Operating instructions

Explosion – proof twin solenoid with protection class:

explosion-proof enclosure

Type : 01 EX11 049x yzyz

Design certificate acc. ATEX: FM 13ATEX 0077 X

II 2G Ex db IIB T4 Gb
II 2D Ex tb IIIC T135°C Db

Design certificate acc. IECEx: IECEx FMG 13.0029 X

Ex d IIB T4 Gb
Ex tb IIIC T135°C Db

Design certificate acc. NEC500 XP, Class I, Div. 1, Grp C, D, T4

And CEC Anex J:

Design certificate acc. NEC500 DIP, Class II, Div. 1, Grp E,F,G T4
And CEC Section 18: DIP, Class III, Div. 1 & 2

Design certificate acc. NEC505: Class I, Zone 1, AEx d IIB T4

Design certificate acc. NEC506: Zone 21, AEx tb IIIC T135°C

Design certificate acc. CEC Section 18: Class I, Zone 1, Ex d IIB T4

Name of certification authority: FM Approvals, 743 Reynolds Rd.

West Glocester, RI 02814 USA

Document : B 22 / 2011
Date as of : 20.04.2016

producer:

Schienle Magnettechnik GmbH

In Oberwiesen 3
D-88682 Salem-Neufrach 0408

+49 (0)7553-8268 60
+49 (0)7553-8268 61
www.schienle.de
 Operating Instructions Schienle Magnettechnik und Elektronik GmbH
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Summary Page

1 Introduction 3
2 Intended use 3
3 Versions 4
3.1 Type coding 4
3.2 Label 5
4 Technical data 5
4.1 General parameters 5
4.2 Electrical data 6
5 Installation and implementing 6
5.1 General 6
5.2 Mounting, Demounting 7
5.3 Compound of the twin solenoid and valve 7
5.3.1 Valve bank design 7
5.3.2 Manifold mounting design 7
5.3.3 Single valve design 7
6 Maintenance, service, troubleshooting 8
7 Norms and regulations 8
8 Specific condition of use – read carefully ! 8
9 Dimensioned drawing 9
10 Non intended use 10
11 EU-Declaration of conformity 11

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1 Introduction
The solenoid was designed, manufactured and tested in compliance with the standards and
regulations generally applicable of the FM approval, ATEX, IECEx and CEC. On leaving the factory
the solenoids safety-related conditions were proven to be faultless. In order to maintain this status and
to ensure safe operation, the operator has to read and observe the notes and warnings contained
within this operating instruction.
The solenoid must only be installed and wire-connected by a qualified technician who is familiar with
works according to the generally accepted engineering standards, the latest legal regulations and
standards of explosion protection.

2 Intended use
The solenoid is provided for use on hydraulic plants.
The device is mounted pressure-tight on the hydraulic device. With this structure an actual heat
conduction is warranted. The interior of the twin solenoid is filled with hydraulic oil and is exposed to
high pressure.
Further on, there are two exciter coils in the interior of the solenoid, whereas only one shall be
activated.The activated coil generates a magnetic field, which executes a force on the solenoid´s
movable part. This force changes the pressure or the flow rate of the medium and causes a
hydraulic actuation which initiates further actuations. The device is manufactured for use as a
proportional solenoid, but can also be used as a black/white device.
An accurate dimension you can find on the page 9, figure 3.

Table 1 Comparison of equipment groups and categories and the associated zones acc. the
regulation 2014/34/EU
Equipment Category Area of use, characteristics (extract from the Directive) Usability in
group acc. acc. zone acc. to
2014/34/EU 2014/34/EU 1999/92/EG
Atmospheres endangered by firedamp (equipment group I), i.e.
underground mines and their surface installations.
I M1 -
Can remain operational in the presence of a potentially explosive
atmosphere. Very high level of safety.
Atmospheres endangered by firedamp (equipment group I), i.e.
underground mines and their surface installations.
I M2 Must be able to be switched off in the presence of a potentially -
explosive atmosphere.
High level of safety.
Potentially explosive atmospheres in which potentially explosive
gases, mists, or vapours are present permanently, or frequently, or
II 1G for long periods (equipment group II). 0, 1, 2
Equates to Zone 0 in accordance with Directive 1999/92/EC.
Very high level of safety.
Potentially explosive atmospheres in which potentially explosive
gases, mists, or vapours are occasionally present (equipment group
II 2G 1, 2
II). Equates to Zone 1 in accordance with Directive 1999/92/EC.
High level of safety.
Potentially explosive atmospheres in which potentially explosive
gases, mists, or vapours are normally not present, or present only
II 3G infrequently, or for short periods (equipment group II). 2
Equates to Zone 2 in accordance with Directive 1999/92/EC.
Normal level of safety.
Potentially explosive atmospheres in which potentially explosive
dust/air mixtures are present permanently, or frequently, or for long
II 1D 20, 21, 22
periods (equipment group II). Equates to Zone 22 in accordance with
Directive 1999/92/EC. Very high level of safety.
Potentially explosive atmospheres in which potentially explosive
dust/air mixtures are occasionally present (equipment group II).
II 2D 21, 22
Equates to Zone 21 in accordance with Directive 1999/92/EC.
High level of safety.
Potentially explosive atmospheres in which a potentially explosive
atmosphere from raised dust is normally not present, or present only
II 3D infrequently, or for short periods (equipment group II). 22
Equates to Zone 22 in accordance with Directive 1999/92/EC.
Normal level of safety.

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Table 2 Device groups II – Temperature classes

Temperature Highest surface Ignition temperature
class temperature of the gas, mist or
vapour
T1 450°C >450°C
T2 300°C >300°C
T3 200°C >200°C
T4 135°C >135°C
T5 100°C >100°C
T6 85°C >85°C

3 Versions
3.1 Type coding
The twin solenoid is manufactured with different supply voltage and power input. The mechanical
structure remains the same.

Table 3 Versions

Labeling NEC 505, NEC 506,

Version Labeling NEC500, CEC Anex J
CEC Section 18

Class I, Zone 1, AEx d IIB T4 Gb

XP, Class I, Div. 1, Grp C, D, T4
Zone 21, AEx tb T135°C
Flame-proof DIP, Class II, Div. 1, Grp E,F,G T4
DIP, Class III, Div. 1 & 2
Class I, Zone 1, Ex d IIB T4

Version Labeling ATEX Labeling IECEx

II 2G Ex db IIB T4 Gb Ex d IIB T4 Gb
Flame-proof
II 2D Ex tb IIIC T135°C Db Ex tb IIIC T135°C Db

Table 4 Type coding

Type coding
01 EX11 049A yzyz

Voltage version e.g. 2424 meaning 24V each coil

Version A with separated ground

Example: solenoid 01 EX11 049A 2424 with separated coils and unshielded cable contains two 24 V
coils.

Table 5 Voltage versions and current consumption

Nominal Nominal Limiting

Version Resistance Suppressor
voltage current current
UN IN R20 IG
[VDC] [A] [Ω] [A]
2x2 voltage-
01 EX11 049x 1212 12 1,9 6,3 1,33
suppressor diode
2x2 voltage-
01 EX11 049x 2424 24 0,89 27 0,63
suppressor diode
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3.2 Label

Figure 1 — Flame–proof enclosure, seprated ground with normal (Version A), shielded
cable (Version B) and common ground normal cable (Version C) and shielded cable
(Version D)

4 Technical data

4.1 General parameters

● Protection type EN 60529, IEC 60529: IP 67
● Operating pressure: max. 50 bar
● Cracking pressure (static): 300 bar
● Coils and coil area are moulded
water-proof and indecomposable.
Insulation class according to DIN VDE 0580 „F“ (155C°)
● Surface protection (casing): DIN50979 Fe//ZnNi4-8//Cn//T0

● Max. temperature of medium

(normally hydraulic oil): 70°C
● Ambient temperature: -40°C until +55°C

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4.2 Electrical data

The electrical data vary depending on the version of the solenoid, see point 3, table 5.

● Nominal voltage: UN = 12[V DC] 24 [V DC] ± 10% max.

● Resistance at 20°C: R20 = 6,3[Ω] -10% 27 [Ω] +10%
● Power-on-time: S1 (100%), but simultaneously only one coil.
● Cold power: P20 = 22 [W]
● Electrical connection: 4(5)+1 x 0,5 mm² / 0,75 mm²
External diameter of the jacket: max. 12 mm
● Protection circuit: Voltage suppressor diode
● The user has to safeguard each solenoid against short-circuit or overload with a fuse
according to IEC 60127-2/V or EN 60127-2/V.

Figure 3 — Connection digramm: unshielded and shielded cable with common ground and
separate connected coils

5 Installation and implementing

5.1 General
The EX-solenoid presented must only be operated on a valve body.
If many valve bodies are connected to a valve composite, the operator shall take care of a minimum
distance between single valves according to point 5.3.1 and point 5.3.2.

The protection class is performed on the label of the solenoid.

The device must only be mounted on an adequately sized hydraulic valve.

Minimum size is according to point 5.3.

The maximum ambient temperature of 55°C and the maximum temperature of the medium (as a rule
hydraulic oil) of 70°C shall not be overstepped.

It is the users duty to ensure free and unhindered heat emission during the operation. That means that
the solenoid shall neither be covered nor stored adjacent to heat sources during the operation. Care is
to be given that the solenoid is not subjected to direct sunlight during operation.

The connection cable must be passed sufficiently protected.

Additionally, the solenoid must be connected to ground via the purpose-built ground clamp at the
connector casing.
Conduit Seal required within 18 inches for use in Division area. Conduit Seal required within 2 inches
(50mm) of the enclosure for use in Zone area.

To maintain IP67 ingress protection, suitable pipe dope or 3 wraps of ½ inch width Teflon tape shall be
required when installing.

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5.2 Mounting, Demounting

Disconnect Power Before Removal!

The solenoid consists of several individual components. These components are fine-tuned to one
another and shall not be replaced or demounted individually.

Notice: The cable and the cable gland must not be changed!

The solenoid is mounted on the hydraulic valve with 3 screws according to ISO 4762-M5x70. To
assure the hydraulic impermeability, two o-rings are placed in the valve slot. The screws must be
tightened with 5 Nm.

No material that can downgrade the heat emission shall be placed between the solenoid and the
valve.

The user has to ensure that the configuration of the solenoids on the valve block is observed
according to the description to point 5.3.

5.3 Compound of the twin solenoid and valve

To ensure adequate cooling, the solenoid shall only be operated in conjuction with a valve block.

When many valve bodies are connected to a valve composite, make sure that the required minimum
size of the single valve and the allowed design of the valve composite are warranted. Following
general condition has to be followed:

All solenoids on a valve composite can be operated simultaneously according to the terms of the
operating instructions.

5.3.1 Valve bank design

3
The minimum volume of a valve body is 380.160 mm . Valves of bigger dimensions can be used.
When using more than one valve, these valves may be directly stringed together in the same axis
with adequate connecting members (screws, con-rods).

On each valve only one twin solenoid must be mounted.

5.3.2 Manifold mounting design

3
The minimum volume of a valve body is 502.603,2 mm . Valves of bigger dimensions can be used.
Particular valves can be mounted on the body material (plate) with a minimum volume of
3
331,620 mm (per valve).
The plate may be composed of several units which are fixed.

When mounting many valves on the plate, a minimum distance of 4,3 mm between the particular
valves must be assured.

Maximum two twin solenoids must be mounted on each valve.

5.3.3 Single valve design

3
The minimum volume of a valve body is 194.400 mm . Valves of bigger dimensions can be used.

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6 Maintenance, service, troubleshooting

The solenoid is largely maintenance-free. The electrical connection shall regularly be inspected on
damages (visual inspection).
The solenoid´s surface is to be checked to dust deposits and is to be cleansed at regular intervals.
The user must not try to open or to repair the device. When failure or damage occurs, the device is
to be replaced.

7 Norms and regulations

FM3600, FM 3615, FM3616, FM3810, ANSI/IEC 60529

ISA 60079-0, ISA 60079-1, ISA 60079-31, ISA 60529
CSA-C22.2 No.0.4, 0,5, 25, 30, 60079-0, 60079-1, 60079-31, 60529
IEC 60079-0, IEC 60079-1, IEC 60079-31
EN 60079-0, EN 60079-1, EN 60079-31, DIN VDE 0580

8 Specific condition of use – read carefully !

● When failure, external damage or defect (also significant corrosion) occurs, the device has to
be shot down and replaced.
● No sedimentations on the solenoid surface shall affect the heat emission.
● Coating of the equipment is permitted as long as its layer thickness does not exceed the limit
value of 2mm for the relevant group "IIB" or EPL "Gb". It is the responsibility of the user to select
a suitable coating that meets the requirements of the IEC/EN 60079-0 standard, in particular as
regards the risk of electrostatic charging.
It is furthermore the user's responsibility to ensure the legibility of the information shown on the
type plate when the coating is applied.
The technical data relating to the electrical system and explosion protection must be
permanently attached by affixing either a type plate or an adhesive label suitable for explosion
protection. It must be possible to restore the legibility of the original type plate by removal of the
coating. The pins of the manual emergency mechanisms should be covered prior to coating
using a small adhesive label for protection.

● Before executing any operation, the solenoid shall be disconnected from the power supply.
● A solenoid shall always be replaced. It must never be repaired!
● No modifications, which could affect the explosion-safety, must be carried out on the solenoid,
on the cable gland or on the cable.
● A solenoid must not be operated separately from the hydraulic valve. See point 5.0
● A solenoid must only be demounted in a non-explosive-area.
• To keep the temperature class the explosion-proof solenoid may only be operated in
combination with a valve block with minimum volume according to the operating instructions.
The maximum media temperature of 70°C must not be exceeded.
• The apparatus has flying lead cable conductors that exit the enclosure. A suitably certified Ex d
or Ex e terminal box is required to be connected to apparatus enclosure for completing to
external supply circuit.

• A repair is not possible.

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9. Dimensioned drawing
Cable protection cap for use
in ATEX and IECEx areas
(no conduit)
Type Hummel HSK-K Flex

Figure 3 — Dimensioned drawing

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10 Non intended use

Any warranty claims are denied in case the regulations in this operating manual are not observed!
Not intended use of this device may rise a risk of serious damage or loose of the explosion proof
safety.

Danger area Danger Safety note

Hydralic connection between Disconnection under pressure Unpressurize the hydrailc
solenoid and hydraulic valve system before disconnecting

Disconnect the solenoid from

Lost of explosion proof safety
the valve only in a de-energized
state
Solenoid surface Skin burning by hot surface of Let the solenoid cool down after
the solenoid de-energizing
Electrical connection Electric shock Work on the solenoid only in a
de-enrgized state
Disconnect the cable from the
electrical voltage
supply/junction box only in de-
energized state

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11 EU-Declaration of Conformity

The manufacturer,

Schienle Magnettechnik und Elektronik GmbH

In Oberwiesen 3
88682 Salem – Neufrach

herewith declares that the product

Description: Explosion – proof twin solenoid

Type : 01 EX11 049x yzyz

EU-certificate: FMG 13ATEX 0077X

Marking: II 2G Ex db IIB T4 Gb
II 2D Ex tb IIIC T135°C Db

Is been designed, assembled and proved in accordance with the EU regulation 2014/34/EU and
following harmonized norms:

EN 60079-0:2012+A11:2013: Explosive atmospheres - Part 0: Equipment - General requirements

(IEC 60079-0:2011, modified + Cor.:2012 + Cor.:2013);

EN 60079-1:2014: Explosive atmospheres - Part 1: Equipment protection by flameproof enclosures

"d" (IEC 60079-1:2014)

EN 60079-31:2014: Explosive atmospheres - Part 31: Equipment dust ignition protection by enclosure
"t" (IEC 60079-31:2013);

Salem-Neufrach 20.04.2016
Place Date Ex-Responsible Person

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