Operating instructions EN

Additional languages www.stahl-ex.com

Ex pzc Overpressure Monitoring System

for Ex p applications with maximum 1000 mbar pressure

Series 7621/54-*001-01**
Ex Zone 2 and 22
Contents

1 General Information ........................................................................................................3

1.1 Manufacturer...................................................................................................................3
1.2 Information regarding the operating instructions ............................................................3
1.3 Further documents..........................................................................................................3
1.4 Conformity with standards and regulations ....................................................................3
2 Explanation of the symbols .............................................................................................3
2.1 Warning notes.................................................................................................................4
2.2 Symbole on the device ...................................................................................................4
3 Safety notes ....................................................................................................................5
3.1 Safe use..........................................................................................................................5
3.2 Modifications and alterations ..........................................................................................6
4 Function and device design ............................................................................................6
4.1 General Information ........................................................................................................6
4.2 Type code .......................................................................................................................8
4.3 Typical label ....................................................................................................................8
5 Transport and storage ....................................................................................................8
6 Technical Data ................................................................................................................9
7 Construction..................................................................................................................10
7.1 Dimensions ...................................................................................................................10
7.2 Cable glands .................................................................................................................10
7.3 Pneumatic connections.................................................................................................10
7.4 Tube connection ...........................................................................................................11
7.5 Pneumatic construction ................................................................................................11
8 Grounding measures / protective conductor connection ..............................................12
9 Bypass function.............................................................................................................12
10 Requirements switch on or stop devices ......................................................................13
11 Requirements for the protective gas.............................................................................13
11.1 Maximum temperature of the protective gas supply.....................................................13
11.2 Purge gas supply line (piping) ......................................................................................13
12 Assembly and installation .............................................................................................14
12.1 Site requirements..........................................................................................................14
13 Mounting positions of the overpressure monitoring system .........................................14
13.1 Assembly and installation .............................................................................................14
13.2 Connection terminals: ...................................................................................................15
14 Start up .........................................................................................................................16
14.1 Function sequence........................................................................................................16
14.2 Checks after commissioning.........................................................................................16
15 Mail function..................................................................................................................17
16 Maintenance work and troubleshooting ........................................................................17
16.1 Maintance .....................................................................................................................17
16.2 Maintance work.............................................................................................................17
16.3 Demontage ...................................................................................................................17
17 Accessories and Spare parts........................................................................................18
18 Repair ...........................................................................................................................18
19 Cleaning........................................................................................................................18
20 Disposal ........................................................................................................................18

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1 General Information

1.1 Manufacturer
R. Stahl Schaltgeräte
Am Bahnhof 30
74638 Waldenburg
Germany

Phone: +49 7942 943-0

Fax. +49 7942 943-4333
Internet: www.stahl-ex.com

1.2 Information regarding the operating instructions

ID-No. 76 206 02 30 1 xx
Publication Code: 2015-10-21·BA00·III·de·01

1.3 Further documents

For documents in further languages www.stahl-ex.com

1.4 Conformity with standards and regulations

See certificates and EC Declaration of Conformity: www.stahl-ex.com.
The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/
Further national certificates can be downloaded via the following link:
http://www.r-stahl.com/downloads/certificates.html.

2 Explanation of the symbols

Symbols in these operating instructions

Symbol Meaning

Tips and recommendations on the use of the device

General danger

Danger due to explosive atmosphere

Danger due to high voltage

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2.1 Warning notes
Warnings must be observed under all circumstances, in order to minimize the risk due to
construction and operation. The warning notes have the following structure:

 Signalling word: DANGER, WARNING, CAUTION, NOTICE

 Type and source of danger/damage
 Consequences of danger
 Taking countermeasures to avoid the danger or damage

DANGER
Danger to persons
Non-compliance with the instruction results in severe or fatal injuries to
persons.

WARNING
Danger to persons
Non-compliance with the instruction can result in severe or fatal injuries
to persons.

CAUTION
Danger to persons
Non-compliance with the instruction can result in light injuries to persons.

NOTICE
Avoiding material damage
Non-compliance with the instruction can result in material damage to the device and / or
its environment.

2.2 Symbole on the device

Symbol Meaning
ATEX-Notified Body for Quality Assessment.

c
According to marking, device approved for hazardous areas.
e

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3 Safety notes
Operating instructions storage
 Read the operating instructions carefully and store the operating instructions at the
mounting location of the device.
 Observe applicable documents and operating instructions of the devices to be con-
nected.
3.1 Safe use
 Read and observe the safety notes in these operating instructions!
 Use the device in accordance with its intended and approved purpose only.
 We cannot be held liable for damage caused by incorrect or unauthorized use of the
device, or for non-compliance with these operating instructions.
 Before installation, make sure that the device is not damaged.
 Work on the device, such as installation, maintenance, overhaul, repair, may only
be carried out by appropriately authorized and trained personnel.

The Ex pzc overpressure monitoring system is a fixed installed device for use in Ex zone 2
and 22. The Ex pzc overpressure monitoring system is not suitable for use in Zone 0, 1,
and 20 and 21. The assembly is done by the included in the product fixed mounting options.
In order for a secure hold on the ground is ensured.

The given on the nameplate maximum ambient temperatures must not be exceeded.

Notice
The Ex pzc overpressure monitoring system and dust hazardous
areas of Ex zone 22.

Generally in hazardous dust areas is stirring up dust problematic. Due

to the low for hazardous dust areas flow rate of ex pzc overpressure
monitoring system of up to 20 l/min and the construction of purge outlet
is at the Ex pzc over-pressure monitoring system 7621/54-*001-01**
during a purging phase is not hazardous dust clouds expected.

The observance of this operating instructions to prevent permanent deformation of the Ex

p enclosure by an increased pressure and thus a hazard to people and system. The re-
quirements for the safety operation of supplying protective gas shall not exceed the limits.

On the Ex pzc overpressure monitoring system type 7621/54-1001-01** may only work
those:
 are familiar with the basic regulations on safety and accident prevention and have
been instructed in the use of Ex pzc pressure monitoring system.
 the operating instructions, as well as other devices supplied documents have read
and understood.

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3.2 Modifications and alterations
WARNING
Explosion hazard due to modifications and alterations to the device!
Explosions protection endangered!
 Do not modify or alter the device.
 No liability or warranty for damage resulting from modifications
and alterations.

4 Function and device design

WARNING
Explosion hazard due to improper use!
Explosions protection endangered!
 Use the device only in accordance with the operating conditions
described in these operating instructions.

4.1 General Information

Protection "pressurization"

The Ex p protection, named "pressurization", is based on the measure that in a closed en-
closure or control cabinet any explosive gases to be purge out and then an overpressure
relative to the surrounding atmosphere generated and maintained. So during downtimes
penetrated ex-atmospheres cannot become a danger, the Ex p enclosure before setup with
purge gas (compressed air or inert gas) are purge. The amount and time depends on the
test during commissioning.
A higher pressure inside the Ex p enclosure during the purging time and the subsequent-
sequent operation prevent further penetration of the surrounding atmosphere into the en-
closure.
For an ex-free area is created in which electrical equipment and motors can be assembled
and operated, which themselves are not explosion-proof.
If the internal pressure during operation under a predetermined pressure, the ex recognizes
pzc pressure monitoring system type 7621/54-*001-01 ** this status and reports this via its
internal alarm contact to downstream devices (light / horn etc.).
As a safe state is achieved inside the Ex p enclosure until the beginning of the operational
phase, the Ex pzc overpressure monitoring system and its components and the purge gas
valve is explosions proof tested.
4.1.1 Application of Ex pzc pressure monitoring system in hazardous dust areas:
In dust-Ex areas before switching the Ex p equipment (e.g .: a pressurized robot) must be
examined inside the Ex p operating equipment for possible dust and in the case of the
presence of dust, this has to be removed. However, the incoming of dust in Ex robots op-
erationally is not possible due to the construction and sealing of the Ex p robot during stand-
still times. Therefore, an investigation of the interior of the Ex robot before commissioning
is not necessary. The penetration of dust during periods of operation is reliably prevented
by the monitored pressure.

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 P = Compressed air inlet
A = Purge gas supply line
B = Purge gas back line

Notice
Anschluss der pneumatischen Spülluft-Leitungen

The construction of the Ex p robot is implemented in such a way that

inside the Ex p robot a tube line of purge gas inlet A in the front area of
the Ex p robot was moved to ensure a safe purging in hazardous gas
areas.
Therefore it should be ensured that the purge air supply line (A) with the
purge gas inlet (A) is connected. The same applies to the purge gas
supply line (B).
If connections are reversed the Ex p robot during a pre-rinse time is sub-
jected to an increased pressure. This can lead to an increase of the seals
of the Ex p robot.

Purge gas inlet (A)

Purge gas outlet (B)

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4.2 Type code

7621 / 5 4 - 2 001-01**

a / b c - d e

a) 7621 = Ex p systems

b) 5 = Ex pzc overpressure monitoring system with integrated valve

c) Connection = for tube connection

d) EPL = only EPL Gc

e) Code numbers without reference to the type of explosions protection

4.3 Typical label

The typical label is fixed in the front of the device

5 Transport and storage

WARNING
Danger by falling equipment
When transporting the under overhead resources is highly dangerous.
 Ensure a secure charging or discharging
 The lifting device and its supporting ropes must be adapted to the
weight of the equipment.

 Operate only transported in original packing.

 Device dry (no condensation) and vibration-free storage.
 Do not rush.
 Report any transport damages or incomplete deliveries immediately on arrival or
recognition of the defect stating the order number directly to R. Stahl GmbH.

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6 Technical Data

Type 7621/54-*001-01**

Explosion protection

Europe (ATEX)
Gas e II 3 G Ex nA [pzc] IIC T4 Gc

Dust e II 3 D Ex tb [pzc] IIIC T80°C Dc

Allowable purge gas Pressed air or inert gas

Power supply AC 230V +- 10%

Eletrical connection terminals Maximum 2,5 mm²

Relay K2 and K3 Maximum AC 253 V; 0,5A; cos phi 0,7

Maximum purge gas flow 100 l/min

Maximum purge gas temperature + 40 °C (dew point -30°C)

Minimum overpressure 50 mbar

Maximum overpressure 350 or 1000 mbar (Option)

Environmental conditions
Operate temperature -20 °C … +60 °C
Surrounding temperature -20 °C … +60 °C

Weight 5,4 kg

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7 Construction
7.1 Dimensions

7.2 Cable glands

The following cable glands are available:

1 x cable gland type 8161; M20x1,5 mm; Clamping range 7-13 mm

1 x cable gland type 8161; M16x1,5 mm; Clamping range 4,5-9 mm
1 x cable gland type 8161; M20x1,5 mm; Clamping range 7-13 mm

7.3 Pneumatic connections

The following connections for the purge gas output and input are available:

2 x hose connectors for 4/6 mm hose

After unscrewing the hose connection parts each is a thread R 3/8 "
internal thread available
1 x Air Input R ¼ "internal thread

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7.4 Tube connection
The pneumatic connection between the ex pzc pressure monitoring system and the Ex p
housing with 2 hoses manufactured, which must meet at least Table 1.

Distance between Ex pzc overpres- Tube diameter and maximum sink gas Purge time using a robot AGILUS
sure-monitoring system and Ex p en- Flow sixx EX with a maximum of 300 mbar
closure enclosure pressure.

Maximum 5 m Innen / Aussendurchmesser 4/6 mm Je nach Ausführung des Roboters.

und maximal 20 l/min
Siehe Abnahmeprotokoll
Zulässiger Werkstoff:
Polyamid PAN-MF oder Polyurethan
Table 1

7.5 Pneumatic construction

B1: Ex pzc overpressure monitoring Y2: Outlet valve

system V3: Flow reducer (fixed)
Y1: Inlet pressure regulator P2: spark resistor
B3: Ex pzc Robot
P1: Pressure detection/Sensor A: pneumatic connection A
B2: Ex p Controller B pneumatic connection B
V1: Flow reducer (fixed)
V2: Flow reducer (fixed)

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8 Grounding measures / protective conductor connection
The protective case is made of plastic and therefore has no external ground connection.
The plastic itself is, however, equipped for possible discharge processes with a surface
resistivity less than 109 ohms and can therefore be used without further measures within
the hazardous area.

9 Bypass function
WARNING
Bypass function
An activated bypass key switch on the Ex pzc overpressure monitoring
system disables all the safety devices.

During commissioning, it may be necessary, to open the Ex p enclosure make adjustments

on active resources. For this purpose, the bypass key to activate on the cover of the Ex pzc
overpressure monitoring system.
To ensure that in Ex p housing is open there is no explosive atmos-phere can enter the
interior of the Ex p housing, the use of a gas detector is a mandatory requirement for the
activation of the bypass key switch. Possibly it may be necessary a fire permit bill.
After activation of the bypass operation, the Ex-p housing can be opened, without the op-
eration of the internal components is interrupted. The required settings can be made and
after the explosion to seal p housing. A new purging phase does not take place by deacti-
vation of the bypass function.

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10 Requirements switch on or stop devices
In general, the electrical and non-explosion-proof equipment may only be placed inside the
Ex p housing under power supply when the purging phase has ended and a permanent
overpressure in the interior from the atmosphere exists. For this purpose, the release Ex p
contact of the Ex pzc overpressure monitoring system can be used to generate a power-up
relay outside the hazardous area.

11 Requirements for the protective gas

The use of compressed air is indicated by a warning on the site of the input valve switch
that the minimum requirement has to correspond to the compressed air of the category 543
to ISO 8573rd.

11.1 Maximum temperature of the protective gas supply

It is indicated by a warning on the site of the input valve switch that the protective gas must
not exceed the temperature of +40 ° C.

11.2 Purge gas supply line (piping)

Notice
Dimensioning of the purge gas supply line.

The under dimensioning the purge gas supply is in most cases the rea-
son for an impossible start by not starting the purging phase.

As a rule, the dimensions of the purge gas supply line can be derived according to the table
below.

Length of the purge gas supply line Minimum diameter of the purge gas supply
line
to 5 m 4 mm inside
to 10 m 6 mm inside
to 30 m 8 mm inside

Another possibility for dimensioning or checking the pressure loss due to friction and the
diameter of the purge gas is calculated proof. Commercially available calculation software
at the end.

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12 Assembly and installation
12.1 Site requirements
The site must have sufficient lighting to allow rapid troubleshooting during installation and
operation is guaranteed.

13 Mounting positions of the overpressure monitoring system

WARNING
Mounting the Ex pzc pressure monitoring system within the hazardous
area.
The Ex pzc pressure monitoring system type 7621 / 54-1001-01 ** is only
suitable for mounting inside the Ex zone 2 and 22.

13.1 Assembly and installation

When setting up and operation of the Ex pzc overpressure monitoring system is to be en-
sured protection against harmful environmental influences which limit the intended use of
the equipment. This may for example be a protection against aggressive fluids.
When installing IEC / EN 60079-14 and other applicable national standards and regulations
must be observed at the construction.
The information on the nameplate must be observed.
The installation of Ex pzc overpressure monitoring system is performed by the fixed mount-
ing options of housing.
The assembly is arbitrary, but preferably horizontal because of readability.

WARNING
Mechanical load
Protect the device against mechanical load
Details on the rating plate!
The device is approved for operation within the technical data shown on
the nameplate.

WARNING
Electrical connection
An error in the connection system may cause short circuit, fire or injury.
Look at the electrical connection to the correct dimensioning of the elec-
trical lines. Detail informations, please refer to the circuit diagrams.

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13.1.1 Electrical connection

WARNING
Electrical connection
The electrical connection may only be carried out by trained and autori-
dized staff.
The use of electric wires must ambient conditions are observed and the
electrical cables must be suitable for the application.

Ex pcz system type 7621/54-*001-01**

Alarm Operate Purge valve L N PE

13.2 Connection terminals:

Terminal Connection Function

1-3 Relay K3 – Alarm Free programmable relay
4-5 Relay K2- Operate Operate relay
6 Purge valve L Control outlet valve
7-8 Power supply L+ Power supply
9-11 Power supply N- Power supply
12-13 PE Grounding

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14 Start up
14.1 Function sequence
14.1.1 Pre purging
The pressurized Ex p enclosure is purged with purge gas so that any existing explosive gas
mixture inside the Ex p housing so far diluted that no explosive gas mixture is more inside.
The pre purging is constantly monitored by the sensors in the sensor module and the pres-
sure monitor.

The steps are as follows:

 Inflow of purge gas.
 Generating an overpressure in the interior is greater than the minimum pressure.
 Switching on the output valve.
 Generating a flow greater than the minimum value.
 Counting down the assigned purge time.
 After the pre-purge the output valve switch is closed.

14.1.2 Operating phase

After purging phase and holding an overpressure inside the Ex p housing relative to the
surrounding atmosphere are not explosion-proof devices in Ex p enclosure are switched.

 The pressure regulator generates a pressure of about 300 mbar.

 Maintain a positive pressure relative to the atmosphere.
 Turn on the relay K2 the Ex pz controller (signal operational readiness)
 Turning off the relay K3 of the Ex pz controller (alarm).

If the pressure below the minimum amount of positive pressure, an alarm contact is acti-
vated via K3. This shows through appropriate equipment (light / horn etc.) indicates that the
pressure has fallen below the minimum value.

14.2 Checks after commissioning

 Remove any extraneous parts or packaging.

 Check the setting of the supply pressure of the pressure regulator.
 Ensure that a possibly installed bypass key switch is off and the key removed.
 Check that all doors and openings of the Ex p enclosure are closed.
 You make sure that the outlet openings of the pressurized enclosure is not closed.d.

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15 Mail function
If the purging is not working properly or the Ex pzc robot after purging automatically switches
off, are generally the following facts.

Facts Reason Help

The purge time Purge pressure Read during the purge time the pressure on the
does not start too low pressure reducer from and compare it with the
minimum value of the basic verification, docu-
mented in the check-out list. If the actual display
on the pressure reducer is too low, the pressure
is at hand wheel to increase to the minimum. If
this is not possible, so the lead in cross-section
is too small.
(See item: purge gas supply lines)

16 Maintenance work and troubleshooting

16.1 Maintenance
The operator of an electrical system in a hazardous environment must keep the loading
equipment designed in proper condition, operate it properly, monitor and carry out mainte-
nance and repairs.

16.2 Maintenance work

Maintenance work and troubleshooting on Ex pzc overpressure monitoring system may only
be performed by trained personnel. The specified safety instructions and warnings on the
Ex pzc pressure monitoring system must be observed!

16.3 Demontage
16.3.1 Power supply
Before dismantling the Ex pzc overpressure monitoring system must be connected from all
power sources. It should be ensured that the quality control cannot be switched on by igno-
rance or by mistake.

16.3.2 Compressed air supply

Before dismantling the supply line of Ex pzc overpressure monitoring system must be
switched completely depressurized. It should be ensured that the shutdown cannot be
turned on by ignorance or by mistake.

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17 Accessories and Spare parts
The Ex pzc overpressure monitoring system is designed so that at a possible malfunction,
the complete system must be replaced. The made possible the construction of a low cost
system.

18 Repair
WARNING
Explosion hazard due to improper repair! Non-compliance results in se-
vere or fatal injuries. Repair work on the devices must be performed only
by R. STAHL Schaltgeräte GmbH.

19 Cleaning
Clean the device only with a cloth, brush, vacuum cleaner or similar items. When cleaning
with a damp cloth, use water or mild, non-abrasive, non-scratching cleaning agents. Do not
use aggressive detergents or solvents.

20 Disposal
Observe national and local regulations and statutory regulation regarding disposal.
Separate materials when sending it for recycling.

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