least be suitable for a temperature of 70 °C. ● The cable must be approved in the country of use and for its location. 12 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 You must also observe the following when connecting: ● Install the mains line separately from the signal lines. ● Provide a mains disconnection device in the direct vicinity of the device (for load rating, see rating plate). This mains disconnection device must be readily accessible and marked. ● Check prior to starting up that the local supply voltage complies with that specified on the rating plate, or correct when necessary! 4.2.5 Connection of the signal lines WARNING Only connect the signal lines to devices which have reliable electric isolation from their power supply. ● The connection lines to the relay outputs, the binary inputs, the analog inputs and the analog output must be shielded. ● The reference ground of the analog inputs is the potential of the housing. ● The analog output is floating, but has a common negative pole. ● As a measure to suppress sparking across the relay contacts (e.g. limit relays), RC elements must be connected as shown in the following figure. Note that the RC element results in a drop-out delay for an inductive component (e.g. solenoid valve). It must also be ensured that a non-polarized capacitor is used. 68%')FRQQHFWRU 0 3RZHUVXSSO\9PD[ 5 ,/ 5/ & 5>˖@[5 />˖@ &>˩)@, />$@ 0 Figure 4-2 Example of spark suppression Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 13 4.2.6 Pin assignments ULTRAMAT 23 Motherboard 68%')FRQQHFWRU56 0b 9 *1' 8 7 9 0b 6 5 4 3 2 1 *1' 5B/HYHO1 1& 5'7'1 5'7'3 5B/HYHO3 1& 1& *1' ,WLVSRVVLEOHWRFRQQHFWEXVWHUPLQDWLQJ UHVLVWRUVWRSLQVDQG 68%')FRQQHFWRU 0b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igure 4-3 14 ULTRAMAT 23 motherboard Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 Optional board 68%')FRQQHFWRURSWLRQ 0b 37 36 19 18 17 35 16 34 15 33 14 32 13 31 12 30 29 28 11 10 27 26 25 24 23 22 21 20 0b 68%');FRQQHFWRU 352),%86'3 9 8 7 6 Figure 4-4 5 4 3 9 8 7 5 4 }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optional board Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 15 CALOMAT 6E Motherboard 68%')FRQQHFWRU56 0b *1' 9 0b *1' 5B/HYHO1 1& 5'7'1 5'7'3 5B/HYHO3 1& 1& *1' ,WLVSRVVLEOHWRFRQQHFWEXVWHUPLQDWLQJ UHVLVWRUVWRSLQVDQG 68%')FRQQHFWRU 0b %LQDU\LQSXWV $QDORJLQSXWVRXWSXWV 0b 0b 0b *1' 1& 1& $QDORJRXWSXW3 $QDORJRXWSXW1 1& 1& $QDORJLQSXW3 $QDORJLQSXW1 $QDORJLQSXW3 $QDORJLQSXW1 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXWVWR1 *1' $QDORJRXWSXWVIORDWLQJ DOVRWRHDFKRWKHU5 /ืവ &RUUHFWLRQRISUHVVXUH $QDORJLQSXWV QRQIORDWLQJWR RUFURVVLQWHUIHUHQFH P$വRU &RUUHFWLRQRI WR9ORZ FURVVLQWHUIHUHQFH UHVLVWDQFH 68%')FRQQHFWRU 0b %LQDU\LQSXWV5HOD\RXWSXWV *1' %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXWVWR1 5HOD\ 5HOD\ 5HOD\ 5HOD\ 5HOD\ 0b 16 &RQWDFWORDG 0D[9$$&'& 5HOD\FRQWDFWVVKRZQ UHOD\FRLOKDV]HURFXUUHQW Figure 4-5 %LQDU\LQSXWV 9WR9 9WR9 )ORDWLQJYLDRSWRFRXSOHU 5HOD\ *1' 1RWH 7KHZLUHDQGFRQQHFWRUPXVW EHVKLHOGHGDQGOLHDW KRXVLQJSRWHQWLDO Pin assignments of CALOMAT 6E motherboard Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 AUTOCAL board &RQQHFWRU68%')RSWLRQ 0 Binary inputs/relay outputs *1' 1& 1& %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXW3 %LQDU\LQSXWWR1 )ORDWLQJ YLDRSWRFRXSOHU 99 99 5HOD\ 5HOD\ 5HOD\ 5HOD\ 5HOD\ &RQWDFWORDG PD[9$$&'& IRUVKRZQ UHOD\FRQWDFWSRVLWLRQ WKHUHOD\KDV]HURFXUUHQW 5HOD\ 5HOD\ 0 5HOD\ *1' Figure 4-6 1RWH &DEOHVDQGSOXJVPXVW EHVKLHOGHGDQGDW KRXVLQJSRWHQWLDO AUTOCAL module of CALOMAT 6E Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 17 4.3 Connection diagrams ULTRAMAT 23 6HH)LJ ಫ$VVLJQPHQW RIJDV FRQQHFWLRQVಬ 6 7 5 3 4 2 3RZHUVXSSO\DQGILQH IXVH ; SLQFRQQHFWRU 2SWLRQPRGXOH %LQDU\LQSXWV UHOD\RXWSXWV RSWLRQ ; SLQLQWHUIDFHFRQQHFWRU RSWLRQHJ 352),%86 ULTRAMAT 23, gas connections and electrical connections 1 1 6DPSOHJDV 2 FDOLEUDWLRQJDV 2 FDOLEUDWLRQJDV 3 $872&$/JDV 3 1RWXVHG 3 4 1RWXVHG 4 1RWXVHG 4 FDOLEUDWLRQJDV 5 (QFORVXUHIOXVKLQJ 5 (QFORVXUHIOXVKLQJ 5 (QFORVXUHIOXVKLQJ 6 $WPRVSKHULF 6 $WPRVSKHULF 6 $WPRVSKHULF 6\PEROVRQ 8/75$0$7 UDFNPRXQWHG HQFORVXUH ZLWKVDPSOHJDVSXPS 6\PEROVRQ 8/75$0$7 UDFNPRXQWHGHQFORVXUH ZLWKRXWVDPSOHJDVSXPS 1 6DPSOHJDV 2 FDOLEUDWLRQJDV ]HURJDV SUHVVXUHVHQVRU &KRSSHUDUHD 7 IOXVKLQJ Figure 4-8 18 ; SLQFRQQHFWRU $QDORJDQGGLJLWDO LQSXWVDQGRXWSXWV ; SLQ FRQQHFWRU 56 *DVFRQQHFWLRQV 1R]]OHPPRU Figure 4-7 1 6DPSOHJDV 6DPSOHJDV SUHVVXUHVHQVRU 7 &KRSSHUDUHD IOXVKLQJ SUHVVXUHVHQVRU &KRSSHUDUHD 7 IOXVKLQJ 6\PEROVRQ 8/75$0$7 UDFNPRXQWHGHQFORVXUH ZLWKWZRVHSDUDWHJDVSDWKV DQGGHVLJQZLWKSLSLQJ ULTRAMAT 23, assignment of gas connections Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 CALOMAT 6E 6DPSOHJDVRXWOHW 3XUJLQJJDVLQOHW RU 6DPSOHJDVLQOHW 1 3 RS485 9-pin connector 25-pin connector, relay outputs and binary inputs 2 4 5 37-pin connector, relay outputs and binary inputs (option) 6 Figure 4-9 15-pin connector, relay outputs and binary inputs 9-pin interface connector, e.g. for PROFIBUS (option) Network connection and fine fuses CALOMAT 6E, gas connections and electrical connections Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 19 5 Commissioning Commissioning can only be performed properly when the person doing the commissioning is familiar with the contents of the manuals and operating instructions provided. The safety and warning information included there must be observed in particular. The sample gas path of the analyzer must be checked for leaks each time it is started up. This is described in the Section Leak testing. The following safety information applies in addition to operation in hazardous areas. WARNING Improper commissioning in hazardous areas Device failure or danger of explosion in hazardous areas. ● Do not commission the device until it has been mounted completely and connected in accordance with the information in Chapter "Auto-Hotspot". ● Before commissioning take the effect on other devices in the system into account. Note Loss of degree of protection Damage to device if the enclosure is open or not properly closed. The degree of protection specified on the nameplate or in "Technical data" is no longer guaranteed. ● Make sure that the device is securely closed. WARNING Dangerous contact voltage Danger of injury through dangerous contact voltage when the device is open or not completely closed. The degree of protection specified on the nameplate or in Chapter "Auto-Hotspot" is no longer guaranteed if the device is open or not properly closed. ● Make sure that the device is securely closed. WARNING Loss of explosion protection Danger of explosion in hazardous areas if the device is open or not properly closed. ● Close the device as described in Chapter "Auto-Hotspot". WARNING Opening device in energized state Danger of explosion in areas subject to explosion hazard. ● Only open the device in a de-energized state. ● Check prior to commissioning that the cover, cover locks, and cable inlets are assembled in accordance with the directives. Exception: Devices having the type of protection "Intrinsic safety Ex i" may also be opened in energized state in hazardous areas. 20 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 Checking the sample gas path for leaks Carry out a leak test prior to commissioning or following each maintenance measure which affects the sensor or the gas path. This is carried out as follows: 1. Connect the sample gas outlet to a relative pressure manometer (e.g. U-tube manometer with measuring range 0 to 150 hPa, resolution 0.1 hPa). 2. Apply air to the sample gas inlet. As soon as an overpressure of approx. 100 hPa has been reached (measure using manometer at sample gas outlet), block the sample gas inlet. 3. Wait approx. one minute until the enclosed air has become adapted to its environmental conditions. Then record the pressure. 4. ULTRAMAT 23: Wait for a further 15 minutes and then record the pressure. The gas path is sufficiently tight if the pressure drop is less than 2 hPa. CALOMAT 6E: Wait for a further five minutes and then record the pressure. The gas path is sufficiently tight if the pressure drop is less than 10 hPa. Note It must be guaranteed during the measurement that the temperature of the gas path and sensor remains constant. 6 6.1 Service and maintenance Analyzer Following maintenance or the retrofitting of parts associated with explosion protection, the analyzer may only be started when an Ex specialist has ensured that the analyzer has the essential features and meets the requirements for explosion protection and issues a certificate to this effect and/or has attached a test symbol to the equipment. When restarting, make sure that the device has sufficient protection from impact energy of over 2 Joules in the area of the windows. Annual maintenance of the analyzer must be carried out to check the electrical safety and reliable operation, in particular the tightness of the sample gas path within the analyzer. Furthermore, a leak test must be carried out following each intervention in the gas path (containment system). The leak test is described in Section Commissioning (Page 20) The owner can extend maintenance intervals in individual cases if no negative effects can be expected on wetted parts materials (gaskets in particular). Further information on maintenance of the analyzer can be found in the associated Operating Instructions. WARNING Impermissible accessories and spare parts Danger of explosion in areas subject to explosion hazard. ● Only use original accessories or original spare parts. ● Observe all relevant installation and safety instructions described in the instructions for the device or enclosed with the accessory or spare part. Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 21 WARNING Commissioning and operation with pending error If an error message appears, correct operation in the process is no longer guaranteed. ● Check the gravity of the error ● Correct the error ● If the device is faulty: – Take the device out of operation. – Prevent renewed commissioning. WARNING Improper connection after maintenance Danger of explosion in areas subject to explosion hazard. ● Connect the device correctly after maintenance. ● Close the device after maintenance work. Refer to Chapter "Auto-Hotspot". CAUTION Dangerous voltage at open device Danger of electric shock when the enclosure is opened or enclosure parts are removed. ● Before you open the enclosure or remove enclosure parts, de-energize the device. ● If maintenance measures in an energized state are necessary, observe the particular precautionary measures. Have maintenance work carried out by qualified personnel. CAUTION Hot parts in the device Temperatures that can burn unprotected skin may be present for some time after the device has been switched off. ● Observe the waiting time specified in the technical data or on the device before starting with maintenance work. WARNING Dust layers above 5 mm Danger of explosion in hazardous areas. Device may overheat du to dust build up. ● Remove any dust layers in excess of 5 mm. WARNING Maintenance during continued operation in a hazardous area There is a danger of explosion when carrying out repairs and maintenance on the device in a hazardous area. ● Isolate the device from power. - or ● Ensure that the atmosphere is explosion-free (hot work permit). 22 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 CAUTION Devices of the protection type "non-sparking" may only be connected and disconnected when in a powered-down state. This also applies to the SUB-D connections. Particular reference is made here to the PROFIBUS DP connection. The bus must be switched off when the plug on the analyzer is connected or disconnected. Please observe the information in Section PROFIBUS DP (Page 12) with regard to the bus connection of PROFIBUS DP. The plug connectors must be mechanically locked. 6.2 Fuses DANGER Explosion hazard If a flammable or ignitable atmosphere exists, plugs must never be disconnected or lamps/fuses replaced when the analyzer is supplied with power. Failure to adhere to these guidelines can result in death, severe injury and/or damage to property and the environment. Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 23 7 Technical data The complete technical specifications are described in detail in the respective Operating Instructions of the analyzers used. The following tables show the data relevant to explosion protection. If the values specified here differ from those in the respective Operating Instructions, the values specified here apply. 7.1 ULTRAMAT 23 ULTRAMAT 23 for operation in hazardous areas Maximum permissible vibrations 5 m/s2 Sample gas pressure ● Without pump ● With pump Depressurized (< 1 200 hPa (1.2 bar) absolute) Depressurized suction mode, set in factory with 2 m hose at sample gas outlet; full-scale value calibration necessary under different venting conditions Ambient temperature 5 ... 45 °C (41 ...113°F) Temperature class T4 Type of protection Ex II 3 G Ex nA II T4 - Non-sparking Basic standards EN 60079-0:2006, EN 60079-15:2005 Supply voltage, input and output current See following table Table 7-1 Supply voltage, input and output current ranges depending on type of analyzer/MLFB No. Description MLFB No. Supply voltage Max. current range 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-0AAx 7MB2337-xxxx0-0xxx 7MB2338-xxxx0-0xxx 100 V, 50 Hz, 60 VA 0.52 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-1AAx 7MB2337-xxxx0-1xxx 7MB2338-xxxx0-1xxx 120 V, 50 Hz, 60 VA 0,43 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-2AAx 7MB2337-xxxx0-2xxx 7MB2338-xxxx0-2xxx 200 V, 50 Hz, 60 VA 0,26 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-3AAx 7MB2337-xxxx0-3xxx 7MB2338-xxxx0-3xxx 230 V, 50 Hz, 60 VA 0,24 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-4AAx 7MB2337-xxxx0-4xxx 7MB2338-xxxx0-4xxx 100 V, 60 Hz, 60 VA 0,49 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-5AAx 7MB2337-xxxx0-5xxx 7MB2338-xxxx0-5xxx 120 V, 60 Hz, 60 VA 0,41 A 1 IR component + O2 2 IR components + O2 3 IR components + O2 7MB2335-xxxx0-6AAx 7MB2337-xxxx0-6xxx 7MB2338-xxxx0-6xxx 230 V, 60 Hz, 60 VA 0,23 A Furthermore, you must use appropriate measures to ensure that interferences cannot lead to a deviation from the rated voltage of more than 40%. 24 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 7.2 CALOMAT 6E Table 7-2 CALOMAT 6E for operation in hazardous areas Ambient temperature 5 ... 45 °C, 5 ... 55 °C with versions 7MB252x-xGA0x-xxxx Sample gas pressure Max. 1 100 hPa absolute Maximum permissible vibrations 5 m/s2 Electrical data: Supply voltage 100 ... 120 V AC, 47 ... 63 Hz or 200 ... 240 V AC, 47 ... 63 Hz, Umax = 264 V AC Analog output 0/2/4 ... 20 mA, potential-free, load: 750 Ω Relay outputs (6 changeover contacts) 24 V AC/DC/1 A, floating Option PROFIBUS DP, PROFIBUS PA Temperature class T4 Protection type(s) Ex II 2/3 G Ex nAC IIC T4 - 'Hermetically sealed' and 'Non-sparking' Basic standards EN 60079-0:2006, EN 60079-15:2005, EN 60079-2:2007 Section 11.2 8 ESD directives NOTICE Electrostatic sensitive devices can be destroyed by voltages which are far below the human perception limit. These voltages already occur if you touch a component or the electric connections of a module without being electrostatically discharged. The damaged caused on a module by an overvoltage is not usually recognized immediately, but only becomes evident after a longer period of operation. Fundamental measures to protect against static discharge ● Provide good grounding: When handling electrostatic sensitive devices, provide good grounding for persons, workstation and packaging. In this manner you avoid static discharge. ● Avoid direct touching: Only touch electrostatic sensitive devices when this is absolutely unavoidable (e.g. during maintenance). Hold the modules so that you touch neither pins nor printed conductors. In this manner, the discharge energy cannot reach or damage sensitive devices. If you have to carry out measurements on a module, discharge yourself before carrying out any actions. To do this, touch grounded metal objects. Only use grounded measuring instruments. Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012 25 A. List of abbreviations Abbreviation/symbol Explanation " Inch (1 inch corresponds to 25.4 mm) < Less than > Greater than ≤ Less than or equal to ≥ Greater than or equal to ° Degrees °C Degrees Celsius cm Centimeter CS Containment system (piped sample gas path inside the analyzer) DIN German industry standard EN European standard Ex aa Explosion protection classified as per ATEX hPa Hectopascal kPa Kilopascal l Liter L Line (phase in power lines) LEL Lower explosion limit MG Sample gas min Minute MLFB Machine-readable product code mm Millimeter mm² Square millimeter MPa Megapascal N Neutral (in power lines) Pa Pascal PE Protective Earth rel. Relative UEL Upper explosion limit VG Reference gas Δp Differential pressure Siemens AG Industry Sector Postfach 48 48 90026 NÜRNBERG Information pursuant to ATEX for use in hazardous areas A5E03084511, 02/2012 26 Information pursuant to ATEX for use in hazardous areas A5E03084511-01, 02/2012