E2S BExBG05D User manual

INSTRUCTION MANUAL (ATEX)
BExBG05D Flameproof Xenon Beacons
For use in Flammable Gas and Dust Atmospheres
1) Introduction
The BExBG05D is a second generation flameproof beacon
which is certified to the European Standards EN 50014:
1992, EN 50018: 1994, the Combustible Dust standard EN
50281-1-1: 1999 and meets the requirements of the ATEX
directive 94/9/EC. The beacon produces synchronised visual
warning signals and can be used in hazardous areas where
potentially flammable gas and dust atmospheres may be
present. The BExBG05D has an output level of 5 joules and
canbeusedinZone1andZone2areaswithgasesin
groups IIA, IIB and IIC and Temperature Classifications of T1,
T2, T3, T4 and T5. The unit can also be used in a
temperature classification T6, if the upper ambient
temperature is restricted to +40ºC. The unit can be used in
Zone 21 and Zone 22 areas for combustible dusts and has
an IP rating of IP 67 and a surface temperature rating of
T100ºC or T85ºC if the upper ambient temperature is
restricted to +40ºC.
2) Marking
All units have a rating label, which carries the following
important information:-
Unit Type No. BExBG05D
Input Voltage: DC Units 12V or 24V or 48V
AC Units 230V or 115V
Code: EEx d IIC T5 (Tamb. –50 to +55ºC)
EEx d IIC T6 (Tamb. –50 to +40ºC)
IP67 T100ºC Ta < +55ºC
T85ºC Ta < +40ºC
Certificate No. KEMA 00ATEX2006 X
Warnings: DO NOT OPEN WHEN AN EXPLOSIVE
GAS OR DUST ATMOSPHERE IS PRESENT
COVER BOLTS CLASS A4-80
USE HEAT RESISTI NG CABLES AND CABLE GLANDS
(Rated 95ºC) AT AMB. TEMPERATURES OVER 40ºC
Year of Construction /
Serial No. i.e. 03 / 1DB13000001
3) Type Approval Standards
ThebeaconshaveanECTypeexaminationcertificateissued
by KEMA and have been approved to the following
standards:-
EN 50014 : 1992 + prA1 General Requirements
EN 50018 : 1994 + prA1 + prA2 + prA3 Flameproof Enclosure ‘d’
EN 50281-1-1 : 1999 Combustible Dust
4) Installation Requirements
The beacons must be installed in accordance with the latest
issues of the relevant parts of the BS EN 60079
specifications or the equivalent IEC specifications –
Selection, Installation and maintenance of electrical
apparatus for use in potentially explosive atmospheres (other
than mining applications or explosive processing and
manufacture):-
BS EN 60079-14 : 1997 Electrical Installations in Hazardous
Areas (other than mines)
BS EN 60079-10 : 1996 Classification of Hazardous Areas
The installation of the units must also be in accordance with
any local codes that may apply and should only be carried
out by a competent electrical engineer who has the
necessary training.
5) Zones, Gas Group, Category, IP Rating and
Temperature Classification
The BExBG05D beacons have been certified EEx d IIC T5
(Tamb. –50 to +55ºC) and EEx d IIC T6 (Tamb. –50 to
+40ºC) for gas and IP67 T100ºC Ta < +55ºC and T85ºC Ta
<+40ºC for dust. This means that the units can be installed in
locations with the following conditions:-
Area Classification Gas:
Zone 1 Explosive gas air mixture likely to occur in
normal operation.
Zone 2 Explosive gas air mixture not likely to occur,
and if it does, it will only exist for a short time.
Gas Groupings:
Group IIA Propane
Group IIB Ethylene
Group IIC Hydrogen and Acetylene
Temperature Classification:
T1 400oC
T2 300oC
T3 200oC
T4 135oC
T5 100oC
T6 85oC
A
mb. +40ºC
0518
II 2G/D
Epsilon
x
Equipment Group and
Category:
CE Marking
Notified Body No.

Area Classification Dust:
Zone 21 Explosive dust air mixture likely to occur in
normal operation.
Zone 22 Explosive dust air mixture not likely to occur, and
if it does, it will only exist for a short time.
IP Rating: IP67 T100ºC Ta < +55ºC
T85ºC Ta < +40ºC
Equipment Category: 2G/D
Ambient Temperature Range: -50°C to +55°C
(T6 = +40ºC)
6) Beacon Location and Mounting
The location of the beacons should be made with due regard
to the area over which the warning signal must be visible.
They should only be fixed to services that can carry the
weight of the unit.
The beacons should be securely bolted to a suitable surface
using the 7mm diameter boltholes in the stainless steel U
shaped mounting bracket (see figure 1). The required angle
can be achieved by loosening the two large bracket screws in
the side of the unit, which allow adjustment of the beacon in
steps of 18°. On completion of the installation the two large
bracket adjustment screws on the side of the unit must be
fully tightened to ensure that the unit cannot move in service.
SAFETY WARNING:
The flashdome guard must not be removed from the unit
at any time.
7) Access to the Flameproof Enclosure
In order to connect the electrical supply cables to the beacon
it is necessary to remove the flameproof cover to gain access
to the flameproof chamber. To achieve this remove the four
M6 hexagon socket head screws (see figure 2) and withdraw
the flameproof cover taking extreme care not to damage the
flameproof joints in the process.
Note the four M6 screws are Class A4-80 stainless steel
and only screws of this category can be used on the
beacons. It is therefore important that these screws and their
spring washers are kept in a safe place during installation.
On completion of the cable wiring installation the flameproof
joints should be inspected to ensure that they are clean and
that they have not been damaged during installation. Also
check that the earth bonding wire between the two casting
sections is secure and the ‘O’ ring seal is in place. When
replacing the flameproof cover casting ensure that it is square
with the flameproof chamber casting before inserting.
Carefully push the cover in place allowing time for the air to
be expelled. Only after the cover is fully in place should the
four M6 Stainless Steel A4-80 cover bolts and their spring
washer be inserted and tightened down. If the cover jams
while it is being inserted, carefully remove it and try again.
Never use the cover bolts to force the cover into position.
8) Power Supply Selection
It is important that a suitable power supply is used to run the
beacons. The power supply selected must have the
necessary capacity to provide the input current to all of the
beacons
The following table shows the input current taken by the
various beacons:-
Unit Type Nominal I/P Input Max.
Voltage Current I/P
Volts
BExBG05D 12V DC 750mA 15V
BExBG05D 24V DC 300mA 30V
BExBG05D 48V DC 180mA 58V
BExBG05D 230V AC 55mA 253V
BExBG05D 115V AC 140mA 126V
The input current will vary according to the voltage input
level. The current levels shown above are for nominal input
voltage. The 12V, 24V and 48V DC units have a converter
circuit and therefore the input current level will decrease
slightly as the input voltage in increased and will increase
slightly as the input voltage is reduced.
The above table also shows the maximum voltages at which
the beacons can be operated.
Flashdome
Guard
Flameproof
Chamber Flameproof
Cover
S/S Bracket
Figure 1
4offM6CoverScrew
s
External Earth
Terminal
Figure 2

9) Cable Selection
When selecting the cable size consideration must be given to
the input current that each unit draws (see table above), the
number of beacons on the line and the length of the cable
runs. The cable size selected must have the necessary
capacity to provide the input current to all of the beacons
connected to the line.
SAFETY WARNING: If the BExBG05D beacons are used at
high ambient temperatures, i.e. over +40ºC, then the cable
entry temperature may exceed +70ºC and therefore suitable
heat resisting cables must be used, with a rated service
temperature of at least 95ºC.
10) Earthing
Both AC and DC beacon units must be connected to a good
quality earth. The units are provided with internal and
external earthing terminals which are both located on the
terminal chamber section of the unit (see figures 2 and 3).
When using the external earth terminal a cable crimp lug
must be used. The cable lug should be located between the
two M5 stainless steel flat washers. The M5 stainless steel
spring washer must be fixed between the outer flat washer
and the M5 stainless steel nut to ensure that the cable lug is
secured against loosening and twisting.
The internal earth bonding wire ensures that a good quality
earth is maintained between the flameproof chamber casting
and the flameproof cover casting.
11) Cable Glands
The BExBG05D beacons have dual cable gland entries which
have an M20 x 1.5 entry thread as standard. Only cable
glands approved for Ex ‘d’ applications can be used, which
must be suitable for the type of cable being used and also
meet the requirements of the Ex ‘d’ flameproof installation
standard BS EN 60079-14 : 1997.
When only one cable entry is used the other one must be
closed with an Ex ‘d’ flameproof blanking plug, which must be
suitably approved for the installation requirements.
For combustible dust applications, the cable entry device and
blanking elements shall be in type of explosion protection
increased safety "e" or flameproof enclosure "d" and shall
have an IP 6X rating according to EN 60529.
SAFETY WARNING: If the BExBG05D beacons are used at
high ambient temperatures, i.e. over +40ºC, then the cable
entry temperature may exceed +70ºC and therefore suitable
heat resisting cable glands must be used, with a rated service
temperature of at least 95ºC.
12) Cable Connections
The cable connections are made into the terminal blocks on
the electronic pcb assembly located in the flameproof
enclosure. See section 7 of this manual for access to the
flameproof enclosure. A four-way terminal block is provided
on both AC and DC beacons. Therefore there are two live
terminals and two neutral terminals for the input and output
wiring on AC units. On the DC units there are two +ve
terminals and two -ve terminals for the input and output
wiring.
Wires having a cross sectional area of up to 2.5mm² can be
connected to each terminal way. If an input and output wire is
required a 2.5mm² wire can be connected to each terminal
way. When connecting wires to the terminals great care
should be taken to dress the wires so that when the cover is
inserted into the chamber the wires do not exert excess
pressure on the terminal blocks. This is particularly important
when using cables with large cross sectional areas such as
2.5mm².
13) Synchronised Operation
All BExBG05D beacons that are connected to the same
supply line will have a synchronised flash rate at one flash
every second. To ensure that the units will be synchronised
check that the pin header is not fitted, i.e. the two header pins
are not shorted together (see Figure 4).
2offM20
Cable Entries
Internal Earth Terminal
Figure 3
Internal
Bonding Wire
Terminal
BExBG05D Beacon Cover Internal View
Figure 4
BExBG05D 5 Joule Beacons
Suppl
y
Terminals
Flip / Flop
Pin Header

14) Flip-Flop Operation
Two beacons can be mounted close to each other to form a
flip-flop operation, where the beacons will flash alternately.
To achieve this mode of operation, fit a pin header to the flip-
flop header pins on the electronics board, i.e. the two header
pins are shorted together, (see figure 4) on one of the two
beacons. The first flash on the beacon that has the header
fitted will be delayed by ½ second. The two beacons will then
flash alternately every ½ a second.
15) End of Line Monitoring (DC Units)
On the BExBG05D DC beacons, dc reverse line monitoring
can be used if required. All DC beacons have a blocking
diode fitted in their supply input lines. An end of line
monitoring diode or an end of line monitoring resistor can be
connected across the +ve and –ve terminals. If an end of line
resistor is used it must have a minimum resistance value of
3k3 ohms and a minimum wattage of 0.5 watts or a minimum
resistance value of 500 ohms and a minimum wattage of 2
watts.