Ex products manual preparation guide

Guide for preparing “user manual" for Explosion proof products

This guide is for manufacturers of Hazardous area equipments to prepare instructions for equipment used in explosive environments based on the ATEX directive and product standards.

It is obvious that preparing instructions and complying with standards and directives is the duty and responsibility of the manufacturer.

The ATEX directive does not suggest a specific format for the instruction, but it must have the minimum necessary information mentioned in related standards to achieve the purpose of the instruction (safety of use).

The manufacturer will add other information required in the instructions based on the specifications of his produced equipment.

The instructions must be prepared in both English and the common language in the area of ​​use of the equipment.

In addition to the electronic version, the instructions must be provided to the user in paper form.

This guide consists of two parts:

a) The necessary information that must be included in the instructions which are placed inside the frame.

Note: The form of presentation of this mandatory information is suggestion and the manufacturer can use its own order and writing style.

b) Explanations outside the boxes to explain and clarify the demands of the standard.

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General information (all products and types of protections)

The instructions should provide the user with the necessary information for the safety of the product and the environment in all stages of using the equipment, including: transportation, installation, assembly and disassembly, start-up, adjustment, operation, service and maintenance.

1. Foreword This ATEX operation instruction provide additional information on the use of XXXX in a potentially explosive atmosphere.

 

The user must be aware of all the required specifications of the product at the time of use.

2. Brief description Device brief description Intended use / scope Manufacturer (contact information of manufacturer of its representatives for repair, maintenance and other activity if required) Power supply Input devices / conditions / characteristics Output devices / conditions / characteristics Model/Types explanation

A list of standards to which the equipment conforms, as well as standards to be cited when in use along with applicable edition, shall be available.

The manufacturer must modify the following list of standards according to its produced equipment:

3.Standards and approvals These products have been manufactured in accordance with: EN IEC 60079-0(2018): Explosive atmospheres - Part 0: Equipment - General requirements the standard(s) which are applicable to the specific type of protection relevant to the equipment, shall be added. for example: EN 60079-1(2014): Explosive atmospheres - Part 1: Flameproof enclosures EN 60079-7(2014): Explosive atmospheres - Part 7: Increased safety Installation, use and maintaining of the equipment, shall be refered to the below references: IEC 60079-14(2013): Explosive atmospheres - Part 14: Electrical installations design, selection and erection IEC 60079-17(2023): Explosive atmospheres - Part 17: Inspection and maintenance of electrical installations in hazardous areas IEC 60079-19(2019): Explosive atmospheres - Part 19: Equipment repair, overhaul and reclamation Edicts, by-laws, laws, directives, circulars, standards, regulations and any other document relating to where the apparatus is installed.

Any misuse, change or non-compliance with the manufacturer’s technical and safety notes by the user, which causes problems in the safety and performance of the product, must be stated. (The figure below is suggested)

4. Manufacturer responsibility The manufacturer declines any responsibility in case of: Use of the product not according to safety regulations and legislation valid in the user’s country. Use of the product in operating conditions not allowed according to the product technical documentation. Improper installation: the instructions given in this User Manual are not followed or not properly followed. Modification of the product. Operations executed by personnel not properly trained or not assigned to such a kind of operations.

The permissible range of environmental conditions, including the ATEX ambient temperature range and other environmental conditions, including pressure, humidity, corrosive environment, chemicals, vibration, etc., must be fully informed to the user.

5. Environmental conditions Ambient temperature range External source of cool or heat Chemical material and aggressive environment Mounting condition (orientation/angle/etc.) Storage conditions

for marking and labeling of the equipment,  the instruction of clause 29 of EN IEC 60079-0:2018 shall be followed.

6. Marking and Labeling ATEX marking explanation relevant to information and elements of ATEX marking the layout of equipment label and description for its elements except serial number and production date material and installation place of the label

In addition to the installation and operating instruction which are prepared by the manufacture to be used by the user, the safety notes related to the use of product in an explosive atmosphere should be added in all steps.

these safety related points can be described in the form of equipment general instruction and/or as ATEX safety instruction in a separate section.

All the below steps below may not include all types of products.

7. Operation instruction a. On-Site assembling: any specialized installation information for the user, such as a specific sequence of assembling; information about the mechanical assembling such as pipe connections; b. Installation and erection Installation procedures and conditions Terminal layout and wiring diagrams information, other than the general requirements given in IEC 60079-14; information about bonding, shield earthing or overvoltage protection; Necessary information to select and install the gland and conduit and suitable cable entry accessories for Exd protection c. Adjustment & parameters setting information about heating devices; d. Putting into service information about verifications / tests prior to the (first) use of the equipment as required by the Type of Protection(s) detailed information about any special installation requirements for the Type of Protection(s) employed e. Use and setting-up ratings such as electrical values, ambient temperatures and pressures, maximum surface temperatures and other limit values related to a designated use; information for the user, not just giving parameters, related to the need of special overload protecting devices for increased safety “e”’ motors or special requirements related to electrostatics; f. Maintenance information, other than the general requirements given in IEC 60079-17; information such as cleaning, oil level check or recalibration requirements; To avoid a possible ELECTROSTACTIC CHARGE the unit must only be cleaned with a damp cloth requirements for the maintenance of the explosion protection; information about troubleshooting; g. Repair information, other than the general requirements given in IEC 60079-19; information related to the fitting or removal of parts / components; information about spare parts; requirements for a documentation of such repairs; information about needed verifications / tests for the restarting of the equipment; h. Tacking out of service and dismantling information about the securing of mechanical parts to prevent a restart or about electrical disconnecting; i. Other: where necessary, training instructions for a safe use; where necessary, the essential characteristics of tools which may be used with the equipment; such as a special screwdriver for trimming

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Additional information required for specific types of protections

1. additional information for Exd

• Type, size, number and characteristics of threads should be noted

• Flameproof threaded joints and cemented joints are not intended to be repaired. (for Exd)

• Units must not be opened while an explosive atmosphere is present.

• instructions shall detail (about flameproof joints) one of the following:

  • dimensions of the flameproof joints shall be detailed; or

  • specific drawing referenced that details the dimensions of the flameproof joints; or

  • specific guidance noted to contact the original manufacturer for information on the dimensions of the flameproof joints; or

  • specific indication that the flameproof joints are not intended to be repaired.

b. additional information for Exi

• Installation procedures and conditions

• Intrinsically safe parameters Uo, Io, Ui, Ii, Ci, …. Should be included in the instruction.

• the value of Um which may be applied to non-intrinsically safe circuits connection facilities;

• the value of Um which may be applied to non-intrinsically safe circuits connection facilities;

• any conditions which are assumed in determining intrinsic safety, for example that the voltage is to be supplied from a protective transformer, galvanically isolated power supply or through a diode safety barrier;

• if separation distances rely upon the enclosure, the IP rating and the measures necessary to maintain the integrity of the enclosure and entries into enclosures

• permitted non-hazardous area accessories;

Information for specific products

a. cells and batteries:

• where it is necessary for the user to replace cells or batteries contained within an enclosure, the relevant parameters to allow correct replacement shall be included in the instructions, including either the manufacturer’s name and part number, or the electrochemical system, nominal voltage and rated capacity. When replacement of the batteries or cells is intended to be done only when an explosive atmosphere is not present, the instructions shall specify the procedure for battery or cell replacement.

b. electrical rotating machines

• speed/torque curves for machines intended to be supplied by a converter;

• For motors in Type of Protection “e” that have been type tested with a converter, the rated motor current, Weighted Voltage Total Harmonic Distortion (WTHD), or pulse frequency and DC-Link voltage of the converter used for the type testing to allow the selection of a comparable converter.

• guidance for the selection and installation of any necessary overload protection or overtemperature protection of the motor

• bearing lubrication requirements for both commissioning and maintaining;

• the permitted axial and radial loading of the shaft;

• the thermal expansion of the shaft and the housing under the rated conditions;

• any necessary maintenance of the protection provided by the manufacturer against stray circulating currents in the bearings or shafts (Annex H – IEC60079-0:2018);

• any necessary protection of the bearings from vibration, including during transportation, storage, or standby service;

• guidance on maintenance and replacement intervals for bearings based on the operating conditions.

• Warning: In case of additional painting of the motor please make sure that the thickness is in accordance with the relevant standards.

c. ventilating fans

• Minimum and maximum air flow rates (with respect to surface temperature and temperature ratings);

• Back pressure if required (to operate the fan within the ratings);

• Any limitations with respect of the ingress of foreign particles (e.g. requirements for IP protection, etc.

• Any special earthing measures to be employed to avoid the buildup of electrostatic charges.