Gonnheimer Elektronic F870S User manual

User's manua
l
Pressurized
enclosure system
F870S
Manual_F870S_v1.0.2_2016.doc

F870S Inhalt Page 2
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Content
1Operation instruction for Explosion protected device............................................................................ 4
2Introduction: Pressurized enclosure system F870S.............................................................................. 5
2.1 Explosion protection: pressurized enclosure ................................................................................. 5
2.2 Pressurized enclosure according to EN 60079.............................................................................. 5
2.3 Pressurized enclosure system F870S ........................................................................................... 6
2.3.1 Simultaneous PID- control of cabinet pressure and flow rate ................................................ 6
2.3.2 Enlarged, free programmable range of operation................................................................... 7
2.3.3 Lowered cabinet stressing due to smaller pressure and pressure gradients ......................... 8
2.4 Components of pressurized enclosure system F870S .................................................................. 8
2.4.4 Leakage compensation........................................................................................................... 9
2.4.5 Continuous flow .................................................................................................................... 10
2.4.6 F870S - Application using „Containment Systems “............................................................. 10
2.5 Peripherals ................................................................................................................................... 11
2.5.1 Ex i- external sensory: ES872 .............................................................................................. 11
2.5.2 Configuration module: CM873.............................................................................................. 11
2.5.3 Operating panels .................................................................................................................. 11
2.5.4 Common operating panels: BT 854.1 and BT 855.1 ............................................................ 11
2.5.5 Intelligent operating panel type BT871 ................................................................................. 11
2.5.6 Disconnector unit SR852 and power relay SR853 ............................................................... 11
2.6 Features in operation zone 21 (Dust) .......................................................................................... 12
2.6.1 Purging period -> cleaning period: cleaning the housing inside........................................... 12
2.6.2 Additional marking ................................................................................................................ 12
2.7 Additional information: EC- type certificate F850-SYST.............................................................. 12
2.8 Conformity with standards ........................................................................................................... 12
3Installation and Connection................................................................................................................. 13
3.1 Mounting ...................................................................................................................................... 13
3.1.3 Control unit FS870S ............................................................................................................. 13
3.1.4 Particle barrier....................................................................................................................... 13
3.1.5 Proportional solenoid valve................................................................................................... 13
3.1.6 Operator panels BT8xx.x ...................................................................................................... 13
3.1.7 Disconnector unit SR852 and power relay SR853 ............................................................... 14
3.2 Connecting and Commissioning .................................................................................................. 14
3.2.1 Connection hints ................................................................................................................... 15
3.2.2 Switching power off ability .................................................................................................... 15
3.2.3 Intrinsically safe (Ex i-) connection of FS870S..................................................................... 16
3.2.4 Connections FS870S of protection class (Ex e) ................................................................... 16
3.2.5 Default parameter ................................................................................................................. 17
3.2.6 Ex works parameter – Reset ................................................................................................ 18
3.3 Maintenance................................................................................................................................. 18
3.4 Repairs......................................................................................................................................... 18
4Operation............................................................................................................................................. 19
4.1 Human interface........................................................................................................................... 19
4.1.1 Display .................................................................................................................................. 19
4.1.2 Joystick ................................................................................................................................. 19
4.1.3 Log file (show Log) ............................................................................................................... 19
4.1.4 How to enter and leave the bypass mode ............................................................................ 20
4.2 Parameter input and parameter query......................................................................................... 21
4.2.1 Operation menu .................................................................................................................... 21
4.2.2 Parameter input menu .......................................................................................................... 21
4.2.3 Menu exposition.................................................................................................................... 22
4.3 Alarm and malfunction indications ............................................................................................... 23
4.3.4 Alert....................................................................................................................................... 23
4.3.5 Error messages..................................................................................................................... 23
5Annex .................................................................................................................................................. 24
5.1 Technical Details.......................................................................................................................... 24
5.1.6 Pneumatic data..................................................................................................................... 24
5.2 Type codes................................................................................................................................... 25
5.3 Marking ........................................................................................................................................ 26

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5.4 Dimensions .................................................................................................................................. 27
5.5 Mounting examples...................................................................................................................... 29
5.6 Flow diagram................................................................................................................................ 29
5.7 Block diagram .............................................................................................................................. 30
5.8 Transport, Storing, Disposal and Repairs.................................................................................... 31
5.9 Sequence of operation diagram................................................................................................... 32
5.10 List of Parameters .................................................................................................................... 33
The symbols WARNING, CAUTION, NOTE
This symbol warns of a serious hazard. Failure to observe this warning may
result in death or the destruction of property.
This symbol warns of a possible failure. Failure to observe this caution may
result in the total failure of the device or the system or plant to which it is
connected.
This symbol highlights important information.
Safety Measures: to read and to comply
Warning! Extreme caution is advised when handling this device. High
electrical discharge is possible and can be fatal.
Work on electrical installations and apparatus in operation is generally forbidden in
hazardous locations, with the exception of intrinsically safe circuits. In special cases
work can be done on non-intrinsically safe circuits, on the condition that during the
duration of such work no explosive atmosphere exists.
Only explosion protected certified measuring instruments may be used to ensure
that the apparatus is voltage-free. Grounding and short-circuiting may only be car-
ried out, if there is no explosion hazard at the grounding or short circuit connection.
Danger of static charge!
Clean only with humid cloth!
Do not open when an explosive dust atmosphere is present!

F870S 1 Operation instruction for explosion protected device Page 4
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1 Operation instruction for Explosion protected device
Application and Standards
This instruction manual applies to explosion-protected devices of types below. This apparatus is
only to be used as defined and meets requirements of EN 60 079 particularly EN60 079-14
"electrical apparatus for potentiality explosive atmospheres".
Use this manual in hazardous locations, which are hazardous due to gases and vapors accord-
ing to the explosion group and temperature class as stipulated on the type label. When installing
and operating the explosion protected distribution and control panels you should observe the
respective nationally valid regulations and requirements.
General Instructions
Work on electrical installations and apparatus in operation is generally forbidden in hazardous
locations, with the exception of intrinsically safe circuits. In special cases work can be done on
non-intrinsically safe circuits, on the condition that during the duration of such work no explosive
atmosphere exists.
Only explosion protected certified measuring instruments may be used to ensure that the appa-
ratus is voltage-free. Grounding and short-circuiting may only be carried out, if there is no ex-
plosion hazard at the grounding or short circuit connection.
To achieve an impeccable and safety device operation, please take care for adept transporta-
tion, storage and mounting, as well as accurate service and maintenance. Operation of this de-
vice should only be implemented by authorized persons and in strict accordance with local safe-
ty standards.
The electrical data on the type label and if applicable, the "special conditions" of the test certifi-
cate BVS 10 ATEX E 112are to be observed.
For outdoor installation it is recommended to protect the explosion protected distribution and
control panel against direct climatic influence, e.g. with a protective roof. The maximum ambient
temperature is 40°C, if not stipulated otherwise.
Terminal compartment in Increased Safety
When closing, it is to be ensured that the gaskets of the terminal compartment remain effective,
thus maintaining degree of protection IP 54 according to EN 60529. Close unused entries by
impact-proof stopping plugs, which are secured against self-loosening and turning.
Do not open the device in Ex area, as long the device is energized.
Inside area with explosive dust do clean the inner of the housing of the dust before closing the
housing.
Maintenance Work
The gaskets of Ex e enclosures are to be checked for damages and replaced, if required. Ter-
minals, especially in the Ex e chamber are to be tightened. Possible changes in color point to
increased temperature. Cable glands, stopping plugs and flanges are to be tested for tightness
and secure fitting.
Intrinsically Safe Circuits
Erection instructions in the testing certificates of intrinsically safe apparatus are to be observed.
The electrical safety values stipulated on the type label must not be exceeded in the intrinsically
safe circuit. When interconnecting intrinsically safe circuits it is to be tested, whether a voltage
and/or current addition occurs. The intrinsic safety of interconnected circuits is to be ensured.
(EN 60079-14, section 12)

F870S 2 Pressurized enclosure system F870S Page 5
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2 Introduction: Pressurized enclosure system F870S
2.1 Explosion protection: pressurized enclosure
The use of pressurized enclosures allows the operation of ‘non explosion protected’ devices
in hazardous areas inside zone 1 and zone 2. The protection type ‘pressurization’ is based
on the principle of maintaining a constant pressure using air or a protective gas to prevent
an explosive mixture forming near the device inside the pressurized enclosure.
Before start-up, the pressurized enclosure must be purged with air or protective gas to re-
move any explosive mixture that may be inside the enclosure.
2.2 Pressurized enclosure according to EN 60079
Since the second issue of the standard EN 50016 (May, 1996) control devices for the pro-
tection type "pressurized enclosure" are classified as security related devices.
At that time, the notified bodies, (PTB, EXAM, TUEV NORD, etc.) declared that an ex p-
control device must fulfill the category 3 of EN 954-1. This concept was taken over also in
the standards EN 60079 ff.
After the replacement of EN 954-1 by the standards IEC / EN 61508-1 and -2, respectively
EN ISO DIN 13849-1 and -2 and DIN EN 50495 a security level of at least SIL 2 is required
for a pressurized enclosure control unit according to EN 60079-2. This is a valid arrange-
ment between the German notified bodies.
Figure 1: Performance levels
The pressurized enclosure system F870S reaches performance level „d“ according to
EN 13849 and therefore it reaches SIL Level 2 according to IEC / EN 61508.

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2.3 Pressurized enclosure system F870S
2.3.1 Simultaneous PID- control of cabinet pressure and flow rate
Based on the first introduction of proportional valve technology within pressurized enclosure
systems (patented system Gönnheimer F850) an additional active proportional valve was
integrated to the F870S in the outlet.
Figure 2: block diagram simultaneous pressure and flow control
This concept permits simultaneous PID-regulation of cabinet pressure and flow rate and
generates new solutions and possibilities for pressurized enclosure systems and attach-
ments.

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2.3.2 Enlarged, free programmable range of operation
In comparison to common Ex p control systems, the FS870S offers an increased and free
programmable range of operation (characteristic pressure / flow curve).
The conventional systems are characterized by a fixed pressure / flow curve (see e.g.
FS850S) with an offset, caused by the opening pressure of the passive mechanical outlet
valve. This typical opening pressure (2... 4 mbar at standard systems) is required to mini-
mize the system leakage rate during normal operation.
Fixed curves by control
devices with flow meas-
urement with plate orifice
Figure 3: Range of operation
The input and output sided PID-control loops allow the FS870S to perform in the whole
range of operation (see figure 2).

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2.3.3 Lowered cabinet stressing due to smaller pressure and pressure gradients
During the purging phase a high flow rate should be achieved to shorten the purge time.
Based on their construction, conventional Ex p- systems show only a smooth rising of the
flow rate while increasing the cabinet pressure.
In this aspect, the FS870S with its reduced flow restriction and back pressure is superior to
any conventional Ex p system.
Within midrange flow rates, the load to the Ex p- cabinet walls is up to four times lower in
comparison to conventional systems!
2.4 Components of pressurized enclosure system F870S
The pressurized enclosure system F870S contains at least the control unit FS870S and a
solenoid valve. Each can be mounted in- or outside the enclosure. Furthermore several re-
mote controls (operation panels) are available to improve ease of operation. It is also pos-
sible to connect intrinsically safe sensors to the control unit FS870S.
The pressurized enclosure system F870S has two basic operation modes:
•Pressurization using leakage compensation
•Pressurization using continuous flow of protective gas.

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2.4.4 Leakage compensation
Within this operation mode the unit generate and hold a pressure level of at lest 0.8 mbar
(80 Pa) inside the Ex p- cabinet.
The use of a proportional solenoid valve prevents wasting of the purge medium while the
pre purging procedure as well later in basic operation mode.
In tradition to the control unit GÖNNHEIMER FS850S, the first Ex p- control unit using pro-
portionally working pressure and flow control, the FS870S works as well as an input-sided
pressure regulator:
The proportional solenoid valve is the actuator of a PID- control and regulates the incoming
purge medium accordingly to the leakage of the cabinet. The benefits of pressure feedback
control are:
1. Considerable less consumption of protective gas - additional costs for proportional valve will
be amortized soon
2. Increased service reliability achieved by constant pressure inside enclosure - increasing leak-
age caused by e.g. ageing of the enclosure will be balanced and sudden failure is pre vented
3. Almost no flow noise and only a small protective gas consumption using a solid enclosure
Figure 4: Consumption of protective gas
Another advantage using a proportional solenoid valve is; that pressure control is also used
during purging. A set-point pressure will be achieved in the enclosure, while the flow vol-
ume, that leaves the enclosure, will be recorded and integrated over time, until the required
purge volume is achieved. The advantages are:
1. A defined pressure while purging - pressure sensitive parts of the enclosure, like mem-
brane switch panels or windows, will not be overloaded.
2. Purge volume accuracy is achieved by integration of the purge medium flow volume at
the outlet. Wasting purge medium is no more a topic of today.
The use of the F870S system leads to a considerable stress relief of the Ex p cabinet and
sensitive parts like foil keyboards, windows etc.. In comparison to conventional Ex p- sys-
tems, the FS870S requires a much lower cabinet pressure to achieve a comparable flow
rate. (Example: A reduction of the cabinet pressure by 5 mbar leads to 50 kg / m² de-
creased load at the cabinet walls).

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2.4.5 Continuous flow
The control unit FS 850S incorporates the operation mode „continuous flow“. This operation
mode is necessary, for example if an analyzer produces an explosive atmosphere inside
the enclosure (containment system). The operation mode continuous flow flushes the en-
closure permanently. After the (pre-) purging procedure (purging process) a set-point flow
rate is adjusted during normal operation. A flow rate minimum will be monitored also.
This system design allows a simultaneous PID- control of cabinet pressure and flow rate
and opens new possibilities within the construction of pressurized enclosure systems and
applications.
In operation mode "continuous flow" the FS870S is capable to lower the flow rate from a
high value during purging to a low value during normal operation at a constant, low cabinet
pressure level. (Example: 3 liters/sec. to 0.3 liters/sec. decrease without pressure variation)
Figure 5: time diagram
2.4.6 F870S - Application using „Containment Systems “
„Containment Systems“ are defined as parts of a device within a pressurized enclosure,
which could emit combustible gas (or occasionally an explosive environment: zone 1, ex-
plosive mixture) from within the enclosure.
In order to receive an Ex p-System including a „Containment System“, which is failsafe ac-
cording EN 60079-2, with the attribute 'no emission', the following conditions must be met:
1. The flammable substance inside the containment system is in the gas or vapor phase
when operating between the specified temperature limits
2. The minimum pressure specified for pressurized enclosure is at least 50 Pa higher than
the maximum pressure specified for the containment system
3. An automatic safety device initiates, if the pressure difference falls below 50 Pa.
This automatic safety device can be activated by a difference pressure switch, looped into
the external alarm loop (terminal 5/6 on FS870S). If an alarm occurs on this loop, the con-
trol device FS870S will turn off the ignition-capable device immediately. After alarm cancel-
ing the control device FS870S starts operation automatically with the purging procedure.
The external alarm loop is made by a normaly closed connection method.