Bartec Ex d 07-4 Series User manual

Ex d
Operating instructions
Ex d Contactor for Zone 1 and 2
Type 07-4..0-...1/0...
Document No. 01-4230-7D0002 Version: 01. August 2011/Rev.0

BARTEC GmbH Tel.: [phone] [email protected]
Max-Eyth-Straße 16 Fax: [phone] 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
Ex d Contactor
for Zones 1 and 2
Type: 07-4..0-…1/0…
Document no.: 01-4230-7D0002
Version: 1 August 2011 / Rev. 0
Contents
Page
English
1 - 36
Appendix
EC Declaration of Conformity
EC Type Examination Certificate

Table of Contents
Ex d Contactor
Type 07-4..0-...1/0...
Technical data subject to change without notice.
1Safety 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 / 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 and Certification 4
1.8 Warranty 5
2Product Description 6
2.1 Ex d Contactor 6
2.2 “Flameproof Enclosure” Type of Protection 6
3Mounting 7
3.1 Mounting Positions 7
3.2 Mounting the Ex d Contactor 4 kW and 7.5 kW 7
3.3 Mounting the Ex d Contactor 11 kW and 18 kW 7
4Connections 8
4.1 Safety Instructions for the Electrical System 8
4.2 Directions for Wiring the Ex d Contactor 8
4.3 Electrical Connection Ex d Contactor 9
5Operation 10
6Commissioning 11
6.1 Commissioning Procedure 11
7Operation 12
7.1 Safety during Operation 12
7.2 Operation of the Ex d Contactor 12
8Maintenance and Care 13
8.1 Inspection Table for Commissioning and Maintenance 13
9Malfunctioning and Troubleshooting 14
10 Technical Data 15
11 Order Numbers 16
11.1 Ex d Contactor 16
12 Appendix 17
12.1 Dimensions and Borehole Patterns 17
12.1.1 Ex d Contactor 4 kW and 7.5 kW 17
12.1.2 Drilling Pattern for Ex d contactor 4 kW and 7.5 kW 17
12.1.3 Ex d Contactor 11 kW 18
12.1.4 Drilling Pattern for Ex d contactor 11 kW 18
12.1.5 Ex d Contactor 18 kW 19
12.1.6 Drilling Pattern for Ex d contactor 18 kW 19
13 Declarations of Conformity and Approvals 20
13.1 EC Declaration of Conformity for Ex d Contactors 4 kW and 7.5 kW 20
13.2 EC Declaration of Conformity for Ex d Contactors 11 kW and 18 kW 21
13.3 EC Type Examination Certificate for Ex d Contactors 4 kW and 7.5 kW 22
13.4 EC Type Examination Certificate for Ex d Contactors 11 kW and 18 kW 26

Ex d Contactor
Type 07-4..0-...1/0...
Safety
Technical data subject to change without notice.
Page 1 of 34
1Safety
1.1 This Manual
O p e ra t i n g i n s t r u c ti o n s
It is essential to read and observe the contents of this documentation and this chapter in
particular before you install and operate the Ex d contactor.
This manual contains the information required for using the Ex d contactor in accordance
with its 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 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 individual 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:
D A N G E R
DANGER draws attention to a danger which will lead to death or serious
injury if not avoided.
W A R N I N G
WARNING draws attention to a danger which can lead to death or serious
injury if it is not avoided.
C A U T I O N
CAUTION draws attention to a danger which can lead to injuries if it is not
avoided.
A T T E N T I O N
ATTENTION draws attention to measures to be taken to prevent damage to property.
N o t e
Important instructions and information on effective, economical and
environmentally compatible handling.

Safety
Ex d Contactor
Type 07-4..0-...1/0...
Page 2 of 34
Technical data subject to change without notice.
1.1.1 Languages
N o 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 will operate 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 Ex d contactor must be mounted properly and securely onto the pressurised
enclosure 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 Ex d contactor serves exclusively as a separately certified switching contactor for
the supply of voltage to pressurised enclosures and is intended for use in Explosion
Group II, Category 2G, 3G and Temperature Classes T4 and T6.
The permissible operational 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 / Managing Operator’s Obligations
The owner/managing operator undertakes to restrict permission to work with the Ex d
contactor to people who:
are familiar with the basic regulations on safety and accident prevention and have
been instructed in the use of the Ex d contactor;
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 observed.

Ex d Contactor
Type 07-4..0-...1/0...
Safety
Technical data subject to change without notice.
Page 3 of 34
1.5 Safety Instructions
1.5.1 General Safety Instructions
In hazardous areas, use only damp cloths to wipe the devices!
Do not open devices in a hazardous area.
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, it is necessary to wear
appropriate clothing and footwear.
Avoid the influence of heat that is higher or lower than the specified temperature
range (see Chapter on “Technical data”).
Avoid exposure to 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, German industrial
health and safety ordinance (BetrSichV), the applicable national 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 maintenance is not necessary if the device is operated correctly with due
consideration to the installation instructions and ambient conditions. In this
context, please refer to Chapter 7.5 “Maintenance and Care”.
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 to explosion-proof operating equipment may be done only by authorised
persons working in accordance with the latest technical developments and using
original spare parts. The applicable regulations must be observed.
Commissioning
Before commissioning, check that all components and documents are there.

Safety
Ex d Contactor
Type 07-4..0-...1/0...
Page 4 of 34
Technical data subject to change without notice.
1.6 Standards Conformed To
The Ex d contactor conforms to Directive 94/9/EC for devices and protective systems for
use to their intended purpose in hazardous areas (ATEX directive). Pursuant to this
directive, the following standards serve as a basis for the Ex d contactor:
Standard
Designation
EN 60079-0:2006
Electrical apparatus for explosive gas atmospheres -
Part 0: General Requirements
EN 60079-1:2007
Explosive atmospheres -
Part 1: Equipment protection by flameproof enclosures “d”
EN 60079-7:2007
Explosive atmospheres -
Part 7: Equipment protection by increased safety “e”
EN 60439-1:1999 +
A1:2004
Low-voltage switchgear and control gear assemblies
Part 1: Type-tested and partially type-tested assemblies
EN 60529:1991 +
A1:2000
Degrees of protection provided by enclosures (IP code)
EN 62208:2003
Empty enclosures for low-voltage switchgear and control
gear assemblies.
- General requirements
EN 60445:2007
Basic and safety principles for man-machine interface
Identification of equipment terminals and conductor
terminations
1.7 Ex Protection Type and Certification
The following markings on Ex protection and certification are put on the device:
II 2G Ex e d IIC T4
PTB 03 ATEX 1024
PTB 03 ATEX 1138

Ex d Contactor
Type 07-4..0-...1/0...
Safety
Technical data subject to change without notice.
Page 5 of 34
1.8 Warranty
W A R N I N G
Risk of death or serious injury if the Ex d contactor 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.
N o 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 Ex d contactor for a purpose other than that for which it is intended.
incorrect installation, commissioning, operation and maintenance of the Ex d
contactor.
non-compliance with the instructions in the manual with respect to transport,
storage, assembly, commissioning, operation and maintenance.
unauthorised structural modifications of the Ex d contactor
inadequate monitoring of parts that are subject to wear
repairs done incorrectly.
disasters due to the effects of foreign matter or events outside human control.
We guarantee the Ex d contactor 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 will not be entitled to on-site repairs.

Product Description
Ex d Contactor
Type 07-4..0-...1/0...
Page 6 of 34
Technical data subject to change without notice.
2Product Description
2.1 Ex d Contactor
The Ex d contactor is used for the safe switching of currents greater than 5 A or 3P+N
mains power supplies in hazardous areas. The contactor is activated by a pressurised
system (e.g. SILAS control, APEX control).
For this purpose it has 4 galvanically isolated switching contacts in a redundant
version by means of 2 switching contactors separated from each other and connected
in series. Three-phase consumers are connected by means of the 4 separate
switching contacts.
The Ex d contactor is available in various power ratings.
2.2 “Flameproof Enclosure” Type of Protection
In the Ex d type of protection, assembly groups which can ignite an explosive
atmosphere are arranged in an enclosure, which in the event of an explosion will
withstand the pressure of an explosive mixture exploding and prevent the transmission
of the explosion to the explosive atmosphere surrounding the enclosure.
Technically required gaps are so long and narrow that any hot gases that escape will
have lost their ignitability by the time they reach the outside of the enclosure. Gaps that
are necessary only for the manufacturing process can be sealed with adhesive.

Ex d Contactor
Type 07-4..0-...1/0...
Mounting
Technical data subject to change without notice.
Page 7 of 34
3Mounting
3.1 Mounting Positions
The Ex d contactor consisting of a flameproof enclosure and an Ex e junction box can be
mounted as required onto the outside wall or inside the pressurised enclosure.
The Ex d contactor functions independently of position and can therefore be mounted
horizontally or vertically.
N o t e
The mounting material for the Ex d contactor is not contained in the scope
of supply.
3.2 Mounting the Ex d Contactor 4 kW and 7.5 kW
For mounting the Ex d contactor, bore four M8 tapped holes at the mounting position
provided for that purpose. The dimensions can be found in the drilling pattern in the
appendix.
Mounting:
Bore M8 tapped holes
Put the Ex d contactor on
Position the screws with retaining ring on the mounting boreholes
Screw the Ex d contactor in securely
3.3 Mounting the Ex d Contactor 11 kW and 18 kW
To mount the Ex d contactor, make two M12 tapped holes at the mounting position
provided for that purpose. Refer to the drilling pattern in the appendix for the dimensions.
Mounting:
Bore M12 tapped holes
Put on the Ex d contactor
Put the screws with retaining ring onto the mounting boreholes
Screw the Ex d contactor in securely

Connections
Ex d Contactor
Type 07-4..0-...1/0...
Page 8 of 34
Technical data subject to change without notice.
4Connections
4.1 Safety Instructions for the Electrical System
D A N G E R
Death or serious physical injury due to work on live parts.
Risk of fatal injury from electrical current.
Observe the 5 safety rules for work on electrical systems: disconnect
mains; protect against unintended reconnection; verify the absence
of voltage; earth and short-circuit; cover or safeguard nearby live
parts.
4.2 Directions for Wiring the Ex d Contactor
D A N G E R
Death or serious physical injury when the cover on the Ex d contactor
is opened in an explosive atmosphere.
Risk of explosion
Before opening the lid of the enclosure, check the atmosphere for
any explosive gases.
A T T E N T I O N
Short-circuits due to loose or protruding wires in the Ex d contactor.
The connected assembly groups might be 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 onto the Ex d
contactor:
Procedure:
Loosen the screws in the lid of the Ex e junction box and take off the lid.
Feed the cable 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 earthing connections onto the PE terminal.
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 Ex e junction box and tighten the 4 fastening screws with
1.4 Nm.

Ex d Contactor
Type 07-4..0-...1/0...
Connections
Technical data subject to change without notice.
Page 9 of 34
4.3 Electrical Connection Ex d Contactor
The Ex e compartment () of the Ex d contactor () serves as a junction box and
terminal distributor. This is where the voltage supply is connected.
The Ex d contactor supplies voltage to the Ex p control unit and in conjunction with the
Ex p control unit releases the voltage supply to the pressurised enclosure.
öeg
Key:
- Contactor (Ex d):
Item
Designation
Function
1
Ex d enclosure
Control supply voltage
2
Ex e junction box
Junction box
-1K1
Contactor 1
Release of supply voltage
-1K2
Contactor 2 (redundancy)
Release of supply voltage
F1
Fuse
Fusing -1K1 and -1K2
F2
Fuse
Fusing Ex p control unit
- Junction box (Ex e):
Terminal
Connection
Function
1 –3
Supply voltage L1, L2, L3
Supply of voltage
4 –6
Supply voltage L1´, L2´, L3´
Voltage supply Ex p
7
Ex p
“L” phase Ex p control
N
Neutral conductor
Neutral conductor
A 1
Ex p
Enabling
A 2
Ex p
Enabling
PE
PE connection
Earthing



Operation
Ex d Contactor
Type 07-4..0-...1/0...
Page 10 of 34
Technical data subject to change without notice.
5Operation
D A N G E R
Death or serious physical injury when the cover of the Ex d contactor
is opened in an explosive atmosphere.
Risk of explosion
> Before opening the lid of the enclosure, check the atmosphere for
any explosive gases.
The Ex d contactor is a component of the Ex p control and it is controlled directly by the
Ex p control unit. Direct operation is not possible.

Ex d Contactor
Type 07-4..0-...1/0...
Commissioning
Technical data subject to change without notice.
Page 11 of 34
6Commissioning
6.1 Commissioning Procedure
The Ex d contactor is a component in Ex p operating equipment. The Ex p operating
equipment consists of the pressurised enclosure, the Ex p control and the Ex d
contactor.
The Ex d contactor is actuated by the Ex p control unit and accordingly releases the
supply voltage for the pressurised enclosure.
The Ex p control unit is connected to the Ex d contactor and enables the supply voltage
in accordance with the following schematic circuit diagram once the purging action has
been completed and a positive level of pressure has been reached.
The complete Ex p operating equipment is commissioned on the basis of the operating
instructions written for the Ex p control unit.
It must be ensured that the supply voltage is not enabled by the contactors -1K1 and -
1K2 until the purging action has been completed and the pressure inside the pressurised
enclosure is higher than the pressure surrounding it.
Furthermore, in the event of malfunctioning, e.g. drop in pressure, the supply voltage
must be deactivated automatically (contactors -1K1 and -1K2 drop out).
Pressurised enclosure
Supply voltage
Ex p control
Ex d contactor

Operation
Ex d Contactor
Type 07-4..0-...1/0...
Page 12 of 34
Technical data subject to change without notice.
7Operation
7.1 Safety during Operation
D A N G E R
Death or serious physical injury due to a damaged explosion
protection measure. It is no longer possible to operate the contactor
without risks.
Risk of explosion
Put the Ex d contactor out of operation and protect it against
unintended reconnection.
7.2 Operation of the Ex d Contactor
The Ex d contactor is a component in an Ex p Control and it activates or deactivates the
supply of voltage to the pressurised enclosure.
If the Ex p operating equipment is activated, the Ex p control unit enables the supply
voltage once the purging action has been completed and a positive level of pressure has
been reached in the pressurised enclosure by means of the Ex d contactor.
If there is a loss of pressure inside the pressurised enclosure, the Ex d contactor is
deactivated by means of the Ex p control unit and the supply of voltage to the
pressurised enclosure is turned off automatically.
No settings can be made or commands entered on the Ex d contactor.

Ex d Contactor
Type 07-4..0-...1/0...
Maintenance and Care
Technical data subject to change without notice.
Page 13 of 34
8Maintenance and Care
N o t e
Regular maintenance is not necessary if the unit is installed correctly,
operated appropriately and if the ambient conditions are observed. Our
recommendation is:
We recommend an annual inspection in accordance with the
“Inspection Table for Commissioning and Maintenance”.
8.1 Inspection Table for Commissioning and Maintenance
Item
Test point
Commissioning
Main-
tenance
OK
OK
1
Visual inspection for damage
2
Attachment of the Ex d contactor
n/a
3
Inspection of wiring for conformance to the
relevant directives
n/a
4
Agreement between mains voltage and the
connection voltage for the individual devices
n/a
5
Total power consumption of the devices less
than the control unit’s maximum switching
capacity
n/a
6
The Ex d contactor has been tested for correct
functioning
7
Sign conforming to EN 60079-2 affixed to
enclosure.
8
Check if the contactor is stuck.

Malfunctioning and
Troubleshooting
Ex d Contactor
Type 07-4..0-...1/0...
Page 14 of 34
Technical data subject to change without notice.
9Malfunctioning and Troubleshooting
It is assumed here that all external electrical and mechanical devices have been
connected in an orderly fashion. For that reason, it should first be checked that the
electrical devices have indeed been set up and connected properly.
N o t e
The following table with descriptions of faults and information on possible
causes presupposes that the components have been mounted and
connected correctly.
Malfunctioning
Possible Cause
Remedy
The supply voltage to the
pressurised enclosure is
not activated
No mains voltage
Check mains voltage supply
line.
The Ex p control unit is not
enabled.
Check enabling of Ex p
control unit.
Internal contactor does not
switch.
Check contactor for correct
functioning.
Fuse F1 defective.
Replace fuse.
The supply of voltage to
the pressurised enclosure
is not deactivated when a
fault occurs.
The Ex p control unit enabling
contactor does not drop out.
Check the Ex p control.
Contactor and redundant
contactor have welded.
Replace contactors.
No supply of voltage to
the Ex p control unit.
Fuse F2 defective.
Replace fuse.
No 3-phase + N voltage
supply available.
Check the supply voltage
and connect it correctly.

Ex d Contactor
Type 07-4..0-...1/0...
Technical Data
Technical data subject to change without notice.
Page 15 of 34
10 Technical Data
Variants
4 kW
7.5 kW
11 kW
18 kW
ATEX marking
II 2G Ex d e IIC T4
Certification
Type 07-4230-1101/….
PTB 03 ATEX 1138
Type 07-4310-0561/….
PTB 03 ATEX 1024
Degree of protection
IP 65
Rated operating voltage Ue
690 V
Rated frequency range
50-60 Hz
Ambient temperature operation
-20 °C to + 40 °C
Max. conductor cross-section
Connection terminals
4 mm²
4 mm²
16 mm²
35 mm²
Cable glands
2 x M25
1 x M20
2 x M25
1 x M20
2 x M32
1 x M20
2 x M50
1 x M20
Rated operating current Ie/AC-1
Uemax. 690 V
20 A
20 A
30 A
50 A
Rated operating current Ie/AC-3
Ue380-400 V
9 A
18 A
26 A
38 A
Rated operating power AC-3
220-230-240 V
2.2 kW
4 kW
6.5 kW
11 kW
380-400 V
4 kW
7.5 kW
11 kW
18 kW
Short-circuit protection in accordance
with type 2 for contactors without
thermal overload relay –without motor
protection Ue< 500 V AC –gG fuse
20 A
20 A
25 A
50 A
Ex d enclosure material
Aluminium varnished
similar to RAL 7016
Aluminium varnished
similar to RAL 7032
Ex e junction box material
Aluminium varnished
similar to RAL 7001
Sheet steel varnished
similar to RAL 7032
Fuse contactor (F1)
2.0 AT
2.0 AT
2.0 AT
2.0 AT
Fuse pressurisation (F2)
4.0 AT
4.0 AT
4.0 AT
4.0 AT

Order Numbers
Ex d Contactor
Type 07-4..0-...1/0...
Page 16 of 34
Technical data subject to change without notice.
11 Order Numbers
11.1 Ex d Contactor
Variants
Order numbers
4 kW
07-4230-1101/0292
7.5 kW
07-4230-1101/0293
11 kW
07-4310-0561/0142
18 kW
07-4320-0561/0248

Ex d Contactor
Type 07-4..0-...1/0...
Appendix
Technical data subject to change without notice.
Page 17 of 34
12 Appendix
12.1 Dimensions and Borehole Patterns
12.1.1 Ex d Contactor 4 kW and 7.5 kW
12.1.2 Drilling Pattern for Ex d contactor 4 kW and 7.5 kW