简易正压防爆控制柜用户手册

简单正压防爆控制柜
使用说明书
Type of Protection “nZ”Control Cabinet
Manual
安全提示（Safety Instructions）:
1．本产品为防爆产品，应严格按照本手册的规定进行安装、调试和运行；
To maintain the explosion protection, the rules on installation, testing and operation in this manual should be strictly observed. 2．本产品的供电电压为230VAC，在进行电气维修时应注意安全；
Special attention shall be paid to personal security while electrical maintaining
for its power supply is 230VAC.
3．本产品在正常工作状态下不能随意旋松柜门上的压紧螺钉或打开柜门，这将导致简单正压防爆控制柜压力低报警；
On normal operation, permission is not allowed to arbitrarily open the door of this cabinet or loosen pressure bolts in the door, which may leads to a low-pressure alarm of this type of Protection “nZ”
Control Cabinet.
4．本产品在正常工作状态下不能随意关闭截止球阀或旋转节流阀旋钮，这将导致简单正压防爆控制柜压力低报警或使控制柜承受较大过压；
On normal operation, permission is not allowed to arbitrarily close the cut-off glove valve or adjust the filter regulator, which may results in a low-pressure alarm of this type of Protection “nZ”
Control Cabinet or an over-pressure on the cabinet.
5．本产品在正常工作状态下应至少每周检查一次过滤减压阀滤杯的情况，并清洗滤杯；
It’s necessary to check and clean filter cup of filter regulator for once a week at leas t.
简单正压防爆控制柜使用说明书
Type of Protection “nZ” Control Cabinet Manual
一、概述
简单正压防爆控制柜产品是本公司开发生产的新型防爆产品，产品的设计生产符合GB3836.8-2003《爆炸性气体环境用电气设备第8部分“ n”型电气设备》标准。

产品属3类电气设备（EEx nZ II 3G/D）。

The type of Protection ‘nZ’control cabinet is a new kind of Ex product developed by our company. Its design and manufactory meet the standards of GB3836.8-2003“Electrical apparatus for explosive gas atmosphere Part 8 ‘n’typed electrical apparatus”. The product is marked as
EEx nZ II 3G/D.
本产品的主要功能是：在其内部安装非防爆电气元件，使之能满足在防爆2区使用的要求。

The major function of this product is
to fulfill all requirements in zone 2
by installing non Ex- electrical
apparatus inside the cabinet.
二、产品组成
简单正压防爆控制柜产品由三部分
组成，包括：防护等级IP55以上的密封
仪表柜（见左图）、简单正压控制报警单
元和气路单元(见下图)。

The control cabinet consists of three parts: airproofed instrument cabinet with its degrees of protection over IP55, simplified alarm unit controlled by positive pressure and pneumatics.
1．压力表(Pressure Indicator)
2．报警指示灯(Alarm
Indicator)
3．电源指示灯(Power
Indicator)
4．电源转换开关(Power Switch)
5．隔爆控制箱(Ex d Control
Box)
6．压力控制器
(Pressure Controller)
7．气路单元(Air System)
密封仪表柜采用SS316冷轧不锈钢板制成，防护等级IP55以上，控制柜配有100mm 底框和203mm的角钢底座。

The instrument cabinet is made up of cold-rolling stainless steel (SS316) with degrees of protection over IP55. It is equipped with a bottom board (100mm) and an angle iron-made base (
203mm) .
正压控制单元安装在控制柜侧面，其连接控制柜内外设备的电缆采用金属电缆格栏密封。

柜体内外的控制系统的电气连接采用铠装电缆，并通过铠装电缆格兰密封。

铠装电缆格兰安装在控制柜底部四块可拆卸的格栏安装板上。

控制柜的门是通过设置在门内侧的密封圈和门上的压紧螺钉密封的。

The positive pressure alarm unit is mounted on the side of the cabinet and its bottom metallic glands provide a good sealing for the cables linking to the apparatus inside the cabinet. The input and output electrical connection is made through armored cables which are airproofed by related glands. Cables entry into cabinet is generally from the bottom.
简单正压控制报警单元(见下图)由： DW812.99压力控制器(详见附件一)、压力表，直流电源，防爆指示灯、防爆转换开关、防爆蜂鸣器(安装在控制柜顶部)、安全栅和中间继电器等组成。

简单正压控制报警单元的配置图见附件二。

Simplified positive pressure alarm unit (the following picture) is composed of pressure controller DW812.99 (for details, see appendix 1), pressure instructor, DC power supply, Ex-lamp, Ex-switch, Ex-buzzer, safe barrier, relay and so on. Its configuration of electrical connection is illustrated in appendix 2.
1．直流电源(Power Supply)
2．中间继电器(Relay)
3．安全栅(Barrier)
4．温度显示控制器
(Temp. Controller)
5．接线座(Terminal)
6．防爆蜂鸣器(Ex d Alarm)
压力控制器DW812.99具有控制柜内压力高时泄压的功能，在一定的压力范围内，柜内压力越高，其泄压能力也越大，泄压口在压力控制器侧面。

（注：不能将此口封堵）Pressure controller DW812.99 features releasing gas when the pressure inside the cabinet is high. To a certain extent, the higher the inner pressure is, the more gas the controller releases. The vent is in the side face of the cabinet . (Note: Don’t stop up the vent)
压力控制器的防爆等级为Ex nL IIC T6，其与关联设备：安全栅KFD2-SR2-Ex1.W组合成一个本安控制回路。

Explosion category of the pressure controller is Ex nL IIC T6. Combined with relating apparatus (barrier KFD2-SR2-Ex1.W) it constitutes an intrinsic safety control circuit.
气路系统(见下图)包括：截止球阀、过滤减压阀、补气/换气节流阀、手动阀、排气气缸等组成。

气路连接采用SS316不锈钢管。

气路系统图见附件三。

Air system includes cut-off globe valve, filter regulator, compensation/purging throttle valve, manual valve, exhaust cylinder and so on. Pneumatics is linked by stainless steel (SS316) pipes. For more details on connection of air system, see appendix 3.
1.过滤减压阀 (Filter regulator)
2.补气节流阀(compensation
throttle valve)
3.排气气缸 (Exhaust cylinder)
4.手动阀 ( Manual valve)
5.换气节流阀 (purging throttle
valve)
6. 截止球阀(Cut-off globe
valve)
7. 电缆格栏 (Cable glands)
三、安装使用(Installation instructions)
在安装本产品前，应先检查外包装是否完好，如发现有比较严重的损坏，应及时与产品供应商联系；
Before install, please check the outside package , if it is seriously damaged, connect timely with the supplier.
包装箱打开后，应检查控制柜外观是否有变形，压紧螺钉是否配齐，安装在控制柜外部的设备是否完好；检查一切正常后，才能打开控制柜门，检查门内侧的密封圈和控制柜内安装的设备的完好情况。

After removing the package, firstly, please give a careful look-over on the cabinet according to the following items: the appearance of the cabinet, the number of the bolt, the outside apparatus. Don’t open the door until all of the above is in good condition, then check the sealing ring on the inner side of the door and make sure the inner equipments intact.
在所有检查完成后，就可以开始控制柜的安装就位。

本产品在安装过程中正压外壳需
可靠固定。

所有进入控制柜的电缆导线必须通过合适的电缆格栏进入控制柜内部并保持密封，备用的电缆格栏必须用堵头密封。

The crust of this product must be stably fixed up. Cables and wires entering into the cabinet thread airproofed glands and the spare glands should be blocked with stems.
本产品需采用0.3~0.6MPa的洁净仪表气体，供气流量应不小于20M3/h。

现场配管连接到G3/8的截止球阀上。

见上图。

Clean instrument gas (0.3~0.6Mpa), with its airflow more than 20M3/h, is required for normal operation. Local pipes are joined to cut-off globe valve (G3/8) . See the upper picture.
简单正压防爆控制柜启用前，应检查电缆格兰是否压紧，门装电气元件的密封状况是否良好，控制柜的前后门是否关好压紧，然后检查仪表气源是否到位。

(注意：在首次启用本产品前，应对现场配管进行吹扫，清除因现场配管而留在气管内的杂质，油污，水份等，确保气路通畅。

)
Before the cabinet is put into use, it is necessary to check the door sealing ring, cable glands, electrical components. And then you should ensure the gas supply prepared.
（Note: To guarantee an unblocked air system, remember to purge the local pipes before the first usage because impurity, dirt, steam may be left in these pipes . )在确认一切正常以后，就可以操作程序提示板（详见附件五，提示板安装在吹扫单元控制箱的正面）进行操作。

首先打开截止球阀，调整过滤减压阀的出口压力至0.3MPa，调整补气节流阀的旋钮，预设简单正压防爆控制柜正常工作时的压力200+20Pa，同时记录吹扫开始时间并将手动阀切换到换气位置，进行控制柜的吹扫程序，吹扫时间为30分钟，在吹扫过程中可调整换气节流阀的旋钮，将吹扫时控制柜内的压力调整在200~240Pa的范围内。

When everything is on good condition, follow the operating steps instructed on the board which is stick to the front side of the purging-control box. (For details, see appendix 5). First, open the cut-off globe valve and regulate the outlet pressure of filter regulator to 0.3MPa; then turn the knob of compensation throttle to pre-set the normal working pressure of the control cabinet within 200+
20pa. Meanwhile record the start- purging time and turn the manual valve to the position of “purging”to start the purging procedure. The purging time is 30mins during which you can regulate the purging throttle to maintain the pressure within the scope of 200~240Pa.
在吹扫的整个过程中，如果控制柜内的压力低于100Pa且无法上调，说明控制柜有比较大的泄漏，这时应停止吹扫程序，检查控制柜，查出泄漏点位置，采取堵漏措施，直至控制柜完全密封。

然后，重新开始吹扫程序。

During purging, an obvious leakage may exists if the inner pressure is lower than 100Pa and could not be further higher. Then it is required to stop purging, inspect the control cabinet and take measures to stop up the leaking site until the cabinet is well sealed again.
吹扫时间到后，将手动阀切换至补气位置，观测压力表的指针读数，如压力值相对200Pa有较大的偏差，可调整补气节流阀旋钮，将控制柜内的压力调整在200±20Pa的范围内。

在确认一切正常后，就可打开电源开关，电源指示灯亮，系统正常工作。

When the purging is over, hold the manual valve at the position of “purging”and observe the finger reading on the pressure gauge. If there is a biggish difference between the reading and 200Pa, adjust the compensation throttle valve o keep the pressure within 200±20Pa, When everything is ok, turn on Power supply switch, Power indicator turns on , system works normally.
如果吹扫结束后控制柜内的压力低于80Pa且无法上调，说明控制柜有比较大的泄漏，这时不能打开电源开关，应检查控制柜，查出泄漏点位置，采取堵漏措施，直至控制柜完全密封，然后，重新开始吹扫程序。

If the inner pressure is lower than 80Pa and could not be further higher, then an obvious leakage may exists. At this time, instead of turning on Power supply switch, you should inspect the control cabinet and take measures to stop up the leaking site until the cabinet is well sealed again. Then, purging procedure is allowed to restart.
控制柜在正常工作时，如果控制柜内压力下降至80Pa以下时，简单正压控制报警单元会进行声光报警，同时可提供一个远传的无源触点信号。

现场工作人员在接到压力
低的报警后，应及时从下列几个方面查明原因，只有在完全排除故障后，简单正压防爆控制柜才能按规定程序重新启用。

On normal condition, if the inner pressure of the control cabinet drop to 80Pa, the alarm unit will give an sound & light alarm, and provide a passive contact signal for remote apparatus. Once receiving the low-pressure alarm, local operators should timely find out troubles according to the following aspects，The control cabinet is not allowed to restart in accord with operation procedure until all troubles has been eliminated.
1) 观察压力表的指针读数，如读数值低于80Pa，则应进行下列2)~6)项检查；如读数值大
于80Pa，则应进行下列7)项检查。

Observe the pressure gauge reading, if the reading is below 80Pa, have a check according to the following steps 2)~6); otherwise, go to the 7) straightly.
2) 检查过滤减压阀压力表读数是否在设定范围内，判断是否气源供应问题；
Make sure the pressure gauge reading of the filter regulator within the set scope
3) 检查控制柜门是否完全压紧关好；
Make the door completely impacted.
4) 打开控制柜门，检查密封圈是否有损坏；
Open the door to see whether there is damage on sealing ring.
5) 检查进入控制柜的电缆格栏是否密封完好。

Ensure the cable glands well sealed.
6) 检查气路系统的连接部位是否有泄漏；
Check the air system to see whether there is a leakage in joint.
7) 打开防爆控制箱，检查简单正压控制报警单元中中间继电器RM2、安全栅SB的工作是
否正常。

Open the Ex-d control box to see if the relay (RM2) and safe barrier (SB) works well.
附件一
Appendix 1
简单正压外壳的压力控制器DW812.99
Pressure Control protected DW812.99
1．概要Outline
压力控制器监测控制柜体中必要的最小压力80Pa。

当超过必要的最小压力过多时，它能通过内置的压力调节阀进行安全的释放（阀塞）。

吹扫气体通过多空喷嘴进入腔体，减少吹扫的噪音。

为控制柜体提供吹扫的气体压力通常是0.3MPa。

吹扫气体的流量要满足维持最小正压80Pa，可以通过螺丝起子在多孔喷嘴上设定。

Pressure controller supervises the necessarily overpressure (80Pa) inside its enclosure. When the pressure is over 80Pa, it can be safely released by an inside regulator. A porous nozzle is used to low the noise of purging. The gas pressure is normally 0.3Mpa and the flux should be guaranteed to maintain the minimum positive pressure (80Pa), which can be set on the porous nozzle by screwdriver.
在打开压力控制器前，必须获得操作许可。

The box mustn’t be opened without operation permission .
图(1)：压力控制器DW812.99
尺寸120*120*90 mm
Dimension 120*120*90 mm
－S1 关闭（蓝色紧闭螺孔）Close (blue closeness screw)
－S2 打开（红色紧闭螺孔）open (red closeness screw)
－P3 控制柜体的过压测量（基于大气压力测量）overpressure measurement
(Based on atmospheric pressure)
2.安装Mounting
2．1 压力控制器固定在控制盒的外部
The pressure controller is fixed up outside the box
如果压力控制器固定在控制柜的外部，处理80Pa压力开关信号的电路必需使用本安型电路。

（见模块图）
If the controller is fixed outside the box, intrinsically safe circuit must be used to handling signals from pressure vessel(80Pa) (见模块图)
2．2 压力控制器安装在控制柜内部
The pressure controller is fixed up inside the box
如果压力控制器固定在控制柜的内部，处理80Pa压力开关信号的电路可以使用本安型电路或最大额定电压直流24V和最大电流20mA的非本安型继电器。

（见模块图）除了电气连接以外，确认安装与环境压力相联的套管
If the controller is fixed up inside the box, the circuit dealing with signals from a pressure vessel can either be intrinsically safe or use non-intrinsically safe relay with max voltage DC 24V and max current 20mA. (see modules) Except the electrical connection , make sure that the bushing used is suitable for environment pressure..
3．简单正压外壳的压力控制器DW812.99的防爆认证证书
Ex-Authentication of pressure controller DW812.99
图(2) 压力控制器DW812.99的防爆认证证书
4．简单正压外壳的压力控制器DW812.99的外形尺寸图
The Dimension of pressure controller DW812.99
图(3) 压力控制器DW812.99的外形尺寸图
5．简单正压外壳的压力控制器DW812.99的安装示意图
The mounting of pressure controller DW812.99
(压力监控器DW812.99正压外壳的内部)
(the inner sketch map of DW812.99)
图(4) DW812.99的安装示意图（1）
图(4) 压力控制器DW812.99的安装示意图
6．简单正压外壳的压力控制器DW812.99的电气原理图
The electrical connection of pressure controller DW812.99
图(5) 压力控制器DW812.99的安装示意图（2）附件二：简单正压控制报警单元电气配置图
Appendix 2: The electrical configuration of alarm unit
图(6) 简单正压控制报警单元电气配置图
附件三：简单正压控制柜气路图
Appendix 3: The air system of type of protection of “nZ” cabinet
图(7) 简易正压防爆控制柜气路图
附件四：简易正压防爆控制柜操作提示板
Appendix 4: Operating procedure for type of protection “nZ” control
cabinet
1.关闭柜门并压紧密封。

Close the door and make the sealing ring impacted.
2. 打开截止球阀，确认过滤减压阀出口压力至0.3MPa。

Open the cutoff globe valve, and confirm the outlet pressure of filter pressure valve to 0.3Mpa.
3.将手动阀切换至换气位置，确认压力表读数为200~240Pa。

记录换气开始
时间。

换气需时30分钟。

Hold the manual valve at the position of ‘purging’, and confirm the gauge reading within the scope of 200~240Pa. then record the starting time of purging and the whole process needs 30mins.
4.换气时间到，将手动阀切换至补气位置，确认压力表读数稳定在200Pa；
When the time is over, hold the manual valve at the position of ‘compensation’ and confirm the purging throttle to maintain the gauge reading at 200Pa.
5.打开电源开关，出现短时声光报警(系统自检)，电源指示灯亮，系统正常
工作。

Turn on power supply switch, Power Indicator turns on after a temporary alarm of self-check. System works normally.
应急处理要点：
Tips for emergency:
1.在吹扫阶段如压力表读数小于100Pa且无法上调，应停止吹扫程序，检查
控制柜的密封情况；
If pressure gauge reading is lower than 100Pa and can not be further higher during purging, then stop purging and check cabinet sealing.
2.如简单正压控制单元压力低报警，马上观察压力表和过滤减压阀出口压力
值。

如读数正常，说明简单正压控制单元有故障；否则，说明气源供气不正常或控制柜和气路单元有泄漏。

Once there is a pressure low-alarm from control unit, Observe the gauge reading and the outlet pressure of filter regulator valve immediately. If the reading is normal, then the control unit has a malfunction. Otherwise there may be a leakage in tubing or an abnormality on air supply.
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