Eaton Crouse-Hinds CU1 Combined Sounder and Xenon Beacon

Introduction

This range of combined sounders and beacons is intended for use in potentially explosive gas atmospheres and has been designed with high ingress protection to cope with the harsh environmental conditions found offshore and onshore in the oil, gas and petrochemical industries.

The unit is available in two versions suitable for use in the following ambient temperatures:

• CU1-S Standard unit – Ex db eb IIB T4 (Tamb -50°C to +50°C) IP66 and IP67
• CU1-H High temperature unit – Ex db eb IIB T4 (Tamb -50°C to +70°C) IP66 and IP67

The flamepaths, flare and body are manufactured completely from a UV stable glass reinforced polyester. Stainless steel screws and mounting bracket are incorporated thus ensuring a corrosion free product. Tapered and threaded flamepaths are used to overcome the problems of assembly of parallel spigot flamepaths.

Units can be painted to customer specification and supplied with identification labels.

General Safety Messages and Warnings

All instructions and safety messages in this manual must be followed to allow safe installation of the device. The device must only be installed and maintained by correctly trained site personnel/installers. Refer also to the installation and maintenance instructions contained in the Essential Safety Information Section 6.0.

• To reduce the risk of ignition of hazardous atmospheres and shock, do not apply power to the device until installation has been completed and the device is fully sealed and secured.
• To reduce the risk of ignition of hazardous atmospheres and shock, keep device tightly closed when the circuit is energised.
• Before removing the cover for installation or maintenance, ensure that the power to the device is isolated.
• Following installation, test the device to ensure correct operation.
• Following installation ensure a copy of this manual is made available to all operating personnel.
• When installing the device, requirements for selection, installation and operation should be referred to e.g. IEE Wiring Regulations and the 'National Electrical Code' in North America. Additional national and/or local requirements may also apply.
• Cable termination should be in accordance with specification applying to the required application. MEDC recommends that all cables and cores should be correctly identified. Please refer to the wiring diagram in this manual (or separate diagram provided with the unit).
• Ensure that only the correct listed or certified cable glands are used and that the assembly is shrouded and correctly earthed.
• Ensure that only the correct listed or certified stopping plugs are used to blank off unused gland entry points and that the NEMA/IP rating of the unit is maintained.
• MEDC recommends the use of a sealing compound such as HYLOMAR PL32 on the threads of all glands and stopping plugs in order to maintain the IP rating of the unit.
• A suitable sealing washer must be fitted to all glands and stopping plugs fitted into the enclosure.
• The internal earth terminal, where fitted, must be used for the equipment grounding and the external terminal, if available, is for a supplementary bonding connection where local codes or authorities permit or require such a connection.
• When installing the device, MEDC recommends the use of stainless steel fasteners. Ensure that all nuts, bolts and fixings are secure.
• The unit should be positioned such that debris, dust or water cannot settle in the re-entrant horn.

Installation

The unit is mounted via the 2 off Ø9mm fixing holes in the U-shaped stirrup/mounting bracket. If required, the unit can be initially placed via the Ø13mm central hole in the stirrup. The unit can then be rotated to the required position and fixed via the other holes.

The two fixing holes have been designed to accept an M8 screw or bolt.

Access to terminals

Unscrew the 3 off M5 screws (4.0mm A/F hexagon key) holding the cover assembly to the base. The screws are retained in the cover. Remove cover to gain access to the interior of the terminal chamber.

Once termination is complete, carefully replace the cover back onto the enclosure, avoiding damage to the mating surfaces. Evenly tighten the 3 off M5 screws (4.0mm A/F hexagon key) in the cover, ensuring the maximum torque value for the cover screws is observed, as marked on the Ex e cover. Ensure the O-ring is correctly seated in its groove during re-assembly.

Operation

The operating voltage of the unit is stated on the unit label.

General arrangement

Diagram showing the general dimensions and mounting points of the CU1 unit.

Access to controls

The volume control, flash rate selection (where available) and tone selection can be accessed through the lens cover assembly.

Unscrew the socket set screw (2mm A/F hexagon key) in the lens cover three full turns. Unscrew and remove the lens cover. The required adjustments can then be made using the correct PCB mounted controls.

Once the required adjustments have been made, replace the cover using the same procedure as above but in the reverse manner. Care must be taken to avoid damage to the threads and mating faces of the cover and enclosure. Ensure the o-ring is correctly seated on the cover and that the cover is screwed down tightly such that the maximum gap between the cover and enclosure is 0.2mm. Ensure the socket set screw in the cover assembly is fully tightened to secure the cover assembly on the body.

Volume Control (10J CU1-S units only)

The volume on both the AC and DC units can be controlled by means of a potentiometer (VR1) mounted on the top face of the xenon PCB. Maximum volume is obtained by turning the potentiometer fully clockwise. Conversely, turning the potentiometer in an anti-clockwise direction will reduce the volume until no sound will be heard. Do not attempt to adjust the potentiometer beyond its limits as this may cause damage and prevent correct operation of the unit.

Flash Rate Adjustment (DC supply units only)

The flash rate can be selected by means of a jumper switch mounted on the top face of the xenon PCB accessible through the xenon cover assembly (see the access to controls section for details). Three positions are available for selection (SP, F80 & F120) which provide the following fpm (flashes per minute) rates:

• SP - 60 fpm (Standard unless otherwise specified when ordering unit)
• F80 - 80 fpm
• F120 - 120 fpm

The flash rate of the AC units is preset by MEDC prior to shipping and cannot be adjusted once set.

Tones

Notes

1. The term 'remote initiate' covers both the telephone initiate and the 24Vdc relay initiate options.
2. 'Single stage' means that bank 1 of the tone selection switches is enabled allowing the selection of 1 of up to 27 user selectable tones.
3. 'Dual stage' means that bank 2 of the tone selection switches is also enabled allowing the selection of 1 of up to 27 user selectable tones. The user can switch between the tones selected on banks 1 and 2. Dual stage is only available on DC units.

The unit is available in the following configurations:

1. DC input, single stage sounder, direct initiate, combined sounder/beacon operation
2. DC input, single stage sounder, remote initiate, combined sounder/beacon operation
3. DC input, single stage sounder, direct initiate, independent sounder and beacon operation
4. DC input, dual stage sounder, direct initiate, combined sounder/beacon operation
5. DC input, dual stage sounder, remote initiate, combined sounder/beacon operation
6. DC input, dual stage sounder, direct initiate, independent sounder and beacon operation
7. AC input, single stage sounder, direct initiate, combined sounder/beacon operation
8. AC input, single stage sounder, remote initiate, combined sounder/beacon operation
9. AC input, single stage sounder, direct initiate, independent sounder and beacon operation

Wiring Configuration Examples:

• Type 1: Supply to T1 (+ve) & T2 (-ve), loop out T3 & T4.
• Type 2: Supply to T1 (+ve) & T2 (-ve), loop out T3 & T4. Initiate supply to T5 (+ve/live) & T6 (-ve/neutral), loop out T7 & T8.
• Type 3: Supply to T1 (sounder +ve) & T2 (common -ve), loop out T3 & T4. Independent +ve supply for beacon to T7, loop out T8.
• Type 4: Supply to T1 (common +ve), T2 (-ve) & T3 (-ve 2), loop out T4, T5 & T6. EOL resistor can be connected to T4, T5 or T4, T6.
• Type 5: Supply to T1 (+ve) & T2 (-ve), loop out T3 & T4. Initiate supply to T5 (+ve/live) & T6 (-ve/neutral), loop out T7 & T8.
• Type 6: Supply to T1 (sounder +ve), T2 (common -ve1) & T3 (common -ve2), loop out T4, T5 & T6. Independent +ve supply for beacon to T7, loop out T8.
• Type 7: Supply to T1 (L) & T2 (N), loop out T3 & T4.
• Type 8: Supply to T1 (L) & T2 (N), loop out T3 & T4. Initiate supply to T5 (+ve/live) T6 (-ve/neutral), loop out T7 & T8.
• Type 9: Supply for sounder to T1 (L) & T2 (N), loop out T3 & T4. Supply for beacon to T5 (L) & T6 (N), loop out T7 & T8.

Dual Stage Switching:

Dual stage units can be switched between stages by:

• Inverting the polarity of the supply (2-wire connection).
• Connecting as a three-wire common +ve system and switching between the two -ve lines (e.g., T1 (+ve) & T2 (-ve) for stage 1; T1 (-ve) & T2 (+ve) for stage 2, or T1 (+ve) & T3 (-ve) for stage 2).

Note: For Type 5 units, dual stage sounder is connected with 2 wires, and the second stage is selected by reversing polarity.

Tone Selection

On AC input units, tone selection is via a 5-way DIL switch on the xenon PCB. On DC input units, tone 1 & 2 are selected using two 5-way DIL switches (SW1 & SW2) on the xenon PCB.

Maintenance

The unit requires minimal maintenance. GRP is resistant to most chemicals. If abnormal environmental conditions occur, visual inspection is recommended.

If a unit fault occurs, it can be repaired by MEDC. All parts are replaceable. It is recommended to have spares available if a significant quantity of units is purchased. Contact MEDC Technical Sales Engineers for requirements.

Replacement of the Xenon Tube

Caution: Ensure power is isolated before removing the cover assembly.

Unscrew the socket set screw in the lens cover, then unscrew and remove the lens cover. Remove the old tube by unscrewing the terminal block screws. Fit the replacement xenon tube, ensuring correct orientation. The legs of the replacement tube may need trimming to achieve the correct height. Replace the cover, ensuring the O-ring is correctly seated and the cover is tightly screwed down. Ensure the socket set screw is fully tightened.

When re-applying grease to the cover/lens assembly, use a PFPE-based grease such as Krytox GPL203 or Perfluorolube 22/6 to prevent damage to the O-ring.

Essential Certification & Safety Information

This is a certified ATEX/IECEX controlled section and must not be changed without authorization.

Special conditions for safe use

• Painting and surface finishes other than those applied by the manufacturer are not permitted.
• Not more than one single or multiple strand lead shall be connected into either side of any terminal, unless multiple conductors have been joined in a suitable manner, e.g. two conductors into a single insulated crimped boot lace ferrule.
• Leads connected to the terminals shall be insulated for at least 275V and this insulation shall extend to within 1mm of the metal of the terminal throat.
• All terminal screws, used and unused, shall be fully tightened down.
• Minimum creepage and clearance distances between the terminals and adjacent conductive parts (including cable entry devices) must be at least 5mm.
• Any cable entry devices or stopping plugs shall be selected and installed to maintain the minimum (IP54) integrity of the enclosure.
• For replacement purposes, the flare fixing screws shall be of stainless steel minimum grade A2-70.

General messages and safety warnings

All instructions and safety messages in this manual must be followed to allow safe installation of the device. The device must only be installed and maintained by correctly trained site personnel/installers.

• To reduce the risk of ignition of hazardous atmospheres and shock, do not apply power to the device until installation has been completed and the device is fully sealed and secured.
• To reduce the risk of ignition of hazardous atmospheres and shock, keep device tightly closed when the circuit is energised.
• Before removing the cover for installation or maintenance, ensure that the power to the device is isolated.
• Following installation, test the device to ensure correct operation.
• Following installation ensure a copy of this manual is made available to all operating personnel.
• When installing the device, requirements for selection, installation and operation should be referred to e.g. IEE Wiring Regulations and the 'National Electrical Code' in North America. Additional national and/or local requirements may also apply.
• Cable termination should be in accordance with specification applying to the required application. MEDC recommends that all cables and cores should be correctly identified. Please refer to the wiring diagram in this manual (or separate diagram provided with the unit).
• Ensure that only the correct listed or certified cable glands are used and that the assembly is shrouded and correctly earthed.
• Ensure that only the correct listed or certified stopping plugs are used to blank off unused gland entry points and that the NEMA/IP rating of the unit is maintained.
• MEDC recommends the use of a sealing compound such as HYLOMAR PL32 on the threads of all glands and stopping plugs in order to maintain the IP rating of the unit.
• A suitable sealing washer must be fitted to all glands and stopping plugs fitted into the enclosure.
• The internal earth terminal, where fitted, must be used for the equipment grounding and the external terminal, if available, is for a supplementary bonding connection where local codes or authorities permit or require such a connection.
• When installing the device, MEDC recommends the use of stainless steel fasteners. Ensure that all nuts, bolts and fixings are secure.
• The unit should be positioned such that debris, dust or water cannot settle in the re-entrant horn.

Installation & maintenance

Replacement of the Xenon Tube:

Caution: Before removing the cover assembly, ensure that the power to the unit has been isolated.

Unscrew the socket set screw (2mm A/F hexagon key) in the lens cover three full turns. Unscrew and remove the lens cover.

Remove the old tube by unscrewing the tube terminal block screws. The replacement xenon can now be fitted into the terminal block provided. If the replacement tube has a flexible trigger wire, ensure the tube is fitted into the terminal block in the same orientation as the original tube.

Note: the legs of the replacement tube may need to be trimmed to allow the tube to be positioned at the correct height from the terminal block. See diagram below:

Once the required adjustments have been made, replace the cover using the same procedure as above but in the reverse manner. Care must be taken to avoid damage to the threads and mating faces of the cover and enclosure. Ensure the o-ring is correctly seated on the cover and that the cover is screwed down tightly such that the maximum gap between the cover and enclosure is 0.2mm. Ensure the socket set screw in the cover assembly is fully tightened to secure the cover assembly on the body.

Certification/approvals

IECEx units

Certified to IEC60079-0, IEC60079-1 and IEC60079-7

Ex de unit (IEC certification No. IECEx BAS 11.0149X)

• CU1-S - Ex db eb IIB T4 (-50°C to +50°C) Gb
• CU1-H - Ex db eb IIB T4 (-50°C to +70°C) Gb

The IECEx certificate and product label carry the IECEx equipment protection level marking Gb

Where Gb signifies suitability for use in a Zone 1 surface industries area in the presence of gas.

ATEX units

Certified to EN60079-0, EN60079-1 and EN60079-7

Ex d unit (ATEX certification No. Baseefa04ATEX0273X)

• CU1-S - Ex db eb IIB T4 (-50°C to +50°C) Gb
• CU1-H - Ex db eb IIB T4 (-50°C to +70°C) Gb

The ATEX certificate and product label carry the ATEX group and category marking:

Ex II 2 G

Where:

• Ex Signifies compliance with ATEX
• II Signifies suitability for use in surface industries
• 2 Signifies suitability for use in a zone 1 area
• G Signifies suitability for use in the presence of gases

These units also have the following approvals:

Ingress protection: IP66 to BS EN 60529 & IP67 to IEC60529