AVENTICS AV03 Valve System Instruction Manual

Operating instructions and safety instructions
Valve system, ATEX certified
AV03/AV05
3 G Ex nA IIC Gc
-10 °C ≤ Ta ≤45 °C

AV03 Valve System

About this Documentation

This documentation applies exclusively to ATEX-certified valve systems of series AV03/AV05.

• Please observe the also applicable documentation. This documentation is intended for system designers, installers, service personnel, and system owners and contains important safety information on the safe and proper assembly, commissioning, and operation of the product.

Required and supplementary documentation

• R412018507, Valve system assembly, and connection, AV03/AV05; assembly instructions
• R412018508 Valve system extension with base plates, supply plates, and combination platesAV03/AV05, assembly instructions
• R412018134, bus couplers, I/O modules, AES, assembly instructions
• R412019225 Pin assignment for D-Sub connection, socket, VS AV03/AV05, pin assignment scheme
• R412015575, Notes on safety, valve systems
• System description of the concerned bus coupler
• Assembly instructions for pneumatic components

All documentation except for the assembly instructions for pneumatic components are also found on CD R412018133.

Presentation of information Symbols

Operation may be impaired if this information is disregarded.

Abbreviations used

VS always refers to the AV03 and AV05 series described in these instructions, unless otherwise specified.

For Your Safety

• Read these instructions completely and the required and complementary documentation before working with the VS (see “Required and supplementary documentation”).
• Keep this documentation in a location where it is accessible to all users at all times.
• Always include this documentation and the required and additional documentation when you pass the VS on to third parties (see “Required and supplementary documentation”).
• Also follow the documentation for the other system components.

Intended use
Valve systems of series AV03/AV05 labeled with the ATEX  identification are approved for use in explosive environments within zone 2 (category 3G). They must always be mounted in a control cabinet that fulfills the requirements in accordance with the ATEX directive 2014/34/EU.

• Use within the limits listed in the technical data and on the nameplates.

Improper use

The device may not be used in firedamp protection areas. It is also considered improper use

• if the VS is used without an ATEX control cabinet,
• when it is used for any application not stated in this documentation,
• it is used for any application not stated in the required and complementary documentation (see “Required and supplementary documentation”),
• when it is used under operating conditions that deviate from those described in this documentation,
• it is used under operating conditions that deviate from those described in the required and complementary documentation (see “Required and supplementary documentation”).

Personnel qualifications
Assembly, disassembly, and commissioning require basic electrical and pneumatic knowledge. Assembly, disassembly, connection, commissioning, and operation may therefore only be carried out by qualified electrical or pneumatic personnel or an instructed person under the direction and supervision of qualified personnel. Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures, due to their professional training, knowledge, and experience, as well as their understanding of the relevant regulations pertaining to the work to be done. Qualified personnel must observe the rules relevant to the subject area.

The following must be observed:
General information

• Observe the regulations for accident prevention and environmental protection in the country where the product is used and at the workplace.
• Observe the applicable national regulations for explosive areas.
• The ATEX approval only applies to the delivered configuration.
• The AV system has component approval. The system owner must evaluate and finally certify the overall system!
• Only use the device within the performance range provided in the technical data and on the nameplate. There is a danger of explosion if you do not comply with the limits. Please observe, in particular, the information from the ATEX identification.
• Always connect the AV03/AV05-VS (if available) grounding connection (1) to the respective grounding system on your installation.

• Ensure the relevant system component is not under pressure or voltage before assembling or when connecting and disconnecting plugs. Protect the system against being restarted.
• Make sure that the supply voltage is protected against overvoltage in explosive areas.
• Protect the product against mechanical impacts.
• Protect the product against UV radiation.

During facility design

• You may use products with ATEX identification in zone 2 (category 3G).
• Use compressed air generated and prepared outside the explosive area as the pressure medium.
• The temperature of the medium and the ambient temperature must not exceed the maximum stipulated in “Technical Data”.
• The overall power consumption of the VS may not exceed 20 W.
• Configure the system accordingly.
  The maximum expansion stage is determined by the AVENTICS online configurator.

On installation

• Always mount the VS in a control cabinet that fulfills the requirements in accordance with the ATEX directive 2014/34/EU.
• Connect conductive metal parts to each other for potential equalization and ground the valve system.
• Connect all electrical push-in fittings and ensure their correct position.
• Always observe the permissible limit values when connecting the device to the power supplies and peripheral devices.
• The warranty will not apply if the product is incorrectly assembled.

During operation

• Only use compressed air as the medium in accordance with ISO 8573-1 that does not corrode the system and sealing materials contained therein (see “Technical Data”).
• Never change from oiled to oil-free compressed air.

Care and Maintenance

• The device must be regularly maintained and cleaned if used in explosive areas. The intervals have to be stipulated by the system operator in accordance with the local ambient conditions, e.g. with dust deposits of approx. 0.5 to 1 mm.
• Only use original spare parts that have also been approved for use in explosive areas.

Exchanging components

• Danger of explosion! Do not release plugs or valves when the VS is under voltage.
• Before you release the plug or replace valves you must disconnect the valve system from the supply voltage and ensure that there is no explosive atmosphere.
• Make sure that all components and seals are mounted correctly before recommissioning the system.

Conversion of the Valve System

• Conversion of the valve system for use in explosive atmospheres is permissible exclusively within the scope described in the documents listed in the section “Required and supplementary documentation”. Generally verify in the AVENTICS online configurator, whether the new configuration complies with the ATEX requirements. Document this verification before commissioning the device.
• The warranty of AVENTICS only applies to the delivered configuration. The warranty will not apply after a conversion that cannot be presented in the AVENTICS online configurator.

ATEX identification

AVENTICS
30880 LAATZEN – GERMANY
AV03 and/or AV05
INERIS 15ATEX3001U
(Serial number)
(Year of construction)
II 3 G
Ex nA IIC Gc
WARNINGS:
– DO NOT SEPARATE WHEN ENERGIZED.
The AV valve system is certified as a component according to the EU directive 2014/34/EU. Final certification including the temperature index for the cover housing must be carried out by the system constructor in conjunction with the system certification. Valve systems of the series AV03/AV05 with ATEX identification comply with the requirements of the EU-directive 2014/34/EU. Characteristics and applications that are derived from the ATEX ID are explained in the following:

INERIS 15
ATEX3001| Design sample certification
U| EX component –see the operating instructions for additional requirement
nA| Ignition protection type: No danger of ignition with normal operation
IIC| Sub-group C
Gc EPL| see equipment category

Warning signs on the device

• Observe the following warning signs on the device:
  

WARNING
Do not separate when energized
Identification on the nameplate

1. Warning: Do not disconnect when energized

2. ATEX symbol

3. Mat. no.

4. Serial number

5. Registered trademark of  AVENTICS GmbH and address

6. Series designation

7. QR code

8. Date of manufacture:
   [Year]W[week]

9. ATEX identification

Technical Data

General data

(measured between two actuated coils)
Permissible medium| Compressed air
Max. particle size| 40 pm (oil-free and oiled compressed air)
Oil content of compressed air| 0…5 mg/m3
The pressure dew poin must be at least 10°C below the ambient and medium temperatures and must not exceed 3°C.
The oil content of compressed air must remain constant during the life cycle.
► Use only the approved oils from AVENTICS.
Operating pressure| -0.9…10 bar (-13…145 psi) with external pilot
3…8 bar (43.5…116 psi) with internal pilot
Nominal flow On at 6 bar and Op = 1 bar| AV03: max. 300 Umin
AV05: max. 700 Umin
Protection class according to
EN 60529/IEC529| IP 65 (only when assembled)
Mounting orientation| Any
Operating voltage for valves| 24 V DC (t10%)
Power consumption per coil| 0.55 W (reduced)
protection| Secure in VS with field bus variants UA and UL each with max. 0.5 A (characteristic B).

Standards and directives complied with
See “Certificate of Conformity”

nach ATEX-Richtlinle 2014/34/EU / in accordance with ATEX Directive 2014/34/EU

1. Apparatus niollel/Product:.— 1 Valve systems of series AVO3 and Avo6-include valves a—s-: well as bus couplers and I/O modules of series AES electronics ‘
2. Name and address of the manufacturer: AVENTICS Gmbh Ulmer Str. 4 30880 Laatzen, GERMANY
3. This attestation of confOnTitYliiisued under the sole responsibility of the manufacturer._ tIT Object of this attestation
4. Valve systems of FteiliiiKV03 and AVO5 with folio-Wing _, marking: ell 3G Ex nA IIC Cc
5. The67314iaorthiieedErraiiiiii described above is in conformity with the relevant European Union harmonization legislation: ATEX Directive 2014/34/EU
6. References to the relevant harmonized standards used:
7. Important information:
   • Valve systems of series AVO3 and AVO5 are intended to be i.ised in an ambient temperature range from -10°C to +45°C. The service temperature range from -10°C to +102°C must not be underrun nor be exceeded.
   • Valve systems of series AVO3 and AVO5 have to be installed in into housing with at least IP54 (corresponding to EN 60019-15). The enclosure must be equipped with ATEX-certified cable glands.
   • All electrical connectors and valves must not be disconnected while powered, electrically.
   • The power consumption of the valve system must not exceed 20W, taking into account external devices connected to the manifold, as well.
   • The instructions in the operation manuals have to be followed strictly, in order to reduce ignition risks as far as possible.

The data specified above only serve to describe the product. No statements concerning a certain condition or suitability for a certain application can be derived from our information. The given information does not release the user from the obligation of their own judgment and verification. It must be remembered that our products are subject to a natural process of wear and aging.
An example configuration is depicted on the title page. The delivered product may thus vary from that in the illustration.
Translation of the original operating instructions. The original operating instructions were created in the German language.
R412026229–BAL–001–AA/2018-01 Subject to modifications. © All rights reserved by AVENTICS GmbH, even and especially in cases of proprietary rights applications. It may not be reproduced or given to third parties without its consent.

AVENTICS GmbH
Ulmer Straße 4
30880 Laatzen, GERMANY
Phone +49 (0) 5 11-21 36-0
Fax: +49 (0) 511-21 36-2 69
www.aventics.com
info@aventics.com

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