SAMCON liteServer® Ex.mini User Manual

1 Introduction

The liteServer® Ex.mini is a compact and robust scene illumination device (type T20) manufactured by SAMCON Prozessleittechnik GmbH. It utilizes efficient and durable COB LED technology, emitting visible white light with a color temperature of 5000K. This luminaire is versatile for various industrial applications, suitable for area illumination or selective illumination of short to medium object distances in plant and process monitoring. It is ideal for complementing camera systems in dimly lit areas and can be controlled via I/Os or an on-site magnet (mag.ON technology). The liteServer® series (type 20) is certified and approved as a pressure-resistant lighting system, suitable for Ex zones 1, 2, 21, 22, including explosion groups IIC (e.g., acetylene) and IIIC (conductive and combustible dust). The explosion-proof liteServer® Ex.mini searchlight supports both stationary installation and mobile use.

2 Technical Data

2.1 Parameters of the explosion protection

Identification marks according to Directive RL 2014/34/EU:

Explosion protection (gas): Ex db IIC T4 Gb

Explosion protection (dust): Ex tb IIIC T130°C Db

Explosion protection (mining): Ex db I Mb* (only MINING variants)

Protection level: IP 66/68 (IEC/EN 60529) (3m/24h)

Transportation / storage temperature: 0°C ... +70°C

Ambient temperature (EX): -50°C ... +50°C

Noticed body: TÜV Rheinland (number 0035)

EU Type Examination: TÜV 21 ATEX 8696 X (2021)

IECEx certificate: IECEx TUR 22.0076X (2022)

Further certificates: https://www.samcon.eu/en/products/luminaires/liteserver-exmini/

Attention!

The instructions stated on the type and instruction plates have to be observed!

2.2 Electrical parameters

Power supply of the luminaire:

Power supply: 24 VDC ± 5%

Maximum power consumption: 20 W @ 24 VDC

2.3 Other technical data

Housing material: Stainless steel 1.4404

2.4 Illustration of the model key

Explanations:

• liteServer® Ex.mini: Functional description of the liteServer® Series (technical data / specification of the individual module)
• liteServer® Ex.mini: Housing combination (stainless steel 1.4404) with diameter ØVA1=79mm
• 24.: Power supply 24VDC
• WL: COB-LED white, color temperature 5000K
• 100: Beam angle 100°
• T20: SAMCON Production type 20
• VA1.2.K1.BOR: T07 Ex d housing (stainless steel 1.4404) with diameter ØVA1=79mm
• VA1.2.K1.BOR=: T07 VA0.x housing with medium body length (LVA1.2.R = 158mm)
• VA1.2.K1.BOR=: K1 cable gland flange (axial cable gland, standard)
• VA1.2.K1.BOR=: Borosilicate sight glass DIN7080 standard execution
• LL.N: Temperature range (-50°C to +50°C)
• xxx.2: Length of the connection line in meter at delivery. The standard cable length is 5 m, minimum / maximum cable length is: 001...100 [m]
• xxx.2 =: Cable type 2; Ölflex Heat 125MC 4x0,75
• XXX.2M =: Suitable for mining applications; cable type 2; Ölflex Heat 125MC 4x0,75; cable gland with certification for mining
• K: Terminal block termination
• T: Terminal box termination (optional)

2.5 Connection cable

ÖLFLEX HEAT 125 MC

Electron beam cross-linked cables for increased application requirements; connecting cable.

Outer diameter: 7.4mm

Conductor design: 4x0.75mm² (ø=1.4mm), fine-wired tinned Cu-strands acc. IEC 60228 or VDE 295

Bending radius: 15 x outer diameter at installation, 4 x outer diameter after installation

Temperature range: -35°C ... +120°C (at point of installation), -55°C ... +125°C (fixed installed)

Outer sheath/characteristics: Electron beam cross-linked, based on polyolefin copolymer, black, halogen free, flame resistant (EN 60332-1-2), UV and oil resistant.

(Ex)

Attention!

For wiring and connection of the liteServer, DIN/EN/IEC 60079-14 has to be observed.

2.6 Cable gland

2.6.1 Cable gland without mining certification

Ex d gland ADE 1F2 Type 4 - M20x1.5 (Capri)

The cable-cable gland combination has been tested with the following values:

Static pressure resistance: ≤ 26 bar

Longitudinal tightness: acc. to IEC/EN 60079-14 Appendix E.

Test reports you can find in the Downloads: https://www.samcon.eu/en/products/luminaires/liteserver-exmini/

2.6.2 Cable gland for MINING applications

Ex d KLE A2F100 (CMP) (with mining certification)

The cable-cable gland combination has been tested with the following values:

Static pressure resistance: < 40 bar

Longitudinal tightness: acc. to IEC/EN 60079-14 Appendix E.

Test reports you can find in the Downloads: https://www.samcon.eu/en/products/luminaires/liteserver-exmini/

2.7 Technical specification of the illuminant / LED illumination

A cold white high-power COB LED with a nominal power of 16.0 W is used as a radiation source for visible light.

The COB LED is characterized by the following technical properties:

LED Type: COB-LED (InGaN), single phosphor dot, non-matrix arranged, divergent, non-focusing

Power consumption: 16W

Max. power consumption: 20W@24VDC

Rated current: 460mA

Color temperature: 5000K cold white

Luminous flux max.: 2490lm

Beam angle: 100°

3 Safety Instructions

Please observe the installation instruction's safety directions of the T20 liteServer® series!

Quick link: https://www.samcon.eu/fileadmin/documents/en/40-Lightening-systems/liteServer-Series-T20-Ex-Installation-Manual.pdf

Adherence to national safety regulations and accident prevention regulations, as well as the safety instructions in this User Manual is mandatory!

(Ex)

Attention!

Luminaires of type liteServer® Series T20 are not suitable for use in zones 0 and 20. The ambient temperature, temperature class, and explosion group stated on the enclosure's type plate must be observed. Alterations to the housing are not permitted. Use only for the intended purpose and in immaculate condition.

(Ex)

Attention!

Only original parts from SAMCON Prozessleittechnik GmbH may be used for repair. Repair works affecting explosion protection must comply with applicable country regulations and be performed only by SAMCON Prozessleittechnik GmbH.

(Ex)

Attention!

Prior to installation, consider external sources of heat or cold. The permissible temperature range must be observed!

(Ex)

Attention!

Observe the warnings given on the type plate!

"WARNING – DO NOT OPEN IN HAZARD AREAS"

Note: Depending on hazard area classification, a work approval may be necessary. When adjusting the lighting fixture, prevent a potentially explosive atmosphere!

(Ex)

Using the luminaire in explosion-protected areas regarding temperature and dust layers is defined in respective national regulations.

(Ex)

When installing the liteServer®, adhere to the requirements of EN/IEC 60079-14.

⚠️

Attention!

The sight glass must not be covered by foreign objects. Light must leave the optics unhindered. Regular cleaning of the sight glass is recommended to avoid dust deposits.

Risk of burns from hot surfaces (≥80°C)!

Do not stare into the direct beam. Danger of impairment of vision due to high exposure to light!

Prior to first use, test the luminaire according to the instructions in the Commissioning chapter.

Please observe national safety regulations and accident prevention regulations, as well as the safety instructions in this User Manual!

4 Installation

For installation and operation of the liteServer® Ex.mini, national regulations and generally accepted rules of technology shall prevail. Before mounting, check the liteServer® for transportation damages, especially at the housing and cable. Installation, electrical connection, and initial commissioning must be carried out by qualified personnel.

Work preparation:

(Ex)

Attention!

Prepare your work carefully and in accordance with relevant regulations.

(Ex)

Attention!

Depending on hazard area classification, obtaining a work approval is imperative. When opening the pressure-resistant enclosure under voltage, it is absolutely necessary to prevent a potentially explosive atmosphere!

To ensure optimal scene lighting, plan the installation site carefully, considering light conditions, object distance, size, angle, and minimum object distance to the focus.

• Use appropriate tools and aids.
• When working, ensure a safe stand.
• Make sure that any static charge is avoided.

(Ex)

Attention!

Please observe national regulations regarding security, installation, and accident prevention (e.g., IEC EN 60079-14) and the safety guidelines described in the user and EX installation manual!

(Ex)

Attention!

Please observe the installation and commissioning advice described in the Ex-installation manual!

Install the liteServer® Ex.mini at the desired location. Mounting options, conditions, accessories, and safety guidelines are described in the EX installation manual of the T20 liteServer® Series.

(Ex)

Attention!

Prior to luminaire installation, take external sources of heat or cold into account! Observe the permissible temperature range!

Drawings for drill hole patterns and further information can be viewed on our product page: https://www.samcon.eu/en/products/luminaires/liteserver-exmini/

Optional mounting accessories

5 Electrical connection

(Ex)

Attention!

The electrical connection of the equipment must be executed by qualified personnel only!

(Ex)

Attention!

It is mandatory that the housing of the liteServer® Series has to be grounded via a PE-connection!

⚠️

Attention!

If possible, carry out initial commissioning when the outside temperature is above 0°C to prevent condensation inside the housing.

The liteServer® Ex.mini is manufactured with a cable pigtail. Any electro-technical or mechanical work inside the flameproof enclosure by the user is prohibited. The cable connection is furnished with a terminal block termination.

5.1 Potential equalization

The potential equalization (earthing of the housing) is mandatory to avoid electrostatic charging and spark generation. The screw terminal on the housing's rear side is intended for this purpose. The profile of the potential equalization must reflect national grounding instructions (min. 4 mm²).

Ex d gland: ADE 1F2 Type 4 - M20x1.5 (Capri)

Cable: Ölflex HT125

Figure 5.1 – PE connection liteServer® Ex.mini: Shows the luminaire housing with a cable gland and a grounding screw terminal on the rear. A red circle highlights the grounding screw.

5.2 Connection and protection

Power supply of the luminaire:

Power supply: 24 VDC ± 5%

Maximum power consumption: 20W @ 24VDC

Figures 5.2 and 5.3 illustrate the cable termination for the liteServer Ex.mini.

Figure 5.2 – liteServer® Ex.mini T20-VA1.2.K1.BOR-LL.N –xxx.2-K: Depicts the rear of the device with a cable connected. Wires are: Black (BK) to 24VDC, Blue (BU) to GND, Brown (BN) to Tr1, and Grey (GY) to Tr2. The cable is secured by a gland.

Figure 5.3 – liteServer® Ex.mini T20-VA1.2.K1.BOR-LL.N –xxx.2-T: Similar to Figure 5.2, showing the rear of the device and cable connections (BK to 24VDC, BU to GND, BN to Tr1, GY to Tr2). The device label with product information is visible.

Via the black cable the illuminant is supplied with voltage.

⚠️

Attention!

No reverse polarity protection! Ensure correct polarity when making the electrical connection!

(Ex)

Attention!

Cables and wires must comply with the requirements of IEC 60079-0/1/7 & 14.

(Ex)

Attention!

The supply line must have sufficient cross-section. Cable protection must comply with national and international regulations.

⚠️

Attention!

Use only terminals approved by SAMCON.

The power supply is connected via the black (BK) and blue (BU) strands.

Figure 5.4 – liteServer® Ex.mini terminal box termination: Shows an open terminal box with wires connected: BK to DC+, BU to DC GND-, BN to Trigger 1, GY to Trigger 2, and PE to the PE terminal.

The dimensioning of the equipment or supply protection depends on cable length and national regulations.

The release current of the protection must be less than the maximum short-circuit current of the power supply.

5.3 Use cases and their wiring

The liteServer Ex.mini can be switched in the following ways:

5.3.1 Operating the liteServer via external triggers (PCS / I/Os)

The liteServer Ex.mini can be controlled via a process control system or I/Os (e.g., a camera's output module). This allows the light to be switched on via camera motion detection or individual controls based on brightness levels.

5.3.2 Operating the liteServer via internal triggers (mag.ON-technology)

The on-site circuit with magnet works according to the following commands:

Figure 5.5 – Magnetic control mag.ON commands: Illustrates commands using short and long magnet impulses (lightning bolt symbols) with corresponding confirmation signals and results (1 min, 3 min, 10 min, OFF).

The magnet must be held to the magnet-sensitive area for the desired duty cycle.

Watch our video: „SAMCON - magOn – Magnetsteuerung für Ex-Leuchten“ http://go.samcon.eu/magOn

Figure 5.6 – Magnetic control mag.ON Video: A screenshot from a video demonstrating the mag.ON technology, showing a person using a magnet near a SAMCON device.

5.4 Tests prior to switching on voltage

⚠️

Attention!

Prior to commissioning, all tests indicated by national regulations must be executed. Ensure proper functioning of the operating device according to this user manual and all applicable regulations.

⚠️

Attention!

Incorrect installation and operation of the liteServer may lead to a loss of warranty!

⚠️

Attention!

If possible, carry out initial commissioning when the outside temperature is above 0°C to prevent condensation inside the housing.

6 Exchanging the illuminant / LED-block

The illuminant should only be exchanged if defective, using an original spare part of the same model. Opening the Ex d housing is permitted and necessary for this. Follow the steps in this user manual and the T20 liteServer® Series Ex installation manual.

6.1 Work preparation

(Ex)

Attention!

Carry out any pre-operational work carefully and in accordance with applicable regulations.

(Ex)

Attention:

Depending on zone classification, a work permit/clearance might be necessary. When adjusting luminaire settings, a potentially explosive atmosphere must be avoided by any means!

• Use appropriate tools.
• Make sure you have a secure foothold.
• Avoid static charge.

6.2 Opening the pressure-resistant housing

Opening the pressure-resistant housing is allowed only to replace a defect LED. Afterwards, the housing must be closed explosion-proof again. Follow these steps carefully:

„WARNING – DO NOT OPEN IN HAZARDOUS AREA“

Attention:

For opening the liteServer®'s pressure-resistant stainless steel housing T07 VA1.2.K1.BOR, follow the step-by-step instructions in the T20 Ex installation manual!

Loosen the six M4 cylinder-head hexagon screws (DIN 912/ ISO 4762) with spring rings (DIN 127A) on the rear side of the cable and power supply flange. Caution: do not touch screw threads with skin or clothes. LOCTITE® 243TM is applied to threads to prevent loosening. Carefully pull out the cable and supply flange straight to the rear. Due to negative pressure, removal may be difficult. Do not tilt the flange. Risk of damage to the flame-proof gap (DIN EN 60079-1:2012)! Caution: do not touch the cylindrical fit surface with skin or clothes. Lubricating paste is applied to protect against fretting corrosion and mechanical stresses.

When opening, do not damage the GYLON® flat seal (blue, RAL5012) or make it dirty. The gasket is loosely attached to the flange. Pull out the luminaire carefully, avoiding clamping the cables.

(Ex)

Attention!

Beware not to damage the surface of the bore hole and shaft (fit) at the flame proof gap, which prevents ignition transmission.

(Ex)

Attention!

Ensure housing sealings are not damaged and are kept clean.

6.3 Replacing the LED block

To replace the LED-block, carefully loosen the 5 grub screws on the side. The LED block is plugged in and can be removed after loosening the grub screws. Separate at the plug contacts.

Figure 6.1 - Removal of the LED block: Shows the LED block being detached from the luminaire, illustrating grub screws and plug contacts.

Insert the new LED replacement block into the connection socket of the housing flange. Ensure plug contacts and the aluminum heat sink surface are clean and undamaged. After replacement, tighten the grub screws again. Use new, original grub screws. Tightening torque is 1.2 Nm! Loctite 243 may be used for screw locking.

Figure 6.2 - Installation of the new LED block: Shows the new LED block being inserted into the luminaire housing and secured.

When touching electrical components, potential equalization (grounding of the body) must be observed (ESD clothing, PE wristband etc.)! When closing the housing, observe cable routing to avoid collisions and strain, and ensure the necessary bending radius by looping the cable.

6.4 Closing of the pressure-resistant housing

Attention:

For closing the pressure-tight stainless steel T07 VA1.2.K1.BOR housing of the liteServer® Ex.mini, follow the T20 Ex installation manual step by step! Proceed in reverse order of opening. Use only original screws. Check threaded holes for damage and cleanliness. Ensure the flame-proof gap (circularcylindrical fit) is checked before closing.

ATTENTION:

In case of any mechanical damages to the flameproof joint, the housing must not be used anymore!

ATTENTION!

Do not lock-in any foreign objects in the housing.

ATTENTION!

Insert the flange to the end position to ensure ignition protection and the housing's protection level (IP).

Dismantled screw locks (spring washers DIN 127A) must be reused. The GYLON® gasket must be used in undamaged condition, placed between the flange and hull according to the flange hole pattern. If the fitting gap surface is dirty or insufficiently lubricated, clean with a cloth and de-grease, then re-grease with suitable lubricant (e.g., Molykote® P-40 gel or OKS 403 for heavy seawater influence). Screwed connections of flange and body must be tightened crosswise to a torque of 3 Nm! Do not overtighten to avoid rupture or thread stretching, which could impair pressure resistance or ignition protection class. Screws must be provided with a little LOCTITE 243.

Cylinder head screws used for explosion-proof connection of the housing body with the flanges must always be tightened evenly and crosswise with a tightening torque of 3 Nm.

7 Maintenance / Servicing / Alterations

National regulations for maintenance and servicing of electrical devices in hazardous areas must be observed. Maintenance intervals are specific to individual devices and determined by application parameters. During maintenance, focus on checking parts related to ignition protection, such as housing integrity, sealings, and cable glands. Initiate or execute necessary maintenance measures.

8 Repairs and Maintenance

Repairs must only be carried out with original SAMCON Prozessleittechnik GmbH parts. Damaged pressure-resistant housings must be replaced completely. Return applicable parts to SAMCON Prozessleittechnik GmbH if in doubt. Repairs concerning explosion protection must be performed by SAMCON Prozessleittechnik GmbH or an authorized qualified electrical technician, in accordance with national regulations. Rebuilding or alterations to devices are not permitted.

9 Disposal / Recycling

When disposing of the device, nationally applicable regulations must be observed. This document is subject to alterations and additions.

10 Drawings, 3D models, certificates & further documentation

Drawings, 3D models, certificates, and more can be found in the download: https://www.samcon.eu/en/products/luminaires/liteserver-exmini/