REMBE EXKOP Mini User manual

page 1 of 25 GBB-EXKOM-08157/2
EXKOP®MINI
Explosion Isolation System

page 2 of 25 GBB-EXKOM-08157/2
Table of contents
1.Operating and safety instructions
1.1 Warning instructions
1.2 Application limitation
2.Description
2.1 General
2.2 Scope of EXKOP
®MINI
System
2.3 Function
3.The QV II Quench Valve
3.1 Installation notes
3.2 Maintenance notes
3.3 Technical data of QV II Quench Valve
4.The EXKOP
®MINI
Safety Controller
4.1 Installation notes
4.2 Description of function
4.2.1 Input modules
4.2.2 Output modules
4.2.3 Internal data storage
4.3 EXKOP
®MINI
Controller – function
4.3.1 EXKOP
®MINI
Controller – operation and wiring
4.3.2 Output modules of QV II Quench Valve - wiring
4.3.3 EXKOP
®MINI
Controller – initializing
5.Function check
6.Transformer isolated barrier KFD2-ST2-Ex1.LB
7.Technical data
Annex:
Log Book (copying collecting main)
QV II Quench Valve Drawing-No.: 05-08-23/2
Installation Instruction:
EXKOP
®MINI
Safety Controller
wiring diagram: 05-11-09/0
05-11-10/4
10-02-39/0

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1.0 Operating and safety instructions
This manual must be read carefully and all instructions must be followed
before starting up the EXKOP
®MINI
safety system.
Any modification or careless installation of the components can result in
failure of the entire system. This can result in explosion propagation which can
cause the destruction of the equipment. The devastating effects of such an
explosion can also endanger human life.
The operating diary which contains the log of all events happened and the access
code for the EXKOP
®MINI
Safety Controller as well, must be kept by the designated
plant safety representative.
The monthly test function (see section 6) must be carried out by the designated plant
safety representative and documented in the operating diary.
1.1 Safety instructions
The pressurization of the air tank of an uninstalled QV II Quench Valve is forbidden
because accidental activation of the QV II Quench Valve could lead to injuries in the
closing area.
Before opening the EXKOP
®MINI
Safety Controller housing you have to make sure
that the power is switched off. Note: Disconnecting of the power system leads to an
activation of the QV II Quench Valve!
Works on the electrical system must be performed by a qualified person.
The re-setting of the EXKOP
®
system after an activation must be carried out
very carefully to avoid the danger of secondary explosions.
If the explosion protection system includes bursting discs, make sure that
personnel presence in the venting area of bursting discs is forbidden.
1.2 Application limitation
The EXKOP
®MINI
explosion isolation system is conceived and certificated in
according to the following application limitations:
Dust: all organic and chemical dusts
K
st-max
-Value: < = 200 bar x m / s
P
max
: < = 10 bar
Pressure: max. reduced explosion pressure < =1,0 bar

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2.0 Description
2.1 General
Despite the high safety standards of modern plant concepts, the risk of a dust
explosion still continues to be underestimated. In addition, modern production
methods have considerably increased the proportion of fine dusts and also the risk of
an explosion.
The explosion pressure and flame must be vented to the outside. This is not always
possible inside buildings, but can only be realized with considerable physical
modification and large expenditure.
The REMBE
®
Q-Rohr
®
offers a flameless explosion venting device with dust
retention allowing safe explosion venting indoors.
The EXKOP
®MINI
explosion isolation system together with explosion venting offers
effective protection for plant components connected by product or aspiration pipes,
where a risk of explosion propagation exists.
The explosion venting devices Q-Rohr
®
or REMBE
®
triple section bursting discs
vents immediately in case of an explosion and activates EXKOP
®MINI
Safety
Controller. The signal will be identified by the transformer isolated barrier KFD2-
ST2-Ex1.LB and triggers the EXKOP
®MINI
Safety Controller.
The EXKOP
®
Safety Controller transmits a closing signal to the QV II Quench
Valve. This isolates the pipe from the oncoming pressure wave and the flame by
means of a pneumatic actuation via fast acting solenoid valves within a few
milliseconds, thus preventing the explosion from spreading out to other plant
sections.

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2.2 Scope of EXKOP
®MINI
System
The EXKOP
®MINI
System normally consists of the following components:
- Explosion venting by Q-Rohr
®
or REMBE
®
triple section bursting discs with
KFD2-ST2-Ex1.LB electronic display electronic
- EXKOP
®MINI
Safety Controller with dynamic self monitoring function and internal
data memory as well as an alarm-control
- QV II Quench Valve with high speed solenoid valves and integrated air tank
•
Q-Rohr
®
• Bursting disc with
signaling unit
• Infrared detector
• Emergency switch
• QV Quench Valves
• Flash light with horn
• plant control
• alert systems, etc.
Output modules
Input modules
bbbbbbbbbbb
EXKOP
®M
INI

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2.3 Function
Normal production sequence
The QV II Quench Valve (D) is open to the full
pipe diameter with no pressure drop across the
valve.
QV II Quench Valve, REMBE
®
bursting discs
and Q-Rohr
®
(B) ensure secondary protection
in the event of a dust explosion without
interrupting any production sequence.
During explosion
Vessel (A) is vented via the explosion venting
action of the REMBE
®
bursting disc or with
flame suppression with the Q-Rohr
®
(B). Thus
the majority of the pressure wave and flame
front developed during the explosion is
reduced.
The explosion venting Q-Rohr
®
(B) or bursting
disc within the system immediately sends a
signal to the EXKOP
®MINI
Safety Controller (C)
which immediately initiates closure of the QV
Quench Valve (D).
During closure, a build-up of product occurs in
front of the QV II Quench Valve (D). This
causes a displacement of oxygen, so that the
dust-air concentration is moved out of the
explosive range and ignition capability is
reduced.
The explosion is completely isolated by the
closure of the QV II Quench Valve.
EXKOP
Safety Controller
EXKOP
Safety Controller
EXKOP
Safety Controller
B
D
A
C
B
D
A
C
B
D
A
C

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3. The QV II Quench Valve
Note:
It is important that all information contained in this manual will be followed
exactly in order to ensure a proper function of the valve.
3.1 Installation notes
The QV II Quench Valve must be installed in the connecting pipes between the
vessels to be isolated. The distances shown in the table below must be followed
exactly.
This minimum distance is necessary to ensure proper isolation in the event of an
explosion, but also maximum distance must not be exceeded, otherwise a secondary
explosion up to detonation in the pipe is possible.
Nominal diameter Quench Valve Distance to protected vessel
DN 80 - DN 200 6m (19.7 feet) to 7m (23.0 feet)
DN 250 7m (23.0 feet) to 8m (26.3 feet)
(Exact values depend on the application!)
The connection flanges of the pipe (up to DN 200) shall be identical with the
dimensions defined in DIN 2632 PN 10 (no lose flanges). For sizes DN 250 flanges
according to DIN 2576 with dimensions described in the following diagrams have to be
used. In order to ensure proper functioning of the system, a frost-free installation must
be ensured (e.g. isolation and/ or heating measures must be taken). The compressed-
air system of the plant can be used to supply air to the Quench Valve. The
compressed-air must be filtered, dry and free from oil residues.
The pressure of the air storage tank is limited by a pressure regulator at an operating
pressure of maximum 6.0 bar. The compressed-air connection is G 1/4" as standard.
In order to ensure the operation of the valve in the event of compressed-air system
failure, a check valve is integrated into the supply connection.

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Note:
The compressed-air connection must be isolated mechanically from the plant system
to prevent vibrations being transmitted to the QV II Quench Valve. A flexible hose is
recommended.
Only when the operating pressure is reached can the entire system be set to an
"armed" status by the reset button at the EXKOP
®MINI
Safety Controller. (See
section 4. The REMBE
®MINI
Safety Controller).
A pressure gauge arranged at the tank serves for visual monitoring of the available
operating pressure.
The pressure regulator and pressure switch, which settings are set at REMBE

,may
only be altered after consulting with our service department. All warranty claims
against REMBE
®
will become null and void in the event of unauthorized adjustment.
For systems operating under vacuum conditions it is necessary to arm the
EXKOP
®MINI
System before switching on the conveying system to prevent a plugging
or an excessive wear of the QV II Quench Valve.
3.2 Maintenance notes
When conducting maintenance work, the compressed-air supply must not be
interrupted.
Minor leaks at couplings will cause a loss of pressure in the tank. In the event that the
supply of plant air to the pressure tank is interrupted, the tank will maintain a safe level
of air pressure for minimum three hours.
If the supply pressure drops below 4.5 bar, the pressure switch signals a system error
which is automatically evaluated by the EXKOP
®MINI
Safety Controller; this results in
an immediate activation of the QV II Quench Valve and shutdown of the production
line.
Below this supply pressure a reliable closure of the QV II Quench Valve is no longer
ensured! In case of power failure the QV II Quench Valve will close immediately as
well (fail safe).
Note:
Before switching off the power, caution must be taken to ensure that the pinch
area of the QV II Quench Valve is clear in order to avoid injuries to personnel!

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3.3 Technical data of QV II Quench Valve
Compressed-air connection: G1/4" at pressure reducer
Compressed-air supply: Minimum 6 bar
Compressed-air monitoring: Via pressure switch at tank,
signal to EXKOP
®MINI
Safety Controller
Commissioning pressure: 5.5 bar
Minimum operating pressure: 5.0 bar
Voltage supply: 24 V DC via EXKOP
®MINI
Safety Controller (max 100 W)
4. EXKOP
®MINI
Safety Controller
4.1 Installation notes
The EXKOP
®
Safety Controller is delivered completely wired in a housing with
lockable door. The controller should be installed in an easily visible location in a dry,
heated room.
Supply voltage variations (24 VDC) in the range of +/-10 % are acceptable. Power
consumption approx. 100 W.
In the case of higher voltage supply variations or extreme transient spikes, the use of
a main filter and/or voltage stabilizer is recommended.
The connecting cables to the transformer isolated barrier KFD2-ST2-Ex1.LB are
monitored for open-circuit and short-circuit.
Faults are indicated by means of LED's cause the immediately closing of QV II
Quench Valve.
For trouble-free operation, we recommend the use of shielded cables at the inputs of
the EXKOP
®MINI
Safety Controller, since disturbing pulses can be produced in
industrial plants through the use of high-current or high-voltage cables and high
inductance or capacitance.
The maximum cable length between the EXKOP
®
Safety Controller and individual
control components (QV Quench Valve, bursting disc,
Q-Rohr
®
etc.) must not exceed 600 m.
The regulations of VDE100 (or equivalent) must be observed.

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4.2 Description of function
The parts of the EXKOP
®MINI
Safety Controller are a central processing unit (CPU)
which monitors the signals of the transformer isolated barrier
KFD-ST2-Ex1.LB and the pressure switches on the QV Quench Valves. The CPU is
running with a fail safe program and observes the signaling cables for lead breakage
and short circuit.
4.2.1 Input modules
The transformer isolated barrier KFD-ST2-Ex1.LB is used for signaling the status of
the connected bursting discs or REMBE
®
Q-Rohr
®
. Upon activation of the Q-Rohr or
other safety devices, a signal is immediately sent to the EXKOP
®MINI
Safety
Controller. The signal is subsequently evaluated and the QV II Quench Valve will be
closed immediately.
The pressure switch is arranged at the compressed-air tank of the QV II Quench
Valve to monitor the operating pressure. If the pressure should fall below the
minimum operating value, closure of the QV II Quench Valve is initiated for safety
reasons.
In addition, other signals can be sent to the EXKOP
®MINI
Safety Controller:
- Infrared and/or pressure detectors for plant monitoring purposes.
- Signals from programmable controllers and/or central monitoring systems of plant
controls.
- Fire detection or fire extinguishing systems
4.2.2 Output modules
The output modules are for the activation of the QV II Quench Valves and the relay
contacts.
This modules supply the solenoid valve at the QV II Quench Valve with power. All
signals which could be determined as failures will lead to an immediate activation of
the output modules (fail safe).
The relay contacts (K), serve for audible and visual signaling of the alarm status
(horn and flashing light). The connection of additional alarm indicators can also take
place via relay contacts. This enables a safe and controlled plant shutdown procedure
in case of an alarm.

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4.2.3 Internal data storage
A change of operating condition, faults and failures of the supply voltage are stored
internally in the EXKOP
®MINI
Safety Controller in chronological order.
The storage capacity is sufficient for storing events over a period of one year. Storage
takes place by means of ring storage, i.e. the oldest data is overwritten when the
storage unit is full.
The TEST-function, to be carried out regularly (see 6. functional test), is stored in the
storage unit. This ensures continuous registration of the operating sequences.
The data can be shown on a PC (not included in the scope of supply of the
EXKOP
®MINI
Safety Controller) or as a print-out.
In an event of explosion, the operating sequences prior to the event can be exactly
reconstructed.
4. 3 EXKOP
®MINI
Safety Controller - function
The EXKOP
®MINI
Safety Controller is operated
by one button only. Start or arm the EXKOP
®MINI
Safety Controller by pressing the RESET/TEST
button.
Different functions of the EXKOP
®MINI
Safety Controller
can be adjusted by different jumper settings. These
different functions are described below and in the
attached drawings
EXKOP
®MINI

page 12 of 25 GBB-EXKOM-08157/3
Schedule of different function
Input 14 15 16
EXKOP
®MINI
terminal X1.16 X1.17 X1.18 Function
0 0 0 2 - 2
0 0 1 2x (1 - 1)
0 1 0 2 - 1
0 1 1 1 - 2
1 0 0 1 - 1
1 0 1 2 - 2 *)
1 1 0 2 - 2 *)
1 1 1 2 - 2 *)
terminal X4.16 X4.17 X4.18 +24VDC
0 = no jumper
1 =jumper
Function 2 – 2: Both signal inputs cause closing of both QV II Quench
Valves; that means any activation signal will close both
QV II Quench Valves.
Function 2x (1 – 1): Two separate lines with one QV II Quench valve each. By
activation the bursting disc #1 the QV II Quench Valve #1
will be closed
By activation the bursting disc #2 the QV II Quench Valve
#2 will be closed
Function 2 – 1: By activation the bursting disc #1 or #2 the one connected
QV II Quench Valve will be closed
Function 1 – 2: By activation the bursting disc #1 both connected QV II
Quench Valves will be closed
Function 1 – 1: By activation the bursting disc #1 the connected QV II
Quench Valve #1 will be closed
*)
If no Function is adjusted by a jumper function 2 – 2 will be automatically activated!
By activation of the QV II Quench Valve #1 the alarm relay K1 will be activated. By
activation of the QV II Quench Valve #2 the alarm relay K2 will be activated. The
alarm relay K3 is a summary relay and will be activated at any event.

page 13 of 25 GBB-EXKOM-08157/3
4.3.1 EXKOP
®MINI
Safety Controller – operation and wiring
The EXKOP
®
Safety Controller controls the connected input and output modules
automatically. A manual handling is only necessary during the initiation and test run.
The power supply of the EXKOP
®MINI
Safety Controller must be connected to a 4-pole
terminal of the CPU-Modules at the clamp + and – with 24V direct voltage.
terminals for
- Inputs
- Outputs
+24VDC
GND
Function of LED’s on the CPU-Module DM 465
The yellow LED U indicates the power supply of in and outputs. Below a power
supply of approx. 18VDC the LED turns dark.
Note: The control modules have 16 Inputs with green LED’s and 16 Outputs with
yellow LED’s. But it will be only shown 8 In-/Outputs at the same time. Press the little
white Key at the modules to switch between:
Yellow LED S#… In-/Output 1 – 8
Yellow LED S#+1… In-/Output 9 – 16
The input status will be shown through green LED’s as follows:
Input #1 Bursting disc #1 Save status = LED on
Input #2 Pressure air QV II #1 Save status = LED on
Input #3 Bursting disc #2 Save status = LED on
Input #4 Pressure air QV II #2 Save status = LED on
Input #5 Reset key pressed = LED on
Input #14 Bypass C Jumper installed = LED on
Input #15 Bypass B Jumper installed = LED on
Input #16 Bypass A Jumper installed = LED on
24VDC
+ +
-
-
connection voltage: 24VDC
max. capacity 100W
PE
CPU 470 DM465
X1
X4
X5
X2

page 14 of 25 GBB-EXKOM-08157/3
The output status will be shown through yellow LED’s as follows:
Output #1 Control Valve QV#1 Active = LED on
Output #2 Control Valve QV#1 Active = LED on
Output #3 Air Valve QV#1 Active = LED on
Output #4 Air Valve QV#1 Active = LED on
Output #5 alarm-relay #1 Save status = LED on
Output #6 Control Valve QV#2 Active = LED on
Output #7 Control Valve QV#2 Active = LED on
Output #8 Air Valve QV#2 Active = LED on
Output #9 Air Valve QV#2 Active = LED on
Output #10 alarm-relay #2 Save status = LED on
Output #11 summary alarm-relay Save status = LED on
Unlisted In-/Outputs are not used.
Terminal 1 and 2 for the connection of the power supply voltage of in- and output are
at the junction block X1 and X2:
Terminal#1: GND
Terminal#2: +24VDC
4.3.2. Output modules QV II Quench Valve - wiring
In case of alarm or all other failure the output modules QV II Quench Valve is
activated by the CPU and isolates the pipe by means closing the QV II Quench Valve.
During normal mode the solenoid valve
of QV II Quench Valve are powered by
the EXKOP
®MINI
Safety Controller.
Also the pressure switch is controlled
by the CPU.
The terminals in the CPU of the EXKOP
®MINI
Safety Controller will be connected to
the terminals of the QV II Quench Valve
acc. following wiring diagram.
Recommend cable:
Shielded cable with cross section of 1mm
2
.
1
Valve
2Air in
V1
PE
PPressure
4switch
5
Valve
6Air out
V2

page 15 of 25 GBB-EXKOM-08157/3
4.3.3 EXKOP
®MINI
Safety Controller – initialization
After switching on the operating voltage, the EXKOP
®MINI
Safety Controller conducts a
self test. All internal and external signals will be checked. If LED’s of the KFD2-ST2-
Ex2.LB-Electronic lights “green” and pressure inside the tank of QV II Quench Valve
is built up, the EXKOP
®MINI
Safety Controller will be armed by pressing the Reset
button.
Now the EXKOP
®MINI
Safety Controller is armed.
5.0 Function check
The EXKOP
®MINI
System has to be checked monthly by using the test button.
Before carrying out the system check the plant safety representative must
ensure that no danger will occur during this procedure.
The test function simulates an activation of the EXKOP
®MINI
Safety Controller.
Therefore press the reset key for 5 seconds. This will cause all Quench Valves
connected to the controller to be closed immediately. The tests have to be
documented in the operating diary. Also all connected systems like process plant
computers, fire alarms or other safety devices will be activated.
According to the quantity of the connected Quench Valves following messages will be
dedicated: „Failure air QV X“ by LED’s. Until the air supply will not feed the air tanks to
the minimum pressure this status will not be changed.
After filling up all pressure air tanks the EXKOP
®MINI
Safety Controller can be armed
by the RESET key again.
The system check must be documented in the log book.

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6. Transformer isolated barrier KFD2-ST2-Ex1.LB
Monitoring of Q-Rohr
®
and triple section bursting discs or other indicators is carried
out by the transformer isolated barrier KFD2-ST2-Ex1.LB electronic.
Three integrated LED's serve for status indication:
Green LED lights: Power supply is connected to the relay = no fault
Yellow LED lights: Output signal = sensor ok = save status
Yellow LED dark: Sensor or bursting disc not ok = alarm status
Red LED flashing: Broken cable to sensor = failure = alarm status
The KFD2-ST2-Ex1.LB electronic is supplied via the
EXKOP
®MINI
Safety Controller. The signal cables are
monitored for lead breakage and short-circuit.
The no-fault-status of the signaling unit is indicated
by the Yellow LED. This also ensures that also
bursting discs, Q-Rohr
®
and other protective
units are reliably monitored for their operating
condition in a central location. Upon activation
of the bursting disc signaling unit, an alarm is
generated (Yellow LED dark).
The EXKOP
®MINI
Safety Controller detects this condition and immediately activates
the QV II Quench Valve as well as alarm. The EXKOP
®MINI
Safety Controller can
only be armed when the signaling unit has no fault status: Yellow LED light is on.
The connection of power supply voltage of the input modules is already wired.
The signaling unit of the bursting disc, Q-Rohr
®
or other signaling units (blue cable)
has to be connected to the junction box as follows:
Junction box near the bursting disc and/or the Q-Rohr
®
500Ω10kΩ
PE 1 2 3 4
EXKOP
®MINI
bursting disc /
Q-Rohr
®
, Q-Box II
KFD2-Relay

page 17 of 25 GBB-EXKOM-08157/3
I
S1: output 7 blocked
S2: output. 9 parallel output 7
S3: input w. LB/SC supervision
II
S1: output 7 inverted
S2: LB/SC Supervision
S3: input without LB/SC
The input of the KFD2-ST2-Ex1.LB electronic has to be connected to the terminals
#1 and #2 in the junction box and in the EXKOP
®MINI
Safety Controller at the
terminals according to the terminal diagram. The signaling unit of the bursting disc or
the Q-Rohr
®
has to be connected to the terminals #3 and #4 in the junction box.
500Ω10kΩ
1 2 3
yel red green
Bursting disc, …
I II
S1
S2
S3
7 8 9
output 7 signal
13 14 15
20 – 30 VDC L+ CPU input
M- M-
Position of switches as standard: I II
S1
S2
S3
In case the module is not in use the switches have to be in the following position:
I II
S1
S2
S3

page 18 of 25 GBB-EXKOM-08157/3
7. Technical data
EXKOP
®MINI


Safety Controller
Electronic control module for high speed monitoring of explosion events and activation
of QVII Quench Valves. Self monitoring Safety Controller with internal data storage.
Status report via display
Supply: 24 VDC
Power consumption: approx. 100 W
Basis Version
Signal input: 2 KFD2-ST2-Ex1.LB Input modules monitoring the signal
cables for open and short circuit
Signal output: 2 QV II Quench Valve
floating switch contact 230V, 5A for line #1, line #2,
collective failure
visual and audible alert
Memory: ring memory
Housing: Polycarbonate housing with lockable door
Dimensions: 234 x 264 x 141 mm (WxHxD)
Degree of protection: IP 54
Weight: approx. 10 kg

page 19 of 25 GBB-EXKOM-08157/3
EXKOP
®MINI
Explosionsentkopplungssytem
Explosion isolation system
Betriebstagebuch / log book Anlage Nr. / Facility no: _________________
von / from ................................. bis / till .................................
Satz-Nr. /
Datum /
Zeit /
Ereignis /
Name /
Unterschrift /
file no. date time event name signature

page 20 of 25 GBB-EXKOM-08157/3
Installation Instructions for QV II Quench Valve
Preparation of installation place
The pipe work has to be fitted with counter flanges
according to the mounting and installation
instructions.
Mounting of the QV II Quench Valves
Be sure to allow the counter flanges to cool after welding.
This is to ensure that the rubber Quench seal is not
damaged by heat during the mounting process.
The electronic supply needs to be cut.
For better inspection the gauge should be easily viewed once the valve is mounted.
The air supply has to be connected to the pressure reducer (1/4“-connecting).
Mounting QV II-3 to QV II-10
The bolt flanges of the QV II Quench Valves have to be tightened to following
specifications:
bolts M 16 80...100 Nm
bolts M 20 80...120 Nm
The screws must be tightened cross over. Torque each bolt in sequence to 80 Nm and
than 2 times again to 100 (120) Nm. After the first operating cycles the torque has to
be checked. Minimum one check per year shall be made and this inspection must be
documented.
Now the electrical wiring of the QV II Quench Valve can be connected.
Pressure
reducing valve
(preset)
manometer