Trolex TX3706 Falcon Exd Connector User Manual

TX3706 • TX3707
FALCON Ex d Connectors Contents
User Manual

Product Overview

1.1 Operating Features

• Multi-pin connector for use in Group I and Group II hazardous areas
• Precision cast metal Free Plug and Free Receptacle for cable mounting
• Precision cast metal Fixed Receptacle for Ex d or Ex e box mounting
• Standard cable glands are utilised to user preference
• Simple connection – no special tools required
• Double insulated contact cartridge for added safety and ease of connection
• Rapid double bayonet engagement ensures that contacts make or break under Ex d protection for live disconnection
• Pilot circuit interlocking safety protection can be incorporated
• Security coding options to prevent non-permitted engagement
• Supplied with flexible ingress protection cover caps
• Ex d blanking cover caps may be supplied where specified
• Mounting clamp available for Unistrut bulkhead mounting of Free Connectors

1.2 Application

• High integrity, multi path, robust, explosion proof connector, designed for extra heavy duty and critical applications.
• ATEX and IECEx industrial hazardous area applications and underground mines. Suitable for use in flammable gas and dust atmospheres.
• Rapid and convenient connect/disconnect of control circuits and power circuits for electrical equipment installation.
• Live disconnect of critical equipment for maintenance and change-out.
• Offshore oil and gas platforms, mining, tunnelling, petrochemical plants, process plants, storage areas, pump stations, well head control panels, mobile equipment, on shore drill
  rigs and top drive control room systems.

1.3 Dimensions

TX3706.3 Fixed Receptacle
M20 or M25 bush mounting on Ex d or Ex e enclosures| TX3706.3 Fixed Receptacle
Surface Mounting on Ex e enclosures
|

1.4 Technical Information

Housing material:| Stainless Steel : ANC4B
Aluminium Alloy : LM25TF with hard anodised protection
---|---
Cable entry on free
plug and receptacle:| Choice of threaded cable entry sizes for standard Ex d cable glands
M20 and M25
Mounting of fixed receptacle:| • Surface fix onto Ex e housing
• M20 onto Ex d or Ex e housing
• M25 onto Ex d or Ex e housing
Connections of fixed
receptacle:| 1.5 mm 2  x 1m / 2m / 3m (L)
2.5 mm 2  x 1m / 2m / 3m (L)
Mating cycles:| 100,000 with no load connected
(Limited to 200 for live disconnect)
Security Coding:| 5 selectable coding positions – A, B, C, D, E
Ingress protection:| IP66 – triple sealed
Temperature limits:| -50 °C to +60 °C
Weight:
Free Plug
Free Receptacle
Fixed Receptacle| Stainless Steel
0.5kg
0.43kg
0.4kg| Aluminium
0.2kg
0.17kg
0.15kg
Conformity:| EN 61984: 2009 – Safety Requirements
EN 60664: 2007 – Insulation Co-ordination
EN60079-0: 2012+A11:2013 – General Requirements
EN60079-1: 2014 – Flame-proof Enclosures
EN60079-31: 2014 – Equipment Dust Ignition Protection
by Enclosure “t”

Contact Inserts

Maximum live disconnect voltage
Power factor 0.4 to 0.5| 80 V ac/dc| 250 V ac/dc
---|---|---
Load breaking current (up to 200 mating cycles):| 1 A| 1 A
Creepage and clearance:  (IEC 60664-1)| 2 mm                            5 mm|
Cable terminations:| 6 or 8 point crimp or solder – IEC 60352-2
Wire size:| 1.5 mm2  or 2.5 mm2
Insert material:| Glass filled polymer
Fire rating:| VL94, V-0
Contacts:| Multi-spring wire socket and solid pin
Insertion force:| 6 N per contact
Contact protection:| Passivated silver plating
Contact resistance:| 400 ohm
Test Voltage:| 2000 V
Insulation:| Class II double insulated BS 61140
Over voltage transients:| 3000 V
Protective earth connections| Screw clamp terminals for 2.5 mm cables

Checkpoint
Intrinsically safe circuits
The contact inserts are clearance compatible for use with approved intrinsically safe circuits up to 30 Volts. This feature can be used to maintain flameproof properties where intrinsically safe circuits are exiting a flameproof enclosure.
Caution Intrinsically safe circuits must not be mixed with non- intrinsically safe circuits on the same connector.

Certification and Conformity

ATEX (European Union) certification for use in underground mines and surface industry with explosive gas and dust atmospheres.
Complies with ATEX Directive 94/9/EC (until 19th of April 2016)
Complies with ATEX Directive 2014/34/EU (from 20th of April 2016)
IECEx (International) certification for use in underground mines and surface industry with explosive gas and dust atmospheres.

2.1 Underground mines (stainless steel versions only)

Ex db I Mb
-50 °C ≤ Ta ≤ +60 °C

2.2 Surface industry with explosive gas and dust atmospheres (stainless steel and aluminium versions)

Ex db IIC T4 Gb
Ex tb IIIC T135 °C Db
-50 °C ≤ Ta ≤ +60 °C

2.3. The following Conditions of Certification and Special Conditions for Safe Use apply to the above ATEX and IECEx Certificates:

1. The total capacity of the 4 or 10 pin contact option must not to exceed 100 A giving each contact a limitation of:
   4 contacts – 25 A
   10 contacts – 10 A

2. The cable entries and cable used with the TX3706 connectors may reach 60 °C above ambient temperatures, therefore they shall be selected accordingly for the operating ambient temperatures.

3. The connector arrangement remains flameproof through the first stage of disconnection which fully disconnects the pins, however, this only applies to circuits with a power factor of 0.6 or less. For circuits outside this range, additional time delays need to be considered before fully disconnecting the connector even if energised.

4. During maintenance and inspection the flamepath dimensions in the tables below shall be observed:

Flamepath Ref.| Description| Type of Flame Path| Max Gap (mm)| Min Length (mm)
---|---|---|---|---
1-2| End Cap (M)
Receptacle (F)| Cylindrical Joint| 0.093| 9.5
3-4| Plug (M)
Receptacle (F)| Cylindrical Joint| 0.093| 9.5
5-6| End Cap (M)
Plug (F)| Cylindrical Joint| 0.093| 9.5
7-8| Ex d Cap (M)
Receptacle| Cylindrical Joint| 0.093| 9.5
9-10| Plug (M)
Ex d Cap (F)| Cylindrical Joint| 0.093| 9.5
Threaded entries| End cap threaded
cable entries| Metric threaded
M20
M25| Threads
engaged

10| M20 = 19 mm
M25 = 16 mm
Flamepath Ref.| Description| Type of Flame Path| Max Gap (mm)| Min Length (mm)
---|---|---|---|---
1-2| Ex d Cap (M)
Receptacle (F)| Cylindrical Joint| 0.093| 9.5
3-4| Plug (M)
Ex d Cap (F)| Cylindrical Joint| 0.093| 9.5

Fitting and Installation

3.1 Precautions

• Special conditions of use relating to the Ex certification may apply to particular applications.
• The cable gland used with Free Plugs and Free Receptacles must be an approved Ex d type which is suitably certified for the equipment and the type of cable to be used.
• Gland entries must be fitted with suitable ingress seals to maintain the overall ingress protection of the connector.
• Ensure that the current and voltage parameters of the electrical circuits are within the limits specified.
• The sealing faces and flame paths will have been treated with a protective film of grease during manufacture. Renew if necessary before assembly or engagement, in accordance with the relevant installation standards and procedures.
• Ensure that the end cap screws are in place and are fully tightened before engagement.
• Always fit either a rubber ingress protection cap or an Ex protection cap to disengaged connectors to protect flame paths and to exclude debris and moisture.
• Do not disengage the connector by pulling on the cable as this may damage the fitting of the cable into the cable gland.
• A connector with a damaged flame path is an explosion risk and should be removed from service.

3.2 Tools and Equipment

• 2.5mm & 3mm Allen key
• Wire cutters
• Wire strippers
• 6 or 8 point crimping tool (or soldering iron for soldered connections)

3.3 Free plug and free receptacle
3.3.1 General assembly and definitions

Product Options

1. Body (Plug or receptacle) Group I
1. Body (Plug or receptacle) Group II| Stainless Steel
Stainless Steel/Aluminium
---|---
2. End cap|
3. End cap screws|
4. Contact insert| 10 way/4 way
5. Backing ring|
6. Contacts| 1.5 mm 2 Pins/Sockets
2.5 mm 2 Pins/Sockets
7. Retainer|
8. Sleeve (Upper and lower pair)|
9. Ingress protection cap|
10. Earth bonding terminal|
11. Flame path|
12. Cable entry for standard Ex cable glands| M20/M25

• PINS or SOCKETS can be fitted into MALE or FEMALE contact inserts
• MALE or FEMALE contact inserts can be fitted into PLUGS or RECEPTACLES

3.3.2 Connecting

• Prepare cable
  Checkpoint
  Use sleeve 8 as a temporary wire length cutting gauge.

• Crimp or solder connectors
  

• Fit backing ring 5

• Clip a retaining clip 7 to each contact

• Load contacts into the contact insert 4

• Slide the backing ring 5 up to the contact insert 4

• Clip the sleeves 8 in place

• Load into connector body 1

• Fit end cap screws and washers
  

3.3.3 Earth Bonding

• External Earth bonding

• Internal Earth Continuity bonding

3.3.4 Security Coding

3.4 Fixed Receptacle
3.4.1 General assembly and definitions
TX3706. 03

Product options

2.5 mm2 X 1M / 2M / 3M  (L)
7.  Female contact insert| 10 way/4 way
(Security code to be specified)
8. Contacts| Pins/Sockets
(Leading earth pin when specified)
(Lagging pilot pin when specified)

3.4.2 Ex d bush mounting
TX 3706.3…20
TX 3706.3…25
A locking ring enables the Receptacle to be radially positioned to suit user preference and incorporates ingress seals to IP66 standards.

• Position the Receptacle to concur with any radial position of the corresponding free plug.
• Align Receptacles for best visual appearance
• Locks against the effect of rotational forces which may occur from the connecting cable.

1. Screw the locking ring all the way home.
2. Screw the Receptacle all the way into the mounting bush on the enclosure. This must be a minimum of five threads engaged on an Ex d enclosure.
3. Use a half-spanner to apply counter-clockwise locking force to the locking ring.

3.4.3 Ex e surface mounting
TX 3706.3…01

Operation

4.1 Engage and separate

Locking Screw

4.2 Safety Precautions
There are three methods of safety protection depending upon the application and local safety regulations.

4.2.1 Isolate elsewhere
Isolate all electrical power at source BEFORE separation

Checkpoint

IP65
**| Ex d + IP66**

---|---
Fit the rubber ingress protection cap when separated.| Fit an Ex protection cap if the system power is to be reinstated.

4.2.2 Pilot circuit interlocking
Automatic isolation of the power source during separation using one of the connector contacts for interlocking a pilot switching circuit.
• Fit a lagging pilot pin TX 3700.032.15 or TX 3700.032.25

Checkpoint

• The pilot relay will isolate the power source slightly in advance of the main contacts during separation
• Breaking of the pilot contract will take place under Ex d protection
• The pilot circuit must be de-energised along with the power source.

IP65
**| Ex d + IP66**

---|---
Fit the rubber ingress protection cap when separated.| Fit an Ex protection cap if the system
power is to be reinstated.

4.2.3 Live engagement
ENGAGE or SEPARATE the connector with live power in the hazardous area, is permitted for short periods to allow maintenance or change-out of apparatus.
Power must originate from the SOCKET ONLY.

Checkpoint

IP65 Only
**| Ex d + IP66**

---|---
Fit the rubber ingress protection cap
during temporary separation to exclude
dust and moisture.| Fit an Ex protection cap if the connection is to remain separated after the permitted maintenance period.

Important:

• Information in this section is provided to enable users to evaluate the risk of live work.
• Live disconnection should be carried out under an appropriate permit to work system based on the risk assessment and should be carried out in a clean and dry environment on a temporary basis only.
• Before an Ex protection cap is fitted and whilst disconnected, the connector is no longer Ex d or Ex tb protected however creepage and clearances of the connector meet requirements of IEC/EN 60079-7 for the maximum rated live disconnection voltages. Fitting Ex protection cap restores full Ex d or Ex tb protection.
• Before a rubber ingress protection cap or an Ex protection cap is fitted, live connectors will have an IP30 rating only and whilst disconnected, both the plug and socket parts need to be protected from mechanical damage.
• The rubber protection cap provides an ingress protection IP65 when fitted but does not provide an enclosure meeting the requirements IEC/EN 60079-0.

Accessories

Mounting clamp| TX3706. 51|
---|---|---
Leading earth pin 1.5 mm2| P5609.23.01|
Leading earth pin 2.5 mm2| P5609.16.01|
Live disconnect/pilot pin 1.5 mm2
Maximum current: 1 Amp| P5609.23.02|
Live disconnect/pilot pin 2.5 mm2
Maximum current: 1 Amp| P5609.16.02|
Ex protection plug cap
Aluminium
Stainless Steel| TX3706.41
TX3706.42|
Ex protection receptacle cap
Aluminium
Stainless Steel| TX3706.43
TX3706.44|

Maintenance

No regular maintenance is required
Flame paths and ingress protection seals should be inspected at periodic intervals, in accordance with local statutory regulations and light protective grease applied when necessary.

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 marketing@trolex.com.
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
© 2016 Trolex® Limited.
Trolex is a registered trademark of Trolex Limited. The use of all trademarks in this document is acknowledged.
Patent pending.
Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK +44 (0) 161 483 1435 sales@trolex.com

Trolex Ltd, Newby Road, Hazel Grove, Stockport, Cheshire, SK7 5DY, UK
t:+44 (0) 161 483 1435 e: sales@trolex.com www.trolex.com

References

• Trolex – At Trolex, we save lives. 60 years of our pioneering safety technology has helped keep workers protected in even the most challenging environments.

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