Pentair F783E User manual

F783E Ex‐ia
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Operang Manual

F783E Ex‐ia
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29/01/2021
We reserve the right to make technical changes without notice.
Technische Anderungen vorbehalten.
Sous reserve de modification techniques.
© Pentair Flow Technologies Pacific Pty. Ltd 2018
Operang Manual
Document Name F783E Ex‐ia Intrinsically Safe
Operang manual
Document Number 00‐ISN‐203
Version B
Date 29/01/2021
Date Change
25/09/2018 New release
29/01/2021 Added ATEX approvals
Rev.
A
B
CHANGE LOG
DOCUMENT CONTROL

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CONTENTS
1. OPERATING INSTRUCTIONS ........................................................................................................................ 6
2. AUTHORISED USE ........................................................................................................................ 7
2.1 Export Restricons ......................................................................................................... 7
3. BASIC SAFETY INSTRUCTIONS ........................................................................................................................ 8
4. GENERAL INFORMATION ...................................................................................................................... 10
4.1. Contact address............................................................................................................ 10
4.2. Warranty ...................................................................................................................... 10
4.3. informaon on the internet ......................................................................................... 10
5. CERTIFICATION DETAILS [START OF CONTROLLED AREA]
5.1 IECEx ...................................................................................................................... 11
5.2 ATEX ...................................................................................................................... 11
5.3 Condions of Cerficate .............................................................................................. 12
[END OF CONTROLLED AREA]
6. SYSTEM DESCRIPTION ...................................................................................................................... 14
6.1. Intended applicaon area ............................................................................................14
6.2. General descripon ...................................................................................................... 14
6.3. Funcons/opons/designs........................................................................................... 15
6.3.1 Structure of the control head ........................................................................... 15
6.3.2 Fluid diagram .................................................................................................... 16
6.3.3 Number of solenoid valves ............................................................................... 17
6.3.4 Pneumac interfaces ........................................................................................ 17
6.3.5 Manual control .................................................................................................17
6.3.6 Posion monitoring system.............................................................................. 17
7. TECHNICAL DATA ...................................................................................................................... 18
7.1. Operang condions.................................................................................................... 18
7.2. Conformity to the following standards ........................................................................ 18
7.3. Rang plate specificaons............................................................................................ 19
7.4. Pneumac data ............................................................................................................ 20
7.5. Posion system data .................................................................................................... 21
8. INSTALLATION ...................................................................................................................... 22
8.1. Safety instrucon ......................................................................................................... 22
8.2. Assembly of the control head ...................................................................................... 22
8.2.1. Mounng the base .......................................................................................... 22
8.2.1.1. Fing the control head—Linear actuator................................... 23
8.2.1.2. Limit Switch Seng ..................................................................... 23
8.2.1.3. Fing the control head—Rotary actuator.................................. 24
8.2.1.4. Limit Switch and Rotary Target Seng ....................................... 24
8.2.2. Pneumac and electrical connecons ............................................................... 24
9. OPENING AND CLOSING THE HOUSING ...................................................................................................... 27
9.1 Safety instrucons........................................................................................................ 27
9.2 Opening and closing the housing ................................................................................. 27
9.2.1 Opening the housing..................................................................................... 27
9.2.2 Closing the housing....................................................................................... 28

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10. PNEUMATIC INSTALLATION ................................................................................................................... 27
10.1. Safety instrucons ....................................................................................................... 27
10.2. Pneumac connecons of the control head................................................................ 27
10.3. Flow restricon funcon of the solenoid valve ........................................................... 28
11. ELECTRICAL INSTALLATION .................................................................................................................... 29
11.1. Electrical connecon opons ................................................................................................ 29
11.2. Electrical data ...................................................................................................................... 29
11.3. Safety instrucons ................................................................................................................ 30
11.4. Electrical installaon and start‐up......................................................................................... 31
11.4.1. Cable gland with spring terminals.................................................................. 31
12. DECOMMISSIONING ...................................................................................................................... 23
12.1. Safety instrucons ................................................................................................................. 32
12.2. Dismantling the F783E control head ..................................................................................... 32
13. DISPOSAL ...................................................................................................................... 33
CONTENTS Cont’d

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The operang instrucons describe the enre life cycle of the device. Keep these instrucons in a locaon which is easily
accessible to every user, and make these instrucons available to every new owner of the device.
The operang instrucons contain important safety informaon!
Failure to observe these instrucons may result in hazardous situaons.
• The operang instrucons must be read and understood.
WARNING!
Symbols:
Warns of an immediate danger!
• Failure to observe the warning will result in a fatal or serious injury.
DANGER!
Warns of a possible danger!
• Failure to observe this warning may result in a moderate or minor injury.
NOTE!
Warns of material damage!
• Failure to observe the warning may result in damage to the device or the equipment.
Refers to informaon in these operang instrucons or in other documentaon.
 Designates a procedure which you must carry out.
Indicates important addional informaon, ps and recommendaons.
!
Warns of a potenally dangerous situaon!
• Failure to observe the warning may result in serious injuries or death.
WARNING!
CAUTION!

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Incorrect use of the control head F783 Easymind Ex‐ia may be dangerous to people, nearby equipment and the
environment.
The control head has been designed for use as actuaon of pneumacally operated valves and / or for recording the switching
states of these.
The authorised data, the operang condions and condions of use specified in the contract documents and operang
instrucons are to be observed during use. These are described in Chapter "6. Technical Data".
In view of the large number of applicaon opons, check and, if required, test prior to installaon whether the control head is
suitable for the specific applicaon case.
If you are unsure, please contact your Pentair Flow Technologies Pacific Pty. Ltd contact.
The device may be used only in connecon with third‐party devices and components which have been recommended or
approved by Pentair Flow Technologies Pacific Pty. Ltd.
Any unauthorized reconstrucons and changes to the control head are prohibited for safety reasons.
Correct transportaon, correct storage and installaon as well as careful operaon and maintenance are essenal for reliable
and problem‐free operaon.
For connecng the control head, use line installaons that do not cause any mechanical stresses.
Use the device only as intended.
If exporng the system/device, observe any exisng restricons.

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These safety instrucons do not make allowance for any:
Conngencies and events which may arise during assembly, operaon, and maintenance of the devices.
Local safety regulaons ‐the operator is responsible for observing these regulaons, also in relaon to the installaon
personnel.
Danger ‐high pressure!
Before loosening lines and valves, turn offthe pressure and vent the lines.
Danger of explosion when used in explosive atmospheres.
Opening the control top in an explosive atmosphere is only allowed in a non‐energised state
Use only cables and cable glands which have been approved for the respecve applicaon area and which have been installed
according to the respecve installaon instrucons. Do not expose the device to any mechanical or thermal loads exceeding
that described in the operang instrucons
DANGER!
Warning ‐Risk of electric shock!
Before reaching into the system switch offthe power supply and secure it to prevent restarng!
Observe applicable accident prevenon and safety regulaons for electrical equipment!
General hazardous situaons.
To prevent injuries:
Ensure that the system cannot be acvated unintenonally.
Installaon and maintenance work, as well as operator control acons may be carried out by authorised and qualified
technicians only and with the appropriate tools.
Do not make any unauthorized internal or external changes to the device!
Aer an interrupon in the electrical or pneumac supply, ensure that the process is restarted in a defined or controlled
manner.
The device may be installed and operated only when in perfect condion and in consideraon of the operang instrucons.
The general rules of technology apply to applicaon planning and operaon of the device.
WARNING!

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Electrostac sensive components
 The device contains electronic components which react sensively to electrostac discharge (ESD). Contact with
electrostacally charged persons or objects may be hazardous to these components. In the worst case scenario, they will be
destroyed immediately or will fail aer start‐up.
 Observe the requirements in accordance with EN 61340‐5‐1 to minimize or avoid the possibility of damage caused by
sudden electrostac discharge!
 Also ensure that you do not touch electronic components when the supply voltage is on!
Risk of damage to property
 Do not connect any mechanically rigid connecon parts, in parcular those with long lever arms, as such connecons could
generate torques that might damage the control head.
 Do not supply the medium connecons of the system with liquids or aggressive or flammable media!
 Do not subject the housing to mechanical loads (e.g. by placing objects on it or standing on it).
 Do not make any external changes to the housings of the device. Do not paint housing parts or screws.
 Only use compable cleaning agents (e.g. isopropanol up to 70%) for cleaning the securely closed control head and always
rinse thoroughly with clean water.
Control head F783E Ex‐ia was developed with due consideraon given to accepted safety rules and is state‐of‐the‐
art. Nevertheless, dangerous situaons may occur.
!
NOTE!
NOTE!

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Check immediately upon receipt of the consignment that the contents are not damaged and that the type and scope agree with
the delivery note and packing list.
If there are any discrepancies, please contact us immediately.
Pentair Flow Technologies Pacific Pty. Ltd
12‐14 Kaimiro St
Hamilton 3200
T: [phone]
F: [phone]
E: Email: Pacifi[e-mail]
Website: hp://foodandbeverage.pentair.com
Please refer to our general terms of sales and business.
The warranty is only valid if the control head is used as intended in accordance with the specified applicaon condions
The warranty extends only to defects in the control head F783E Ex-ia and its components.
We accept no liability for any kind of collateral damage which could occur due to failure or malfunction of the device
!
The operang instrucons and data sheets for F783E control top can be found on the Internet at:
hp://foodandbeverage.pentair.com

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Pentair Flow Technologies Pacific Pty. Ltd
2. Model : F783E Ex‐ia
3. Cerficate Number : IECEx ITA 11.0016X
4. Ex. Marking Code : Ex ia IIB T5 Ga IP65
:Ex ia IIC T5 Gb IP65
: Ex ia IIIC T90°C Da IP65
5. Rangs : IP65, 0°C ≤Tamb ≤40°C
6. Standards : IEC 60079‐0:2011 Ed. 6
IEC 60079‐11:2011 Ed. 6
Pentair Flow Technologies Pacific Pty. Ltd
2. Model : F783E Ex‐ia
3. Cerficate Number : TÜV 16 ATEX 7985X
4. Ex. Marking Code : II 1G Ex ia IIB T5 Ga
: II 2G Ex ia IIC T5 Gb
:II 1D Ex ia IIIC T90°C IP65 Da
5. Rangs : IP65, 0°C ≤Tamb ≤40°C
6. Standards : EN 60079‐0:2012/A11:2013
: IEC 60079‐11:2012

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 It is a condition of safe use that the apparatus must be mounted so that there is a low risk of
mechanical damage.
 The Valve Control Top F783E Ex-ia version may only be used as explosion safe after proper
installation to the process equipment (e.g. actuator) either directly or via. a suitable mounting
adaptor so that an ingress protection degree to a minimum of IP65 has been achieved.
 The equipment is to be cleaned with a damp cloth to ensure the minimization of electrostatic charge
build up.
 The equipment is not to be mounted in direct sunlight
 It is up to the user to provide correct barrier components in accordance with the guidelines in this
manual
 The maximum ambient temperature the intrinsically safe version of the equipment used in Group
IIIC applications may be increased to 50°C, in which case the temperature classification of T100°C
applies

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The control head F783E Ex‐ia has been designed for use as actuaon of pneumacally operated process valves and / or for
recording the switching states of these.
The control head F783E Ex‐ia is used for actuang pneumacally operated hygienic process valves.
For process valve actuaon, the control head can be equipped with a single 2/5 solenoid valve.
For the recording and feedback of the process valve switching posions to a higher‐level control, the control head has been
equipped with two posion feedback switches. These are NAMUR style 2‐wire inducve proximity switches.
The F783E Ex‐ia control head mounts directly on standard Pentair actuators of figure number F257 and F272S. This produces an
integrated, compact and decentralized system of actuaon, valve funcon and feedback. The following advantages over
centralised soluons working with valve clusters are achieved:
 low installaon expenditure
 easy start‐up
 shorter switching mes and less air consumpon due to shorter distances between the pilot valve and the
process valve.
There is a wide range of mounng opons available for many other brand actuators in the hygienic food and beverage industry,
as well as common industrial actuators. Please consult a customer services representave for more details on mounng opons
available.

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Fig 1: Structure of the control top

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Control head F783E Ex‐ia—fluid diagram (with restricon capability for solenoid valve)
Fig 2: Pneumac circuit for SMC SYJ5315 air switch as installed in the F783E Ex‐ia control head

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The F783E Ex‐ia control head for process and buerfly valves has been designed for single‐acng and double‐acng valve
actuators as well as for double seat and mul‐posion valves using a single solenoid valve.
The air switch is a 5/2 type, with common exhaust. Flow restrictors are installed in the exhaust line of both ports, meaning the
operang speed of the actuator can be controlled in both direcons
Intake & exhaust air connecons: 6.0mm “One Touch” push in air fings
Working connecons: 6.0mm “One Touch” push in air fings or internal porng opon when fied to the
F257 type actuator (for ¼ turn operaon) Integrated flow regulator in the air switch exhaust
air ports
The pilot solenoid valve is provided with a push buon to operate the pilot valve manually.
The SMC SYJ5153 air switching valve has also a manual operator, which is parally obscured by the pilot valve, so should not
be used.
The switching posions of the actuator are reported to the control system by feedback signals from two switches mounted on
switch pillars within the housing.
The height and orientaon of these switches can be adjusted to accommodate the stroke length of all F257 and F272S type
actuators. This is achieved by adjusng the screw on the switch pillar to raise or lower the switch and turning the switch
around in the retaining clip.
The ¼ turn actuators use a special adjustable target set to accommodate target rotaon between 0 and 180°.

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Risk of injury from overheang of the control head.
Ambient temperature:
Ex‐ia version: 0° ... +40 °C (Max. 95% humidity; non‐condensing)
General hazardous situaons.
To prevent injuries:
 Ensure that the system cannot be acvated unintenonally.
 Installaon and maintenance work, as well as operator control acons may be carried out by authorised and qualified
technicians only and with the appropriate tools.
 Do not make any unauthorized internal or external changes to the device!
 Aer an interrupon in the electrical or pneumac supply, ensure that the process is restarted in a defined or controlled
manner.
 The device may be installed and operated only when in perfect condion and in consideraon of the operang
instrucons.
 The general rules of technology apply to applicaon planning and operaon of the device.
Degree of protecon:
Ex‐ia version:
IP65 according to EN 60529
(only if cables, plugs and sockets have been connected correctly, the cap has been sealed correctly and the adaptaon to the
process valve was done correctly)
WARNING!
Danger of explosion when used in explosive atmospheres.
Opening the control top in an explosive atmosphere is only allowed in a non‐energised state
Use only cables and cable glands which have been approved for the respecve applicaon area and which have been installed
according to the respecve installaon instrucons. Do not expose the device to any mechanical or thermal loads exceeding
that described in the operang instrucons
DANGER!
 Certain variants only of the control head F783 EASYMIND Ex‐ia comply with the EC direcves according to the EC
Declaraon of Conformity. The applied standards which are used to demonstrate compliance with the Direcves are
listed in the EC Declaraon of Conformity. This may be requested from Pentair Flow Technologies Pacific Pty. Ltd.
The specificaons on the respecve rang plate apply to the respecve control head. The symbols on the rang
plate indicate the applicable direcves or approvals:

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Fig. 3: Dimensional drawing – Ex‐ia version
Weight: approx. 0.7 kg
Housing material: exterior: PA66 + PA6, TSC10/4, EC
inside: ABS
Sealing material: exterior: EPDM (O‐rings)
Santoprene (gasket)
inside: NBR

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Use clean dry air
Do not use compressed air which contains chemicals, synthec oils containing organic solvents, salts or corrosive gases, etc., as
this can cause damage or malfuncon.
WARNING!
Install air filter
Install air filters close to valves at their upstream side. A filtraon degree of 5 μm or less should be selected.
Install an air dryer, aer cooler or Drain Catch (water separator) etc.
Air that includes excessive moisture may cause malfuncon of valves and other pneumac equipment. To prevent this, install
an air dryer, aer‐cooler, or water separator, etc.
If excessive carbon dust is generated
Eliminate it by installing mist separators at the upstream side of valves. If excessive carbon dust is generated by the
compressor, it may adhere to the inside of valves and cause malfuncon.
CAUTION!
Control medium: Air, neutral gases
Quality classes in accordance with DIN ISO 8573‐1
(5µmfilter recommended)
Dust content Quality class 7: max. parcle size 40µm
max.parcle density 10mg/m³
Water content Quality class 3: max. pressure dew point –20°C or min. 10°C below the lowest operang temperature
Oil content Quality class X: max. 25mg/m³
Temperature range
of compressed air: ‐10 … +50° (non‐condensing)
Pressure range: 3.0 … 7 bar (minimum air pressure of system may be higher than minimum pressure to
operate solenoid, as required by product condions, valve or actuator)
Connecons: 6mm “One touch” push‐in fings, collets and O‐rings are replaceable
The exhaust flow rates for both ports can be controlled separately to control the actuator speed in both energising and de‐
energising direcons
Fig. 5: Solenoid operated air switch