KSB AMTROBOX Series Configuration guide

Type Series Booklet
8525.12/5--10 AMTROBOX ATEX for zone 22 (Dust)
Limit switch box
for pneumatic actuators
ACTAIR and DYNACTAIR,
and manual actuators MR
On/Off position detection
ATEX for zone 22 (Dust)
Applications
•Explosive atmospheres.
•All sectors of Water, Energy and Industry markets.
General information
•AMTROBOX ATEX for zone 22 (Dust) is specially designed
for the ACTAIR series of double acting pneumatic actuators
and DYNACTAIR series of spring return pneumatic
actuators, and the manual actuators MR.
•This box integrates the On/Off position detection function by
microswitches (IP 67 and gold plated) in standard.
•Its adjustable cams device for position detection makes it
very reliable and easy to adjust.
•The electrical connections are made by packing--gland or
debrochable connector.
•It is equipped with a bicolor visual pointer large size allowing
the visualisation of the quater--turn valve position.
•Use is restricted to zone 22: potentially explosible
atmosphere due to infrequently or over short periods
presence of flammable dusts.
ATEX
II 3 D 85°C
•AMTROBOX ATEX Dust is marked:
IP 67
Protection
•Protection level: IP 67
•Its cataphoresis coating ensures a good resistance in
corrosive environments.
Temperature range
•From –20°to +80°C
Materials
•Cover: Aluminium
•Base : Aluminium
Standard variantes
•Low cover version: X1149 and XA 1149
•High cover version: X1140 and XA 1140
This leaflet is also to be used as a start--up guide ref. 42 409 826

AMTROBOX ATEX for zone 22 (Dust)
2
Non return valve
High cover version
Boxes X1140 and XA1140
Low cover version
Boxes X1149 and XA1149
Microswitches fitted on metallic sheet
Adjustable cams
Printed circuit board
with microswitches
External earth terminal
Electric packling--
gland or Binder
connector (option)

AMTROBOX ATEX for zone 22 (Dust)
3
Contents
Page
General technical data
-- Common parts 4
-- General technical characteristics 5
-- Overall dimensions 5
Position detection by microswitches on printed circuit board
Boxes X1140 and X1149
-- Description 6
-- Technical characteristics of proximity detectors, wiring diagram, adjustment of cams 7
Position detection by microswitches on metallic plate
Boxes XA1140 and XA1149
-- Description 8
Commissioning
-- W a r n i n g 9
-- Electric and pneumatic connections 9
-- Open/close position detection adjustment 10
Declaration of conformity 11

AMTROBOX ATEX for zone 22 (Dust)
4
Common parts
629
Q412.1
970.1
900.1
554.1
Q410.1
314
932.1 890
81--84.1
626
970.2
970.3
903.1
903.3
412.2
626
Q412.1
970.1
210
900.1
554.1
Q410.1
629
970.2
81--84.1
932.1
314
970.3
903.1
903.3
412.2
160 99.14 486.1 412.6 81--2.1 900.4
900.5
890
Q410.2
412.2
747
486.2 486.3
81--18
900.9
Low cover version
Boxes X1149 and XA1149
High cover version
Boxes X1140 and XA1140
160 629 626 412.1 Q 81--2.1 900.4
900.5 410.1
890
Q410.2
210
412.2
747
900.9
81--18
486.2 486.3
QParts included in the spare parts kit

AMTROBOX ATEX for zone 22 (Dust)
5
Common parts
Item Designation Materials
160 Cover Light alloy with cataphoresis coating
210 Shaft Acetal + 30% fibreglass
314 Thrust washer 304 type stainless steel
410.1 QCover gasket Nitrile
410.2 QBase plate cover Nitrile
412.1 QO--Ring Nitrile
412.2 O--Ring Nitrile
412.6 Rope (High cover version) Nitrile
486.1 Ball (High cover version) Stainless steel
486.2 Ball Steel
486.3 Ball Steel
554.1 Plain washer A2--70 stainless steel
626 Sight glass Transparent polycarbonate
629 Pointer Polyamide
747 Non return valve sub--assembly -- -- -- -- -- -- --
81--18 Faston snap -- -- -- -- -- -- --
81--2.1 Ground wire Copper
81--84.1 Wiring diagram -- -- -- -- -- -- --
890 Base Light alloy with cataphoresis coating
900.1 Cheese--head screw A2--70 stainless steel
900.4 Sel--cutting screw Zinc coated steel cl.8--8
900.5 Cheese--head screw Stainless steel
900.9 Pozidriv screw Zinc coated steel cl.8--8
903.1 1/4’’ Gas threaded plug Polyamide 6--6
903.3 Bored plug -- -- -- -- -- -- --
932.1 Spring retaining ring Steel
970.1 Identity plate Adhesive polyester
970.2 Instruction notice Untearable paper
970.3 “No Air” sticker Adhesive polyester
QParts included in the spare parts kit
Technical data
Environment
Housing material: molded light alloy AS9U3
Coating: black cataphoresis
Protection level: IP 67 with output via packing--gland, IP 65 with output via 12--pin connector
Resistance to impacts: IK 10
Resistance to vibrations: according to IEC 60068--2--6 Test Fc. Frequency: 5 to 100 Hz. Displacement: ±1 mm. Acceleration: ±0,7 g
Electromagnetic compatibility: EN 61000--6--2; EN 61000--6--4
Test standards: EN 55011; EN 61000--4--2; EN 61000--4--3; EN 61000--4--4; EN 61000--4--5; EN 61000--4--6
Working temperature from -- 20 °Cupto+80°C
Electric connection
Two packing--gland M 20 plastic (for wire dia. 6 to 12) or metallic (for wire dia. 7 to 12) or one Binder connector (only for ACTAIR and
DYNACTAIR).
Overall dimensions (mm) and weight (kg)
78
209
209
69 50
78
F
View from F
FView from F
High cover version
Low cover version
Weight: 1.5 kg
Weight: 1.1 kg
144
58

AMTROBOX ATEX for zone 22 (Dust)
6
Position detection by microswitches on printed circuit board --
Boxes X 1140 and X 1149
•Detection by 2 microswitches: 1 sur opening and 1 on closing, changeover function,trigger action adjustable by cam on each
microswitch.
81--2.3 82--2.1 Q62--2 Q900.2 554.2 191.2
970.7
970.6 970.5 82--2.1 Q
62--2 Q
554.2
900.3
191.2
191.1 900.2 554.2
970.5
AMTROBOX X 1149 AMTROBOX X 1140
Item Designation Materials
191.1 Support of printed circuit board (AMTROBOX X1140) Acetal
191.2 Support of printed circuit board Polyamide 6--6
554.2 Plain washer Stainless steel
62--2 Q3 cams sub--assembly Acetal + 30% fibreglass
81--2.3 Round cable terminal (AMTROBOX X1149) -- -- -- -- -- -- -- --
82--2.1 QPrinted circuit board with 2 microswitches -- -- -- -- -- -- -- --
900.2 Cheese--head screw A2--70 stainless steel
900.3 Cheese--head screw A2--70 stainless steel
970.5 Item sticker Adhesive aluminium
970.6 Item sticker Adhesive aluminium
970.7 Item sticker Adhesive aluminium
QParts included in the spare parts kit

AMTROBOX ATEX for zone 22 (Dust)
7
Microswitches characteristics
•Manufacturer: CROUZET
•Material: Housing Polyester UL94V0
Button Polyester
Contact Ag/Ni gold plated
Membrane Silicone
•Rating: Cut--off capacity 6 A under 24 VDC and 250 VAC
•Life: Electrical under I = 5 A 7 x 104operating cycles
under I = 1 A 3 x 105operating cycles
under I = 0.2 A 106operating cycles
Mechanical 2 x 106operating cycles
•Resistance to vibrations: CEI 60068--2--6 standard / 3 axis / 50g from 10 to 500 Hz
•Electromagnetic compatibility: EN 61000--6--2; EN 61000--6--4
•Electric connection: Welded on circuit
•Protection level IP 67
I
(
A
)
Alternating current (AC)
I
(
A
)
24 V 48 V 127 V 230 V 380 V
AC--12 66665
AC--13 21,5 1 1 0,5
AC--14 ≤72 VA
AC--15 21,5 1 1 0,5
I
(
A
)
Direct current (DC)
I(
A
)24 V 48 V 115 V 230 V
DC--12 6 2 0,4 0,2
DC--13 3 1 0,2 0,1
DC--14 0,6 0,15 0,02 0,01
I (A) : Allowable maximum intensity (A)
According to IEC 60947--5--1 standard:
AC--12: Control of resistive loads and solid state loads with isolation by optocouplers
AC--13: Control of solid state loads with transformer isolation
AC--14: Control of small electromagnetic loads (≤72 VA)
AC--15: Control of electromagnetic loads (≥72 VA)
DC--12: Control of resistive loads and solid state loads with isolation by optocouplers
DC--13: Control of electromagnets
DC--14: Control of electromagnetic loads having economy resistors in circuit
This microswitch is designed to operate indifferently on circuits of bi--level type: low intensity (1 mA, 4 V minimum) or medium
intensity (6 A maximum). However, a microswitch must change over only one and same type of PCB during its all use.

AMTROBOX ATEX for zone 22 (Dust)
8
Option : Intermediate detection position by third microswitch on printed circuit card
Box ref. X1140
One third switch, identical to the two other ones, can be added to detect any point of the valve travel (adjustable on 90°).
Closed
SWC
Black
Open
SWO
Blue
123456
C
NC
NO
C
NC
NO
Internal wiring diagram : Connection by packing--gland
Box X1149 Box X1140
Connection diagram by Binder connector
Position detection by microswitches fitted on metallic sheet
AMTROBOX XA1140 and XA1149
Various types of microswitches or inductive proximity detectors can be fitted on a metallic sheet in the AMTROBOX for extreme
positions indication (opening and closing).
Connection is done via:
-- two packing--gland plasti or metallic,
-- one debrochable connector (mounting on ACTAIR and DYNACTAIR).
In this version, the box can be equipped:
-- either with one position detector on closing,
-- or with one position detector on opening,
-- or with one detector on closing and one detector on opening.

AMTROBOX ATEX for zone 22 (Dust)
9
Commissioning
The installation and start--up of the electro--pneumatic actuators must be according to the best safety practices and
mainly:
Piping:
Starting--up of a new installation requires cleaning the piping by air before connection to the actuator. This will remove any
impurities impossible to eliminate during construction (fillings, flux, paste, PTFE, etc.)
Electric wiring:
-- The electric components are “CE” marked in accordance with 89/336/EEC and 94/9/EC european directives.
-- The electric supply voltage and the electric values of the signals must be checked before connecting the components.
-- An external earth terminal allows grounding of the metal parts of the control box.
Never uncouple or disassemble the AMTROBOX or its accessories when pressurized or energized.
Make sure to disconnect electrical cables before dismantling.
During the mounting and dismantling of the boxes, take care the correct installation of all sealing gaskets.
Quality and integrity depends of this correct installation.
During workshop or on- site checking, the valve associated with the actuator and its AMTRONIC EEx-ia box can
be operated from full open to full closed position.
This operation may be of a high significant risk of personnal injury if the safety steps required are not taken to
prevent access between the disc and the seat.
CAUTION !
WARNING
Never exceed the values stipulated in this leaflet!
The dust thickness on the box must not exceed 5 mm.
Do not open the box in dust atmosphere.
Do not clean using a compressed air gun to avoid sending dust in the atmosphere.
To remove dust, use a duster a little bit damp.
Electric connections
The electric connection is obtained via 2 packing--gland M20, plastic (for wire dia. 6 to 12) or stainless steel (for wire dia. 7 to 12) or a
Binder connector.
The good tightness of the box depends on cable selection and the tightening level of the packing--gland.
Pneumatic connection
The pneumatic connection is done directly on the actuator or on the solenoid valve fittedon the actuator.
Direct connection Connection on solenoid valve

AMTROBOX ATEX for zone 22 (Dust)
10
Open/close position detection adjustment
The limit switches or detectors are factory adjusted.
It is not necessary to re--adjust before valve mounting on site.
Nevertheless, if you wish to re--adjust after a maintenance operation, proceed as follows:
-- Remove the cover of the box.
-- Put the disc in extreme position (opening or closing).
-- Unscrew the two metal screws one turn.
-- Adjust triggering of the required detector by turning the coloured screw corresponding to the colour of the cam to adjust.
-- Proceed in the same manner with the opposite switch.
-- Each cam is adjusted independently and the adjustment does not affect in any way the adjustment of the other cam.
-- When adjustments are completed, slightly tighten the two metal screws to prevent adjustments being changed.
-- Replace the cover of the box.
.
1 -- Unscrew the metallic screws 2 -- Adjust the cams 3 -- Scew the metallic screws