Operating Instructions Ex UPS Combination of > 8265/5 GUBox control panel > 8316 battery box
Contents 1 Contents 1 Contents 2 2 General Information 2 3 Safety Instructions 2 4 Conformity to standards 3 5 Function 3 6 Technical Data 5 7 Arrangement and fitting 5 8 Installation 6 9 Commissioning 7 10 Maintenance and servicing 7 11 Accessories and Spare Parts 7 2 General Information 2.1 Manufacturer R. STAHL Schaltgeräte GmbH Am Bahnhof 30 74638 Waldenburg, Germany Telephone: +49 7942 943-0 Fax: +49 7942 943-4333 Internet: www.stahl.de 2.2 Information about the Operating Instructions Publication Code: Subject to alterations. 2.3 Symbols Attention! This symbol marks notes whose non-observance will endanger your health or the functioning of the device or component. 3 Safety Instructions The most important safety instructions are summarised in this chapter. They supplement the corresponding regulations, which the personnel in charge must study. When working in hazardous areas, the safety of the personnel and system depends on compliance with all relevant safety regulations. Assembly and maintenance staff working on installations therefore have a particular responsibility. They require precise knowledge of the applicable standards and regulations. 2
As user, please observe: - the national safety and accident prevention regulations, - the national assembly and installation regulations (e.g. IEC/EN 60079-14) - the generally recognized technical regulations, - the safety guidelines and information in these operating instructions and the enclosed mechanical assembly drawings, wiring diagrams and operating instructions of the built-in devices, - in particular the operating instructions of the flameproof control panels (Type 8265/5..) and the operating instructions of the battery boxes (Type 8316/22-..) - the characteristic values and rated operating conditions on the rating and data plates, - the information plates fixed directly to the device, - that any damage to the device can invalidate the Ex protection, - that switching device combinations may only be operated within completely closed enclosures. Use the devices in accordance with their designated use and for their intended purpose only (see "Function"). Incorrect or impermissible use or non-compliance with these instructions invalidates our warranty provision. No modifications or alterations to the devices or components, impairing their explosion protection, are permitted. They may only be fitted and operated if they are undamaged. 4 Conformity to standards The devices comply with the following standards and the following directive: Directive 94/9/EC IEC/EN 60079-0, IEC/EN 60079-1, IEC/EN 60079-7 The devices are approved for use in hazardous areas of Zones 1 and 2. 5 Function 5.1 Use The Ex USP is used as a back-up power supply unit in hazardous areas. According to EN 61131-2/Part 2 (Limit values for the rated direct voltage at 24 V DC), the operating voltage for electronic control panels is DC 24V (DC 20.4V - DC 28.8V eff.). Power supply units must be designed accordingly. In standard equipment, the UPS is delivered with an integrated charging unit for charging the individual batteries. In the connection chamber, 2 miniature circuit breakers (MCB) (F1, F2) are fitted. They serve as protection for the maximum permitted battery current and for disconnecting the batteries from the UPS control panel during maintenance and repair work. As additional equipment, the devices from Series 8562 are equipped with a remote trip, which will disconnect the batteries when an error occurs in the UPS. In the event of a power failure, the UPS will deliver a stabilized output voltage (DC 22V or DC 20.6V). The output circuit is designed short-circuit-proof. In case of a battery undervoltage (DC 17V), the battery will be disconnected automatically. - Automatic charging - IU characteristic curve Optionally, the UPS Controller is equipped with integrated power supply units and DC UPS modules. They can be connected without problems in a secondary parallel circuit and thus guarantee safe protection of your system in combination with easy handling. 3
The patented technology of our DC UPS module makes it unnecessary to use switching regulators such as boost converters. Therefore, no EMC problems are encountered. All EX UPS modules are assembled in a compact design with battery and are easy to mount. The DC UPS module is available in the version DC 24V 10A. Further versions are available on request. The electronics of the module monitors the output voltage and connects the battery when the voltage drops below the preset threshold (DC 22V or DC 20.6V). The internal battery serves as power supply for the consumer via a defined period supplying a maximum current of 10A limited internally. During this, the output voltage is controlled to the threshold value (DC 22V or 20.6V) (see diagram). 24V 22V bzw. 20,6V For visual display, LED indicating lamps (H1 H5) have been attached. Designation Colour Designation H1 Green Ex UPS Guard (see 5.3) H2 Blue UPS operation H3 Green Charging state >75% H4 Yellow Charging state <25% H5 Red Battery maintenance Optionally, all signals can be wired as potential-free contacts on terminal blocks. To activate the module, a control switch has been provided for controlling the UPS module. Designation Colour Designation S1 Black UPS "0 1" To extend the product range, customer-specific solutions are also available on request, in addition to the standard versions. 5.2 Charging the batteries The charging technology has been integrated into the UPS control panel, following the recommendations of the battery manufacturers. The batteries Type 8316 are charged according to the I-U characteristic curve. Charging according to the I-U characteristic curve The I-U characteristic curve is the most suitable characteristic curve for charging dryfit batteries. The battery is charged at a constant current until reaching the recommended charging voltage. After that, they keep the voltage constant. The battery limits the charging current according to the characteristic curve. 4
Batteries in dryfit technology are sealed VRLA batteries (Valve Regulated Lead Acid). They are lead-acid batteris in which the electrolyte is fixed in gel. These batteries are distinguished by maximum operational safety and are maintenance-free. Fully charged state The fully charged state has been reached when the residual charging current no longer changes within 2 hours. 5.3 Ex UPS Guard The Ex UPS Guard is used for independent monitoring of the charging and discharging functions. In the presence of soft- or hardware faults in the UPS control panel, safety-relevant errors may occur. The voltage trips of the miniature circuit breakers (MCP) are actuated and thus switched off. This function guarantees safety during charging and discharging of the batteries. It monitors the proper functioning of the charging and discharging electronics in compliance with explosion protection. When operated properly, the function is indicated by a green light of the signal lamp. 6. Technical data The technical data can be seen from the component documentation and the rating plates of the delivered devices. Type designation EC Type Examination Certificate Publication code of the operating instructions Type: 8265/5. PTB 06 ATEX 1077 S-BA-8265-01-DE Type: 8316/22-..- KEMA 04 ATEX 2237X S-BA-8316-02-DE Please observe the rating and data plates and the operating instructions of the devices and components! Please consult the manufacturer if operating conditions are non-standard. For further technical data, please refer to the R. STAHL catalogue or request them from R. STAHL. Special conditions When changing batteries in the hazardous area and transporting the device through the hazardous area, make sure that there is no risk of explosion. The batteries may only be charged using the proper charging device and following the manufacturer's specifications. 7 Arrangement and fitting 7.1 Dimension tables and dimensioned drawings The data can be seen from order documentation included in the delivery. 7.2 Assembly Information regarding mechanical assembly, such as location of attachment points, dimensions or weight of the devices, can be found in the enclosed assembly drawing. Install a protective roof or wall if the explosion-protected electrical devices are mounted outdoors. 5
8 Installation Installed battery - Open and maintain the device with special work permit only. Installation and commissioning of the device is only to be performed by a qualified electrician! Open the enclosure only - if there is no risk of explosion! - for changing the batteries and for performing installation, maintenance and repair work. - The enclosure must be closed carefully again after installation work is complete. 8.1 External wiring Run the connecting wires with intact external insulation jackets through the cable entries into the connection chamber. Make sure that the cable diameter and the terminal cross-section on the cable entry are identical. When using cable entries for cables with double sheathing or armouring, the special operating instructions of the components must be observed. Run the connecting cables in the connection chamber such that the bending radii for the respective conductor cross-section do not fall below the minimum permissible values. mechanical damage to the conductor insulation on sharp-edged or moving metal parts is effectively prevented. Please note when installing the devices: - Particular care should be taken when making the connections. The connecting cable must comply with the relevant regulations and must have the required cross-section. The crosssection must be identical to the data on the cable entry. - To ensure that the maximum permissible conductor temperatures are not exceeded, select suitable cables and means of running them. - When stripping insulation, it must be ensured that the conductor insulation reaches right up to the terminals. - Do not damage the conductor when removing the insulation. - To avoid moisture and dirt inside enclosures, install them in a clean and dry environment. Connection torques values on the terminals Tighten the screws of the connection terminals in accordance with the specified connection torques. Mains connection Open the enclosure. - Run the connecting cables with intact external insulation jackets through the cable entry into the connection chamber. - Run the connecting cables in the connection chamber such that the bending radii do not fall below the permissible minimum values. - Connect the conductors according to the enclosed documentation (e.g. wiring diagrams). - The protective conductor must always be connected. - Remove any loose metal particles, dirt and traces of moisture from the enclosure. - Carefully close the enclosure after finishing the work. 6
9 Commissioning Before commissioning, ensure that - the device has been installed according to standards, - the connection has been made correctly, - the device is not damaged, - there are no foreign objects inside the device and the connection chamber is clean, - the cables and wires have been inserted correctly, - all screws and nuts have been firmly tightened, - the cable entries and stopping plugs have been securely tightened, - unused cable entries have been sealed with plugs certified to IEC/EN 60079-0 (Directive 94/9/EC), - unused holes have been sealed with stopping plugs certified to IEC/EN 60079-0 (Directive 94/9/EC) for the relevant type of protection, - all covers and partitions for live parts have been installed and fastened. 10 Maintenance and servicing Observe the relevant national regulations in the country of use! Maintenance, overhaul and repair work on the devices may only be carried out by appropriately authorized and trained personnel. Before any maintenance work is started, the devices must be disconnected from the supply! To prevent defects in the system, perform maintenance work regularly. The maximum permitted interval between the inspections is three years. 10.1 Inspection intervals Include the following items when determining the inspection intervals: Ambient conditions (installation outdoors, wind, rain, sunlight), operating conditions (utilization rate of the battery boxes, operating error),manufacturer's specifications in the technical documentation, significant changes in the whole system (e.g. change of zone classification) Inspection content Repair damage to the insulation of the connection terminals of the batteries, before putting them back into service! Depending on the local conditions, run visual, close or detailed inspections! Any defects that have been detected and can affect the explosion protection must be rectified immediately! To rectify the defects, the system must be put out of service! 11 Accessories and spare Parts Use only original accessories and spare parts from R. STAHL Schaltgeräte GmbH. Using accessories and spare parts from a different company shall invalidate the warranty of R. STAHL Schaltgeräte GmbH. Observe the national standards for waste disposal. 7