ABTQ-103 rev 01
Last review: 21-02-12
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS FOR
ABTECH ‘PCS’ Control Station
Purpose of Instructions
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Working in hazardous areas, the safety of personnel and plant depends on complying with all relevant safety regulations.
Installation and maintenance personnel working on installed product have a particular responsibility to ensure any applicable
standards and regulations are complied with.
These instructions give a brief summary of the most important safety measures. It should be read in conjunction with the product
certificate and any applicable national and local regulations.
Safety Instructions
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The PCS control station should be used only for its intended purpose.
PCS control stations are not suitable for Zone 0 hazardous areas!
No alterations to the apparatus is permitted.
The PCS control station should not be used if damaged
Any damage may invalidate the Ex protection.
Observe the following during installation and operation:
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Any relevant National safety regulations;
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Local safety regulations:
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International installation regulations(e.g. IEC 60079-14);
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The following installation instructions contained in this manual
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Any values or instruction printed on the apparatus label.
The PCS control stations are designed, manufactured and tested in accordance with ISO 9001. The PCS control stations complies the following
standards:
IEC60079-0:2004 EN60079-0:2006 IEC60079-1:2003 EN60079-1:2004 IEC60079-7:2001
EN60079-7:2003 IEC61241-0:2004
EN61241-0:2006 IEC 61241-0:2004
EN61241-0:2006
Applicable Scope
The function of the apparatus is based on the performance and use of built-in components.
The permissible Ex components can be used as following:
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CZ0201 Series Explosion-proof switch module. This module can be used in the PCS control station when installed in a circuit where
rated working voltage is AC250V (+28%) or below to control electromagnetic starter, contactor, relay and other electric circuits.
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CZ0202 Series Explosion-proof signal lamp. Lamp modules can be used in the PCS control station where working voltage is AC24240V or DC24-36V. The correct module should be chosen for the applicable working voltage.
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CZ0205 Series Explosion-proof ammeter module. The ammeter module can be used to measure or display the current in an ac circuit.
Technical Data
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Coding:
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Control station with ammeter only:
II 2GD Ex e IIC T6/Ex tD A21 IP66 T80ºC -40°C≤Tamb≤40°C
II 2GD Ex de IIC T6/Ex tD A21 IP66 T80ºC -40°C≤Tamb≤40°C
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Control station(except with ammeter only):
Certificate no.:
DNV 12 ATEX 13746
Degree of protection:
IP66
Ambient temperature:
-40°C≤Tamb≤40°C
Material of enclosure:
Polyamide
Tightening torque for cover screws:
2.0Nm
Internal earthing:
Terminal 2x 2.5mm² (tightening torque: 1.1Nm)
Abtech Limited, Sheffield, S9 2UA, United Kingdom
www.abtech.eu
1/5
ABTQ-103 rev 01
Last review: 21-02-12
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Main technical data of built-in Ex components:
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CZ0201 Series Explosion-proof switch module
ƒ Ex- mark:
G ll 2G Ex de llC
ƒ Test certificate:
IECEx CQM 08.0005U
DNV-2008-0SL-ATEX-21657U
ƒ Degree of protection :
IP20
ƒ Rated voltage:
250V;
ƒ Rated current:
16A max.
ƒ Rated insulation voltage: 690V
ƒ Rated withstand voltage: 6KV (Uimp)
ƒ Conventional closed heating current: -55ºC≤Ta≤40°C - Ithe16A; -55ºC≤Ta≤60ºC - Ithe - 10A
ƒ Breaking capacity: Rated voltage
250V
250V
110V
24V
ƒ Utilisation category:
AC12
AC15
DC13
DC13
ƒ Rated current:
16A
10A
0.5A
1A
ƒ Contact type:
1N0+1NC, 2NC, 2N0
6
ƒ Mechanical life:
10 times (3600/h)
ƒ Connection type:
Terminal 2 x 2.5mm²(With spring washer). Terminal material 304 stainless
ƒ Connecting lead:
2 x 2.5mm² (tightening torque: 1.1Nm)
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CZ0202 Series Explosion-proof signal lamp module
ƒ Ex- mark:
G ll 2G Ex de llC
ƒ Test certificate:
IECEx CQM 08.0006U
DNV-2008-0SL-ATEX-21658U
ƒ Degree of protection :
IP20
ƒ Rated insulation voltage: 300V;
ƒ Rated service voltage:
AC24 ~ 240V
DC24 ~ 36V
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ƒ Electrical life:
10 working hours
ƒ Ambient temperature:
-55ºC≤Ta≤60ºC
ƒ Connection type:
Terminal 2 x 2.5mm²(With spring washer). Terminal material 304 stainless
ƒ Connecting lead:
2 x 2.5mm² (tightening torque: 1.1Nm)
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CZ0205 Series Explosion-proof ammeter module
ƒ Ex- mark:
G ll 2G Ex e ll
ƒ Test certificate:
IECEx CQM 08.0007U
DNV-2008-0SL-ATEX-21659U
ƒ Rated insulation voltage: 690V
ƒ Accuracy class:
1.5
ƒ Operation type:
Electromagnetic
ƒ Ambient temperature:
-40ºC≤Ta≤60ºC
ƒ Connection type:
Terminal 2 x 2.5mm²(With spring washer). Terminal material 304 stainless
ƒ Connecting lead:
2 x 2.5mm² (tightening torque: 1.2Nm)
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P†/K†/L† Switch Operators
ƒ Ex- mark:
G ll 2GD Ex e ll
Ex tD A21
ƒ Test certificate:
IECEx CQM 08.0012U
DNV-2008-0SL-ATEX-46028U
ƒ Degree of protection:
IP66
ƒ Ambient temperature:
-40ºC≤Ta≤55ºC
ƒ Tightening torque:
5Nm (operator retaining nut)
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Cable Glands:
ƒ Certification level:
ƒ Degree of protection:
ƒ Ambient temperature:
ƒ Tightening torque:
G ll 2GD Ex e ll
Ex tD A21 (Atex certified)
IP66
-40ºC≤Ta≤55ºC
M20 x 1.5p – 3.0Nm; M25 x 1.5p – 4.0Nm
Abtech Limited, Sheffield, S9 2UA, United Kingdom
www.abtech.eu
2/5
ABTQ-103 rev 01
Last review: 21-02-12
PCS Control Station Dimensions
PCS01
PCS02
PCS03
PCS05
PCS06
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PCS01
95 X 86 x 76
135 x 86x 76
175x86x 76
175x 100 x 76
215x 100 x 76
PCS02
PCS03
PCS05
PCS06
PCS51
Type
P1
P2
P3
P4
Y0
Y1
Operator
Pushbutton (rubber)
Double Pushbutton (Rubber)
Emergency Stop
Black Mushroom Head
Red Mushroom Head (key)
Pushbutton (key)
L (mm)
15.5
15.5
41.2
41.2
24.0
28.0
Type
K4 – K8
S4 – S8
L†
P†/B1
DW
EXM
Operator
Selector Switch (small)
Selector Switch (large)
Signal Lamp Bezel
Illuminated Pushbutton/Stopping Plug
Potentiometer Head
Ammeter Window
L = Height of operator head from front face of control station (mm)
Abtech Limited, Sheffield, S9 2UA, United Kingdom
www.abtech.eu
3/5
L (mm)
30.5
30.5
22.6
17.5
30.5
12.0
ABTQ-103 rev 01
Last review: 21-02-12
Operation & Installation
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Transport and storage in original packaging only. Any national or local safety and/or installation regulations and good engineering
practice must be observed when mounting and operating this equipment.
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The user shall observe the following conditions in order to ensure the safe operation of the PCS control station.
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The Abtech PCS control station is suitable for use in hazardous areas, zone 1, 2 and 21, 22.
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The Abtech PCS control station should be used under the following atmospheric/ambient conditions:
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The pressure is 80kPa(0.8bar)-110kPa(1.1bar)
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The volume ratio of standard oxygen content is 21% air;
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The Ambient relative humidity is less than: 95%;
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The PCS control station is designed for use subjected to normal industrial levels of vibration. It should not be
mounted such that it is exposed to excessive levels of vibration or shock.
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Conductors must be connected with due care, e.g. multi stranded conductors should be fitted with a ferrule
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Insulation must be stripped back no more than 1mm from throat of terminal;
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Damaged conductors or conductors with damaged insulation should not be used;
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All screws, used and unused, on the connection terminals, must be fully tightened. This should be checked prior to
commissioning;
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The earth conductor should be at least the same cross sectional area as the live conductors;
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It is the users responsibility to ensure the IP rating of the apparatus is maintained;
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Caution: de-energize before opening!
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Cable gland & stopping plug
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Only certified cable glands and stopping plugs should be used with this apparatus.
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If a cable gland or stopping plug with degree of protection lower than IP66 is used, the IP rating of the apparatus will be
reduced to that of the entry device. (Cable gland or stopping plug must have minimum IP rating: IP54)
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The installation, operation and maintenance instructions applicable to the cable gland or stopping plug must be adhered to.
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Ensure that the cable gland, appropriate for the cable diameter and type is used.
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Unused operator holes and cable entry holes must be closed with a certified blanking plug appropriate for the hole diameter
in order to ensure the required minimum protection category.
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IMPORTANT: Cable glands and stopping plugs should be tightened according to the manufacturers instructions. Care
should be taken not to over tighten of cable glands or blanking plugs as this may impair the ingress protection properties of
the device.
Component Installation
Contact Block/Lamp Module
The required contact block/lamp module (item 1) should be snapped
onto the plastic rail moulded into the body (item 2) ensuring that it
clicks into one of the spacing slots.
Plastic Moulded Earth Terminal
Plastic earth terminal (item 3) can be fitted to either the top or bottom
of the enclosure (item 2)
Metal Earth Plate
Where metallic cable glands or stopping plugs are used they should
be fitted to the metal earth plate (item 4) The metal earth plate is
threaded to suit the appropriate cable gland or stopping plug.
Combining Enclosures
It is permissible to join two enclosures together using the connecting
bolt (item 5) and locknut (item 6). Corresponding 25mm diameter
holes should be drilled in the adjoining faces of the enclosures to be
connected and the seal (item 7) clamped between the two enclosures.
Abtech Limited, Sheffield, S9 2UA, United Kingdom
www.abtech.eu
4/5
ABTQ-103 rev 01
Last review: 21-02-12
Installation of Operator/Lamp Bezel
The operator/lamp bezel (item 8) should be fitted to the cover,
ensuring that the tab on the operator is aligned with the keyway in the
cover hole. The locknut (item 10) should be fitted to the rear of the
operator and tightened using the appropriate socket spanner (item 9)
to the recommended torque of 5Nm.
Ensure that the actuating pins of the operator align with the plungers
in the contact block or the lamp bezel aligns with the lamp module.
Operator Label
The labels (item 11) fitted to the operator heads may be changed by
placing screwdriver or other implement behind label and levering off.
New label is push into slots.
Tag Labels
Tag labels may be fitted to the top of the enclosure as shown.
IP Cover
Key operated pushbuttons may be supplied with an IP cover which
should be replaced when the key is not being used in order to
maintain the IP rating of the enclosure.
Components and Spare Parts
Only, operators, bezels, contact blocks and lamp modules supplied by Abtech should be fitted to the PCS control stations. Similarly, only spare
parts supplied by Abtech should be used.
Maintenance
The conditions of certification and any special conditions for safe use, noted in the certificate should be strictly adhered to, along with the
instructions laid down in this manual. The apparatus must be de-energised prior to removing the cover or replacing any parts.
This work must be carried out by a competent person.
The following should be checked during maintenance:
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Check for compliance of the apparatus with respect to ambient temperatures.
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Check for any damage to seals and gaskets.
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Check for any damage to contact block/lamp module and operator head/lamp bezel.
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Check contact block/lamp module is securely positioned in enclosure
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Check contact block/lamp module terminals for tightness
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Check condition of conductors and wiring insulation
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Check earth connection
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Check cable glands/stopping plugs as per manufacturers recommendations.
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Clean exterior of enclosure with a damp cloth to remove any build up of dust.
Disposal/Recycling
Any local or national regulations regarding the disposal of this equipment should be adhered to. For further information please contact Abtech
technical department.
Abtech Limited, Sheffield, S9 2UA, United Kingdom
www.abtech.eu
5/5