Trolex TX6649 User manual

TX6649 User Manual
TX6649-UM-EN-02 3
TX6649 Intrinsically Safe Power Supply (Ex eq)
Contents
1. Product Overview 4
1.1 Operating Features 5
1.2 Application 5
1.3 Product Options 5
1.4 Dimensions 6
1.5 Technical Information 7
2. Certification 9
2.1 Certification Parameters 10
2.1.1 Input and IS Output
Connectors 10
2.1.2 Other Connections 10
3. Installing 11
3.1 Safety Precautions 11
3.1.1 Handling 11
3.2 Tools and Test Equipment
Required 11
3.3 Siting Recommendations 12
3.3.1 Positioning Requirements 12
3.4 Connections 13
3.4.1 Group 1 Areas 13
4. Maintenance 14
4.1 Technical Maintenance 14
4.2 Troubleshooting 14
4.2.1 Warranty 14
4.2.2 Diagnostics 14
4.2.3 Connectivity 15
4.2.4 Support 15
5. Compliance with ATEX
Directives 16
Disclaimers 17
Trademarks 17
Document History 17
Contact Details 17
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1. Product Overview
The TX6649 Power Supply converts an ac supply voltage into a stabilised and
regulated Intrinsically Safe source of power to approved sensors and electronic
control devices.
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1.1 Operating Features
• Input voltage options: 110 V ac or 230 V ac
• Input supply is protected by two primary fuses
• Intrinsically Safe output voltage: 12 V dc
• Output circuit is resistively limited in accordance with certification standards for
Intrinsically Safe, ia, equipment
• Output circuit incorporates voltage regulation, current limiting and continuous
short circuit protection
• Robust stainless steel housing
• Integral 20 Ah back-up battery with automatic uninterrupted power transfer and
charge to full capacity
• Output relay contact to signal power failure
• Analogue output signal to indicate battery charge condition
1.2 Application
• Mining
• Tunnelling
1.3 Product Options
TX6649.105.101 110 V ac input
TX6649.106.101 230 V ac input
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1.4 Dimensions
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1.5 Technical Information
1Input voltage 110 V ac ± 10% or 230 V ac ± 10% - 50/60 Hz
2Output voltage 12 V dc
Output current 750 mA
Output ripple/noise 150 mV max
Line regulation <5% over the input voltage range
Load regulation <5% over 0 to 90% of load current
<10% between 90% and 100% of load current
Voltage limiting Over voltage detection with crowbar protection and
short circuit protection
Current limiting Automatic current limiting of the intrinsically safe
output also limits the current to less than the
rupturing capacity of the output protection fuse.
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3Max. operating
temperature
–20°C to +40°C
Storage
temperature
–20°C to +70°C
Humidity 0 to 95% RH, non-condensing
Vibration limits / low
frequency
0.25 mm peak, sinusoidal vibration in the range
10 Hz to 100 Hz in 3 perpendicular planes
Medium frequency 2g peak, sinusoidal vibration in the range 10 Hz to
600 Hz in 3 perpendicular planes
Mechanical shock 1000 shocks of 40g minimum in 3 perpendicular
planes
Housing material Stainless steel
4Back-up battery Sealed lead-acid. 20 Ah
Automatic charge control to full capacity
Automatic uninterrupted output power transfer
following input power failure
Power fail indication Relay contacts change state on power failure.
Contact rating: 0.25 A at 30 V dc max.
Charge condition Analogue output signal proportional to the charge
level of the battery
Choice of 0.4 V to 2.0 V or 4 to 20 mA signals
Battery life 6 years at 20°C
3 years at 30°C
1.5 years at 40°C
Net weight 35 kg
Important note Following initial commissioning or long periods of
storage the TX6649 requires a minimum of
24 hours charge time before the batteries will be at
full capacity.
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2. Certification
Ex certified for Group I applications:
Europe:
Ex Certificate Number: SIRA 02ATEX3419X
Ex eq [ia Ma] Mb I (when mains powered)
Ex ia I Ma (when battery powered)
Special Conditions for Safe Use:
All cables used for external connections shall be terminated by the
use of suitably certified Ex e cable glands. The use of conduit is not
permitted.
General Conditions for Safe Use:
Prior to installation, it is essential that the user refers to the above Ex
certificate to ensure that the termination and cable parameters are
fully complied with and are compatible with the application. Copies of
certificates are available from Trolex.
ATEX directive 94/9/EC
EMC directive 2004/108/EC
International (IECEx):
Ex Certificate number: IECEx SIR 10.0109X
Special Conditions for Safe Use:
All cables used for external connections shall be made by the use
of suitably certified Ex e cable glands. The use of conduit is not
permitted.
General Conditions for Safe Use:
Prior to installation, it is essential that the user refers to the above Ex
certificate to ensure that the termination and cable parameters are
fully complied with and are compatible with the application. Copies of
certificates are available from Trolex.
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South Africa (MASC):
Ex Certificate number: MASC M/11-315X
Russia: GOST-R version is available.
Please contact Trolex for more information
2.1 Certification Parameters
2.1.1 Input and IS Output Connections
TX6649.106.101 (230 V ac, 12 V dc, 750 mA)
TX6649.105.101 (110 V ac, 12 V dc, 750 mA)
Um 250 V ac
Uo 13.0 V
Io 1.76 A
Co 30.29 µF
Lo/Ro 36.17 µH/Ω
Po 12.73 W
2.1.2 Other Connections
Refer to appropriate certificate for Certification Parameters for analogue output
(charge condition), relay contact and switch terminals.
See section 5 Compliance with ATEX directives for more information applicable
to your location.
MASC
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3. Installing
3.1 Safety Precautions
1. Make sure that all covers on Ex e housings and their fixing devices are properly
secured in compliance with statutory regulations before switching on the input
supply.
2. Never remove the cover of an Ex e housing whilst the input supply is
connected. Isolate elsewhere before removing the cover in accordance with
statutory regulations.
3. The housing of all power supplies must be securely earthed in compliance with
statutory regulations.
4. Carry out a current consumption audit to ensure that the maximum current
loading of the power supply is not exceeded.
5. Ensure that the installation of the power supply, particularly with regard to the
connecting cables, complies with the certification parameters (section 2.1).
6. The Ex e housing must be inspected and maintained regularly in accordance
with statutory regulations.
7. All cables entering the mains input terminal chamber must be terminated with
suitable, certified cable entry devices.
8. Do not drill holes in the Ex e housing or modify it in any way.
9. The battery contains corrosive substances and must be disposed of in the
correct way.
10. Please return the complete unit to Trolex or an approved distributor for servicing
and replacement.
3.1.1 Handling
Checkpoint
This is a heavy item, 35 kg, and therefore safe handling and transportation should
be applied in line with the health and safety recommendations on your site.
3.2 Tools andTest Equipment Required
No special tools are needed.
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3.3 Siting Recommendations
1. The TX6649 may be located in a hazardous area with flammable gases and
vapours with Group I apparatus.
2. The equipment is only certified for use in ambient temperatures in the range
–20°C to +40°C and should not be used outside this range.
3. Installation shall be carried out in accordance with the applicable code of
practice by suitably trained personnel.
3.3.1 Positioning Recommendations
Mount horizontally as shown in the illustrations on pages 4 and 7.
3.3.1.1 Power Requirements
See Technical Details section 1.5.
3.3.1.2 Output Signal
0.4 to 2 V dc Battery charge level monitor
4 to 20 mA Battery charge level monitor
Relay Mains fail output contact
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3.4 Connections
3.4.1 Group 1 Areas
Connecting cables must conform to the requirements of the appropriate Approval
and Certification standards for Mining applications. Trolex recommends that they
conform to BS5308.
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4. Maintenance
Make periodic visual inspections to check for physical damage.
Check connections in both terminal chambers are secure.
4.1 Technical Maintenance
Trolex recommends that the batteries are replaced every three years. This must be
carried out by a competent person. If the unit is returned to Trolex for this re-work, a
test of the internal safety integrity will also be carried out.
4.2 Troubleshooting
4.2.1 Warranty
See Terms and Conditions for the Supply of Goods and/or Services at
www.trolex.com.
4.2.2 Diagnostics
Condition: Output reading of 800mV instead of 12Vdc.
Diagnosis: The internal safety crowbars have activated due to an external
condition on the input voltage or output side, the crowbars will
attempt to automatically reset. If this does not happen remove main
power for about 2 minutes.
Condition: The output has dropped to zero
Diagnosis: It is probable that the input fuses have ruptured which has resulted
in the batteries completely discharging. To check this, remove
main power momentarily. If the relay does not change state then
it confirms the unit is continuously operating on the battery supply
only.
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4.2.3 Connectivity
Check the correct function of the mains-fail relay by connecting a suitable test
meter across the contacts.
A 12 V dc output should be available at the intrinsically safe output terminals with
mains power input present, or absent.
Also check that the analogue battery monitoring signal is available at the output
terminals.
4.2.4 Support
If you need technical support to operate this product, or would like details of our
after sales technical support packages, contact [email protected].
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5. Compliance with ATEX Directives
Instructions specific to hazardous area installations (reference European ATEX
Directive 94 /9/EC, Annex II, 1.0.6. )
The following instructions apply to equipment covered by certificate numbers SIRA
02ATEX3419X:
The TX6649 (SIRA 02ATEX3419X) may be located in a hazardous area with
flammable gases and vapours with Group I apparatus.
The equipment is only certified for use in ambient temperatures in the range –20°C
to +40°C and should not be used outside this range.
Installation shall be carried out in accordance with the applicable code of practice
by suitably trained personnel.
Replacement of fuses or repair of this equipment shall be carried out in accordance
with the applicable code of practice.
Certification marking as detailed in drawing numbers P5531.09.
If the equipment is likely to come into contact with aggressive substances, then
it is the responsibility of the user to take suitable precautions that prevent it
from being adversely affected, thus ensuring that the type of protection is not
compromised.
Aggressive Substances: e.g. acidic liquids or gases that may attack metals or
solvents that may affect polymeric materials.
Suitable Precautions: e.g. regular checks as part of routine inspections or
establishing from the material’s data sheet that it is resistant to specific chemicals.
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Disclaimers
The information provided in this document contains general descriptions and
technical characteristics of the performance of the product. It is not intended as
a substitute for and is not to be used for determining suitability or reliability of
this product for specific user applications. It is the duty of any user or installer to
perform the appropriate and complete risk analysis, evaluation and testing of the
products with respect to the relevant specific application or use. Trolex shall not be
responsible or liable for misuse of the information contained herein. If you have any
suggestions for improvements or amendments, or find errors in this publication,
please notify us at [e-mail].
No part of this document may be reproduced in any form or by any means,
electronic or mechanical, including photocopying, without express written
permission of Trolex.
All pertinent state, regional, and local safety regulations must be observed
when installing and using this product. For reasons of safety and to help ensure
compliance with documented system data, only Trolex or its affiliates should
perform repairs to components.
When devices are used for applications with technical safety requirements, the
relevant instructions must be followed.
Trademarks
© 2013 Trolex® Limited.
Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this
document is acknowledged.
Document History
Issue 1 20 July 2005 Original publication of this document
Issue 2 6 September 2013 New format and minor revisions
Contact Details
Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK
[phone] [email protected]
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