Operating instructions

Explosion-proof DC twin solenoid

Type : 01 EX01 049A 2424

01 EX01 049B 2424
01 EX01 049C 2424
01 EX01 049D 2424

ATEX 95

Design certificate: TÜV-A 02ATEX0007 X

Registry-No. of above authority: 0408

Declaration of conformity: K10 / 2009

0408
Document : B 01 / 2002

Date as of : 27.01.2010

Producer :

Schienle Magnettechnik GmbH

In Oberwiesen 3
D-88682 Salem-Neufrach

+49 (0)7553-8268 60
+49 (0)7553-8268 61
www.schienle.de
[email protected]
 Explosion-proof twin solenoid – Operating instructions Schienle Magnettechnik GmbH
_______________________________________________________________________________________________________________________________________

Summary page

1 Introduction ……..................................................................................... 3
2 Application ….......................................................................................... 3
3 Apparat …….…........................................................................................ 3
3.1 Apparat overview…………………………….…………………………….….. 3
3.2 Apparat construction – mechanical type ….…………………………….….. 4
3.3 Apparat construction – electrical type …….…………………………….….. 5
3.4 Type coding ………………………………….…………………………….….. 5
3.5 Marking …………………..……..…………………..……………………...….. 5
3.6 Label ……………………………….…………….……………………………. 6
4 Installation and implementing …..….………………………………..…… 7
4.1 Generally ……………………………………………………………………… 7
4.2 Assembly details ………………………………………………………..…… 7
4.2.1 Mounting, Demounting ……………………….….……………..…………… 7
4.2.2 Differential protection …………………………………..………………….… 7
4.3 Compound of the twin solenoid and valve ...........………………………… 8
5 Specification ………………………………………………………………… 8
6 Electrical data ………………..……..………………………………………. 9
6.1 Solenoid with common ground connection ……….….……………………. 9
6.2 Solenoid with separated ground connection ……………….……..………. 9
6.3 Solenoid force characteristic ……………………………….….……………. 10
7 Maintenance, service, troubleshooting .............................................. 10
8 Norms and regulations......................................................................... 11
9 Hints of security ……………………...................................................... 11

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Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

Fax 49 (0) 7553-8268 61 Approved by : D. Gaković As date of : 27.01.2010
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 Explosion-proof twin solenoid – Operating instructions Schienle Magnettechnik GmbH
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1 Introduction
The solenoid was designed, manufactured and tested in compliance with the standards and
regulations generally applicable within the European Union (e.g. ATEX 95). 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 it
works according to the generally accepted engineering standards, the latest legal regulations and
standards of explosion protection.

2 Application
As part of the ATEX-guidelines the solenoid is assigned to device group II, category 2.
The device is designated to be used in areas with explosive gas-, vapor-, aerosol- and air-mixtures.
Pursuant to DIN EN 60079-0 / DIN EN 60079-18 / DIN EN 61241-0 / DIN EN 61241-18, the solenoid with
ignition protection type “mb“ and “mbD” is assigned a maximum permissible surface temperature of
120°C and/or temperature class T4.
To be operated in the following ranges: zone 1, zone 2, zone 21, zone 22.

The basic healthy and safety requirements are fullfilled in according to:

DIN EN 60079-0:2007-05
DIN EN 60079-18:2005-01
DIN EN 61241-0:2007-07
DIN EN 61241-18:2005-07

See installation notice according to point 4!

3 Apparat

3.1 Apparat overview

The explosion-proof DC twin solenoid can be build in different mechanical and electric construction.
More information about the construction in point 3.1 – 3.3.

Table 1 Apparat overview

Type ground connection manual override

01 EX01 049A 2424 common no
01 EX01 049B 2424 common yes
01 EX01 049C 2424 separated no
01 EX01 049D 2424 separated yes

_____________________________________________________________________________________________________________________________________________________________________________________________________________________________

Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

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 Explosion-proof twin solenoid – Operating instructions Schienle Magnettechnik GmbH
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3.2 Apparat construction – mechanical type

Two different versions of the twin solenoid exists (see figure 1 and 2), the version with and without
the manual override.
The manual override is used to move the plunger manually in the energized position when the device is
de-energized.
The port for activating the manual override is located upside of the device (see figure 2).

Figure 1 — Explosion-proof twin solenoid without the manual override

Figure 2 — Explosion-proof twin solenoid with the manual override

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Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

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 Explosion-proof twin solenoid – Operating instructions Schienle Magnettechnik GmbH
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3.3 Apparat construction – electrical type

The both coils of a solenoid are depending on the solenoid connected differently. The ground connection
is either shared or separately connected. When connected shared, the cable occurs 4 wires; the
separated version occurs 5 wires.
The electrical data specification is listed in chapter 6.0.

3.4 Type coding

Type coding
01 EX01 049x yzyz

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

Version, A, B, C, D

3.5 Marking
The marking for all Explosion-proof DC twin solenoid is

II 2G Ex mb II 120°C (T4)

II 2D Ex mbD 21 T120°C

according as EC-Type Examination Certificate: TÜV-A 02ATEX0007 X

_____________________________________________________________________________________________________________________________________________________________________________________________________________________________

Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

Fax 49 (0) 7553-8268 61 Approved by : D. Gaković As date of : 27.01.2010
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3.6 Label

228514/101

228514/101
01 EX01 049A 2424 01 EX01 049B 2424
24V DC R20=27Ω 24V DC R20=27Ω
IG=0,63A IP67 IG=0,63A IP67
TÜV-A 02 ATEX 0007X TÜV-A 02 ATEX 0007X

0408 0408
II 2G Ex mb II 120°C (T4) II 2G Ex mb II 120°C (T4)
II 2D Ex mbD 21 T120°C II 2D Ex mbD 21 T120°C

0405

0405
external fuse IN=1,6A-T external fuse IN=1,6A-T
-35°C ≤ Ta ≤ +40°C -35°C ≤ Ta ≤ +40°C
Schienle D-88682 Salem Schienle D-88682 Salem
www.schienle.de www.schienle.de

Figure 3 — Solenoid 01 EX01 049A 2424 without manual override, common ground connection
Solenoid 01 EX01 049B 2424 with manual override, common ground connection
228514/101

228514/101
01 EX01 049C 2424 01 EX01 049D 2424
24V DC R20=27Ω 24V DC R20=27Ω
IG=0,63A IP67 IG=0,63A IP67
TÜV-A 02 ATEX 0007X TÜV-A 02 ATEX 0007X

0408 0408
II 2G Ex mb II 120°C (T4) II 2G Ex mb II 120°C (T4)
II 2D Ex mbD 21 T120°C II 2D Ex mbD 21 T120°C
0405

0405
external fuse IN=1,6A-T external fuse IN=1,6A-T
-35°C ≤ Ta ≤ +40°C -35°C ≤ Ta ≤ +40°C
Schienle D-88682 Salem Schienle D-88682 Salem
www.schienle.de www.schienle.de

Figure 4 — Solenoid 01 EX01 049C 2424 without manual override, separate ground connection
Solenoid 01 EX01 049D 2424 with manual override, separate ground connection

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Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

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 Explosion-proof twin solenoid – Operating instructions Schienle Magnettechnik GmbH
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4 Installation and implementing

4.1 Generally

● The twin solenoid shall only be operated in a mounted order.

● The ambient temperature range of -35°C until 40°C and the maximum temperature of the
medium (as a rule hydraulic oil) of 70°C shall not be over or rather under stepped.

● It is the user´s 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.

4.2 Assembly details

4.2.1 Mounting, Demounting

● To ensure adequate heat emission only individual valves with predetermined minimum
dimensions shall be used. Dimensions: See below, under 4.3.

● The solenoid must always be mounted on to a clean and plane surface (roughness max. Rz 16).

● The fixing screws of the solenoid shall be tightened with 5,5 Nm and must be locked against
loosening (Gas-nitrided individual valves do not require extra screw locking).
The connection cable must be laid out with sufficient cover.
The device may only be operated with stationary passed connection cable.

● The free end of the connecting cable (open-ended cable) of the solenoid must be connected
by using a suitable certified explosion proof junction box.

4.2.2 Differential protection

● Each coil has to be provided with a fuse (max. 3xIG, slow tripping characteristic), that means on
solenoids with separated coils (type 01 EX01 049C 2424 and 01 EX01 049D 2424) each coil
must be provided with a fuse. This fuse can be positioned separately or mounted in the
associated control unit. The breaking capacity of the fuse has to be identical or greater than
the maximum short circuit current on the installation site
The fuse occur a switching capacity of max. 1.500A short-circuit current (max. 250V at the same
time) according to IEC 60127-2 or EN 60127-2 Recommended: IN=1,6 A-T

● EX-secured components must be used during mounting in case the fuse and/or the
interface are within the EX-range.

● In addition, the solenoid must be connected to earth at the purpose-built ground clamp
on the connector casing

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Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

Fax 49 (0) 7553-8268 61 Approved by : D. Gaković As date of : 27.01.2010
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4.3 Compound of the twin solenoid and valve

The explosion-proof solenoid presented herewith shall only be operated in conjunction with a valve.
The following conditions must be adhered to in all cases where multiple valve stacks are arranged as
interconnected groups as well as in regard of the valve stacks’ minimum dimensions.

a) Valve banks:

● The minimum dimensions of each valve body are 96 x 80 x 49.5 mm. Valve bodies with bigger
dimensions can also be used.
● In case valve banks are intended, these must be lined up directly along the same axis and
must be connected with appropriate connecting elements (screws or tie rods etc.)
● A maximum of one solenoid can be mounted per valve bank section.
● All solenoids of a valve bank can be operated simultaneously in accordance with the provisions
of the operating instructions.
● Never apply a current to both coils simultaneously.

b) Manifold mounting:

● The minimum dimensions of each valve body are 96 x 83.5 x 62.7 mm. Valve bodies with
bigger dimensions can also be used.
● The individual valve bodies are mounted onto a sub-plate (manifold). The minimum
dimensions of the sub-plate are 100 x 67 mm for each valve body. The manifold must be at least
49,5 mm thick.
● The manifold can consist of multiple units that are firmly connected to one another.
● When mounting the individual valve onto the manifold, a minimum gap of 4,3 mm must be
maintained between the individual valve bodies.
● A maximum of two solenoids can be mounted per valve body.
● All solenoids of a valve bank can be operated simultaneously in accordance with the provisions
of the operating instructions.
● Never apply a current to both coils simultaneously.

5.0 Specification
● Coils and plug cavity molded and watertight. Insulation class “F“ (155 °C)
● Protection type DIN VDE 0470, EN 60529 and/or IEC 529 Device: IP 67,
● Insulation of winding and coil body with insulation class IAW DIN VDE 580: “H“ (180 °C)
● O- rings: Viton 85 Shore
● Surface protection (casing) : zinc-coated or chromated
● Colour chromate coat: Yellow or blue
2 2
● Connecting cable: 3+1x0,5 mm or 4+1x0,5 mm Type: Ölflex 440P (4G05 or 5G05) or
HK-SO-UNIPUR 304 (4G05 or 5G05)
● Cable glands, which may be applied:

Tabel 1 Cable Glands

manufacturer manufacturer identification EC type-examination certificate

U.I. Lapp GmbH SKINTOP® MSR-M16 ATEX IBExU01ATEX1041 X

Capri - Codec ADE 1F M16x1,5 LCIE 97 ATEX 6008 X
Hummel HSK-M-Ex 1610.****.** DMT 03 ATEX E 051 X

● Max. operating temperature for operating medium: (e.g. hydraulic fluid) 70°C
● Max. ambient temperature: +40°C minimum –35°C
● Max. operating pressure for operating medium (as a rule: hydraulic fluid): 50 bar

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6 Electrical data

Rated voltage: 24 V DC ± 10% max. supply voltage 24 V DC (for electronics)

Ripple voltage: ± 15%
Limiting current: 0,63 A
Resistance at coil 1: 27,0 Ω ±5% at 20 °C
Resistance at coil 2: 27,0 Ω ±5% at 20 °C
Duty time: S1 (100%ED)

Never apply a current to both coils simultaneously!

6.1 Solenoid with common earth connection

Suppressor are bidirectional voltage limiter – diodes UZ = 36 V, bipolar

Figure 5 — Circuit diagram - common ground connection, wire 1

6.2 Solenoid with separated ground connection

Figure 6 — Circuit diagram - separated ground connection, wire 2 and 3

The circuit board contains 4 bipolar threshold-diodes - only 2 diodes are necessary. 4 diodes create the
system redundant and more safe .

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6.3 Solenoid force characteristic

Figure 7 — Characteristic curves

7 Maintenance, service, troubleshooting

The solenoid generally requires almost no maintenance. All electrical connections shall be checked
regularly for possible damages (visual check).

The surface of the device shall be checked regularly for dust deposits, which should be cleaned off.

The solenoid must always be replaced as one piece. Never try to open or repair the solenoid.

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Fon 49 (0) 7553-8268 60 Compiled by : Z. Krecelj Document : B 01 / 2002

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8 Norms and regulations

Directive 94/9/EG of European Parliament and European Council

(known as ATEX 95)

DIN VDE 0580, Version:2000-07

Elektromagnetic devices and components – general provisions

DIN EN 60079-0:2007-05: Electrical apparatus for explosive gas atmospheres - Part 0: General
requirements (IEC 60079-0:2004, modified); German version EN 60079-0:2006

DIN EN 60079-18:2005-01 Electrical apparatus for explosive gas atmospheres - Part 18: Construction,
test and marking of type of protection encapsulation "m" electrical apparatus (IEC 60079-18:2004);
German version EN 60079-18:2004-04

DIN EN 61241-0:2007-07: Electrical apparatus for use in the presence of combustible dust - Part 0:
General requirements (IEC 61241-0:2004, modified) + Corrigendum Nov. 2005); German version
EN 61241-0:2006-12

DIN EN 61241-18:2005-07: Electrical apparatus for use in the presence of combustible dust - Part 18:
Protection by encapsulation "mD" (IEC 61241-18:2004); German version EN 61241-18:2004-07

9 Hints of security – 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.
● In order not to affect the readability of the solenoid label, the solenoid shall not be varnished.
● Before executing any operation, the solenoid shall be disconnected from the power supply.
● A solenoid shall always be replaced. It shall never be repaired!
● No modifications, which could affect the explosion-safety, shall be carried out on the solenoid, on
the cable gland or on the cable.
● A solenoid shall not be operated separately from the hydraulic valve. See point 4.2
● A solenoid shall only be demounted outside of a explosive area.

Any warranty claims are denied in case the regulations in this operating manual
are not observed !

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