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AT E X - S O L U T I O N S

FROM

AERZEN

AERZENER

MASCHINENFABRIK
GMBH

A1-020 03 EN
2000

9.2008

Customers benet and ATEX-requirements


Aerzener Maschinenfabrik has been manufacturing Positive Displacement blowers since 1868 and Screw
compressors since 1943. It is one of the oldest and biggest manufacturers worldwide and is in some ranges
the market leader in Europe. Technical competence, experienced employees and continuous dialogue with
the customers are the basis for successful new developments from Aerzen. The connection between changing regulations as well as the ATEX-guideline and additional benet for customers by innovative products for
plant manufacturers and operators is also in the focus.

Ranges of application and use


DELTA BLOWER units made by Aerzener and DELTA
SCREW compressor units made by Aerzener were designed for conveying air and neutral gases and are used
in chemistry- and process technology, for pneumatic
transport of bulk materials and in many other ranges of
the present industrial technology.
The installation of the European machine directive 94/9/
EG for explosive areas in all applications plays a more
and more important role. The blower- and compressor
units made by Aerzener are especially designed for the
requirements in categories 2 and 3 for
dust- as well as for gas zones and certied accordingly by the manufacturer.
Machines for category 1 however must
be subject to an EG-type test referring
to the individual case.

For certain individual projects this was already carried out successfully. For special conditions in industrial vacuum technology the High vacuum blowers
and the new canned motor blowers were subject to
a complete successful type test. These machines,
used in pressure ranges up to 10-5 mbar (abs.), are
approved for zone 0 (internal) and certied by an
appointed authority.

Example of machine labelling


Ex II 2 (o) G E Ex c T4

Temperature class concerning gas, surface temperature conc. dust T4 = 135 C


Type of ignition protection constructive safety
Explosion protection
European standards EN
Ex-atmosphere (G = gas, D = combustible dust)
Internal / external explosive atmosphere (i = internal, o = external)
Category 2
Device group II
Label for prevention of explosions

Measurements taken
Aerzen DELTA BLOWER units:
Overpressure

Negative pressure

internal ex-atmosphere external ex-atmosphere internal ex-atmosphere external ex-atmosphere


(suction from ex-Zone)
(ex-free suction)
(suction from ex-Zone)
(ex-free suction)

Measures

zone
21 1 2
x
x
x
x
-

1
x
x
x
x
x
x
-

Gastight machine
Explosion pressure proof accessories
Additional strength test
Disch. temperature monitoring
Gas alarm device (at site)
Starting strainer
Intake sided lter (lter silencer)
Intake sided lter (same design as zone separating
lter but without suction valve, only DN 80-150)
Intake sided lter (at site)
Zone separating lter (only DN 80-150)
Intake pressure monitoring by pressure switch
p-monitoring via zone separating lter
Protection via vacuum switch
(suction valve not necessary)
Vibration monitoring
Electrical operating means
Atex-certicate
Additional label
Additional operating manual

zone
22 1 1
21 1 2
22 1
x
x
- x(G2) - x(G2) x x(L2) x x(G2) x

x
-

x
-

x
-

x
-

x(G )
-

x
x
x

x
x
x

1
x
x
x
x
x
-

zone
21 1 2
x
x
x
x
-

22 1
-

1
x
x
-

zone
21 1 2
x
x
-

22 1
-

x(G )
-

x
-

x
x
x

x
-

x
x
x

x
-

x
-

x
-

x
-

x
Are always to be procured acc. to the corresponding zone
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

x
x
x

x
x
x

It must absolutely be avoided, that dust atmosphere develops inside the machine. In case of suction from a dust atmosphere or in case of suction-pneumatic applications
a suitable lter is to be used acc. to the above chart. These Aerzen lters in connection with the corresponding monitoring facility serve as zone separating element.

G=gas-fuelled operation , L= air operation

For zone 0-applications a type test by an appointed authority is necessary. For such machines a technical release is necessary.

Aerzen DELTA SCREW compressor units:


Overpressure
Measures

internal ex-atmosphere
(suction from ex-Zone)

1
Convey. chamber gastight,
connect oil demister to continuing pipe, or are
Additional strength test
Disch. temperature monitoring
Gas alarm device (at site)
Coupling
Starting strainer
Suction-sided lter
Intake side lter (same design as zone separating lter but without suction valve (provided by
customer)
Intake sided lter (at site)
Zone separating lter (provided by customer)
Intake pressure monitoring by pressure switch
p-monitoring via zone separating lter
(provided by customer)
Vibration monitoring
Electrical operating means
(driving motor, oil demister, instrumentation,
electr. fan, etc.)
Atex-certicate
Additional label
Additional operating manual

zone
21 2
2

x
x
x

x
-

x
-

Negative pressure

external ex-atmosphere
(ex-free suction)

22 2

zone
21 2 2
-

internal ex-atmosphere
(suction from ex-Zone)

22 2

zone
21 2
2
-

external ex-atmosphere
(ex-free suction)

22 2

zone
21 2 2

22 2

x
-

x3

x
x
x
x
x
x
Is always to be procured acc. to the corresponding zone
x
- x(G)4 - x(G)4 x
x
x
x x(L)4 x x(L)4 x
-

x
-

x
-

x
-

x
-

x
-

x(G)4
-

x(G)4
-

x
-

x
x
-

x
-

x
x
-

x
-

x
-

x
-

x
-

x
x
x

x
x
x

x
x
x

Are always to be procured acc. to the corresponding zone


x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

x
x
x

Is only possible for VM-machines (except VM 8R). Not possible for VML-machines.

It must absolutely be avoided, that dust atmosphere develops inside the machine. In case of suction from a dust atmosphere or in case of suction-pneumatic applications
a suitable lter is to be used acc. to the above chart. These Aerzen lters in connection with the corresponding monitoring facility serve as zone separating element.

not for gearbox machines

G=gas-fuelled operation , L= air operation

For zone 0-applications a type test by an appointed authority is necessary. For such machines a technical release is necessary.

Aerzen vacuum blowers series HV and CM:


Measures
Strength test as spot check
Discharge temperature monitoring
Differential pressure monitoring *
Differential pressure monitoring
Starting strainer
Vibration monitoring (online)
Vibration monitoring (at intervals)
Bypass control
Electrical equipment
Coupling with certicate
Atex certicate
Additional nameplate
Additional operating manual

Vacuum pressure
internal ex-atmosphere
external ex-atmosphere
zone
zone
0
1
21
2
22
0
1
21
2
22
not applic.
not applic.
not applic.
x
x
x
not applic.
not applic.
not applic.
x
x
x
x
not
applic.
not
applic.
not
applic.
x
not applic.
not applic.
not applic.
not applic.
not applic.
not applic.
x
x
x
not applic.
not applic.
not applic.
x
not applic.
not applic.
not applic.
x
x
x
not necessary, machine can be own through via frequency converter and direct
drive under atm. conditions
to be carried out acc. to corresponding zone
not applic.
not applic.
not applic.
x
x
x
x
not
applic.
not
applic.
not
applic.
x
x
x
x
x
x
x
not applic.
not applic.
not applic.
x
x
x
x
x
x
x
not applic.
not applic.
not applic.
x
x
x
x
x
x
x

* only necessary for zone 0, does not serve as monitoring unit, but controls the additional switching of the drive of the Roots pump when falling below 100 mbar, resp. as
option with zone 0 the switching on /-off of monitoring units.

Ex-protection for units acc. to ATEX


guideline 137

Ex-protection in the pneumatic bulk


material conveyance

The EU-directive 1999/92/EG (ATEX 137) xes that


employer (unit operator) fulll certain requirements
on the eld of safety and health protection for employees who have to face the risks of explosive atmospheres. In the ex-proof document possible ignitian sources are analysed and technical (constructive) and preventive measures must be described.
Prior to commissioning of new units this ex-proof
document must be issued. Based on the ex-proof
document the work halls need to be modied until
30th June 2006 according to the minimum regulations of EU-directive 1999/92/EG and to be documented correspondingly.

If combustible bulk material is conveyed pneumatically, in case of certain dust-/air concentrations inammable gas mixtures may develop in the unit.
Unit components are allocated to different zones.
For example, silo content is declared with zone 21
as explosive atmosphere may be present continuously or for a longer period of time. The conveying
piping is dened also as zone 21 as an explosive
dust-/air mixture occurs only occasionally.
For these two zones according to Atex guideline
also in case of possible damages protection against
explosion must be guaranteed. As zone 22 areas
are marked where the explosive atmosphere hardly
occurs or only for a short period of time.

Diagrammatic section of pressure conveyance

bulk material
entrance

* Spark arrester

bulk material
entrance

* Spark arrester can


be omitted on use of
Aerzener compressors

* Spark arrester

Blower

* Spark arrester can be


omitted on use of Aerzener
blowers

Compressor
zone 20

zone 21

zone 22

External areas of constantly technically safe units


are declared as zone-free, i.e. preferred installation place of blowers, compressors and pumps. The
zone clarication and denition of temperature class
are carried out by the unit operator.
An aspect not being considered very often in the
pneumatics is that in case of unusual failure the
blower may produce sparks, these will then be
blown into the conveying piping, where ingnition
of the dust/air mixture may take place. In case of a
bearing damage caused by e.g. insufcient maintenance, the consequence might be that the rotary
pistons touch and ignition sparks develop. Organic
dust/air mixtures are inammable at temperatures
between 200 ... 500 C. One ignition spark reaches
a temperature between approx. 800 C and 1000 C,
so that in such a case some resulting damage cannot be excluded. Unit manufacturer and operators who consider this would install additional spark
stops causing investment and considerable installation costs as well as pressure losses.

Certied Aerzen base support


Aerzener Maschinenfabrik has faced this challenge
and has worked on a solution which was certied by
the TV Nord. Base is DELTA BLOWER units serving as discharge silencer. The sound developed is
dampened in this especially designed base support
without application of absorption material.
In expensive practical tests articial sparks had
been produced and fed through the base support
for several minutes with an air ow corresponding

to the conveyed volume ow of a blower with the


consequence that the sparks are deleted by internal deviations. Therefore, costly spark traps tted in
addition can be omitted in future. The secret of success is the innovation of Aerzen discharge silencer.
The absorption material normally used which is
combustible and not foodstuff-compatible is not
necessary anymore.
The certication
of Aerzen blower
units includes the
nominal
widths
from DN 50 to
DN 250 and was
extended besides
the current designs (Generation
5) onto the Delta
Blower-designs supplied since 1994.
A subsequent certication for units already
supplied (series Delta Blower) for preparing the
explosion protection document is thus possible.
This ATEX certication was extended to the new
compressor units Delta Screw Generation 5 for
which the innovative discharge silencer takes the
function of the spark arrester.

air inlet

air deviating

air outlet
discharge piping

base support of blower: diagrammatic section

Special lter element for the suction


pneumatic (for blowers only)
Depending on the product and system conguration
bulk goods are conveyed however not only in overpressure operation, but also by means of suction
pneumatic transport. In suction operation it has to
be ensured in case of a malfunction in the separation lter (e. g. lter fracture) that no combustible
dust-air-mixture is sucked into the blower. For this
reason normally an additional lter element (emergency lter) is provided by the plant manufacturer.
Consequently an additional expenditure for project
work, assembly and installation will occur. Therefore
Aerzener Maschinenfabrik has developed a puncture-proof lter element which can be integrated in
the suction silencer. The lter is monitored by a differential pressure measurement. Consequently the
Aerzen special lter element replaces the previous
additionally necessary emergency lter.
Schematic description in case of
suction conveyance (blowers)
Emergency
lter

Separation lter
Bulk material
entrance

New
puncture-proof
Aerzen lter element
(for blowers only)

Listing of customer benet


The innovative silencer operating without absorbent material realizes the spark arrester for the
compressor.
Subsequent certication of Aerzen units (series
Delta Blower) for preparing the explosionprotection document is possible.
With the innovative and certied Aerzen base support resp. discharge silencer unnecessary installations are avoided and consequently pressure- and
energy loss prevented!
Plant safety acc. to 1999/92/EC (explosion protection document) for the operator! Re-certication
for Aerzen Blower Units (Delta Blower) possible in
existing plants!

Filter

Clear cost advantages by the new integrable


Aerzen lter element (blowers). This replaces a
costly external lter element.
Integrated emergency lter
(option)

Separation lter
Bulk material
entrance

Aerzen Blower Units DELTA BLOWER (blower


stage and pressure-containing accessories) can
be designed to be pressure shock-proof up to an
explosion overpressure of 13 bar (extra price).
The acoustic hood ventilation is effected by a mechanically driven fan (Aerzen Standard for blowers
and compressors). The costly electrical integration
and monitoring of an explosion-proof motor for the
necessary hood ventilation is not included.

Filter

Thanks to optimized logistics attractive delivery


dates as well as inexpensive additional documentation and marking!
zone 20

zone 21

zone 22

Advantages for the customer


Aerzen Vacuum Blowers external casing is designed for temperature class T4 guaranteeing
safety for difficult applications!
When using Aerzen Vacuum Blowers the application of an external bypass control is no longer
necessary, causing a considerable cost saving in
the plant manufacturing!
The possible shutdown of the monitoring device
below 50 mbar ensures process safety for the operator!
Pressure shock resistance up to 13 bar!
Inexpensive documentation!

The Aerzen Vacuum Blower series HV is designed


for the conveyance of air and neutral gases and can
specially be used in the industrial vacuum technology, for example, coating of glass and foils, in the
packaging technology, the metallurgy and in many
further applications.
There are 19 blower sizes in the vacuum range covering suction flows from 180 m/h up to 97.000 m/h
as well as pressure ranges (abs.) from 10-3 mbar up
to 200 mbar. Specially in the chemical industry, but
also in other applications, the ATEX-requirements increase constantly. Many manufacturers interpret the
ATEX-guideline so that machines, which are used in
a pressure range of below 800 mbar, are not subject
to certification. However this is only partly correct,
as the harmonized standard EN 13463-1:2001 (D)
clearly supplements that in case of machines not
within the range of validity of this standard, the
suitability of the devices for possible application
conditions have to be clearly shown and proven.
Against this Aerzener Maschinenfabrik has decided,
that the complete vacuum series is subject to a type
testing acc. to guideline 94/9/EC to be able to offer
the plant manufacturers and operators safe solutions corresponding to ATEX.
Afterwards the Aerzen Vacuum Blower Series HV
as well as the blowers with canned motor of the
series CM were certified for zone 0 (internal), temperature class T3 (200 C) in April 2005. The blowers are externally admitted for zone 1, temperature
class T4 (135 C). For zone 0 a temperature and
vibration monitoring on the blowers is additionally to
be provided. Materials of grey-cast iron or nodular
cast iron can be used.
A special advantage for the customer with the Aerzen ATEX-solution is that an extremely costly bypass
- solution is omitted. The Aerzen ATEX-certification
admits a so-called suction of the fore pump and a
frequency converter operation at restricted speed of
the Aerzen Vacuum Blowers.

Sectional model GM 11.3 HV


for the suction
pneumatic

ATEX-solutions for the vacuum


technology

Conventional bypass pipe


(marked in red)
can be omitted in future!!

TS+
PZS+

A good address, everywhere


Federal Republic
of Germany
Aerzener Maschinenfabrik
GmbH . Reherweg 28
31855 Aerzen / Germany
Tel. + 49 51 54 8 10
Fax + 49 51 54 8 11 91
Vertriebsbro Nord
Weier Kamp 23
29683 Bad Fallingbostel
Germany
Tel. + 49 51 62 98 13- 0
Fax + 49 51 62 98 13 20

Aerzen Machines Ltd.


Aerzen House, Langston Road
Loughton, Essex, IG 103 SL
United Kingdom
Tel. + 44 20 85 02 81 00
Fax + 44 20 85 02 81 02
Aerzen Belgium NV
Zone Guldendelle
A. De Coninckstraat 11
3070 Kortenberg / Belgium
Tel. + 32 2- 7 57 22 78
Fax + 32 2- 7 57 22 83
for Belgium and Luxembourg

Vertriebsbro Ost
Klosterstrae 8-9,
13581 Berlin / Germany
Tel. + 49 30 36 75 84-6
Fax + 49 30 36 75 84 80

Aerzen Nederland B.V.


Fotograaf 3
6921 RR Duiven
The Netherlands
Tel. + 31 26- 311- 26 41
Fax + 31 26- 311- 73 69

Auenstelle Taucha:
August-Bebel-Str. 13c
04425 Taucha / Germany
Tel. + 49 34 29 81 46 86
Fax + 49 34 29 81 46 87

Aerzen Iberica S.A.


c/Urogallo 13
28946 Fuenlabrada / Spain
Tel. + 34 91- 6 42 44 50
Fax + 34 91- 6 42 29 03

Vertriebsbro Mitte
Erfurter Strae 2
63796 Kahl / Germany
Tel. + 49 61 88 91 04- 0
Fax + 49 61 88 91 04 20

Aerzen Iberica S.A.


Rua: Sacadura Cabral, 216, 7 B
2765-349 S. Joo do Estoril
Portugal
Tel. + 35 12 14 68 24 66
Fax + 35 12 14 68 24 67

Vertriebsbro Sd
Fhrenweg 1
89275 Elchingen / Germany
Tel. + 49 73 08 96 08- 0
Fax + 49 73 08 96 08 20
Vertriebsbro West
Taubenstrae 12
42551 Velbert / Germany
Tel. + 49 20 51 98 54- 0
Fax + 49 20 51 98 54 18
Auenstelle Nahlbach
Meisenweg 13
66809 Nahlbach / Germany
Tel. + 49 68 38 89 95 95
Fax + 49 68 38 98 58 78
Europe
Aerzen-France S.A.S.
10, Avenue Lon Harmel
92168 Antony Cedex
France
Tel. + 33 1- 46 74 13 00
Fax + 33 1- 46 66 00 61
for France, Algeria, Morocco
and Tunesia

Aerzen Svenska AB
stra Bangatan 20
19560 Arlandastad
Sweden
Tel. + 46 8- 59 12 21 90
Fax + 46 8- 59 11 72 09

Aerzen (Schweiz) AG
Zrcherstrasse 300
8500 Frauenfeld
Switzerland
Tel. + 41 52- 7 25 00 60
Fax + 41 52- 7 25 00 66
for Switzerland and
Liechtenstein
Aerzen Italia SRL
Via Vittor Pisani, 28
20124 Milano / Italy
Tel. + 39 02- 67 07 52 77
Fax + 39 02- 67 07 50 03
MANGRINOX S.A.
14, Grevenon Str.
11855 Athens / Greece
Tel. + 30 210-3 42 32 01-3
Fax + 30 210-3 45 97 67
Aerzen Makine Sanayi Ve
Ticaret Ltd. Sti.
Yukar Dudullu Bostanc Yolu
Cad. Keyap Sitesi A-2 Blok No:12
34775 mraniye - Istanbul
Turkey
Tel. + 90 420 00 32
Fax + 90 420 00 79
Aerzen Polska S.A.
Ul. Marconich 9/17
02-954 Warszawa / Poland
Tel. + 48 22 642 29 09
Fax + 48 22 642 33 08
Aerzen Slovakia S.R.O.
Marinska 17
90031 Stupava / Slowakia
Tel. + 42 12 65 93 46 94
Fax + 42 12 65 45 71 01

Aerzen Finland Oy AB
Teollisuustie 15
02880 Veikkola / Finland
Tel. + 35 89 - 8 19 47 20
Fax + 35 89-4 77 22 25

Aerzen Hungria Kft.


Bcsi t 52.III./4.
1036 Budapest / Hungary
Tel. + 36 14 39 22 00
Fax + 36 14 39 19 22

Bran & Luebbe AS


Sandviksveien 22
1363 Hvik / Norway
Tel. + 47 67 83 26 50
Fax + 47 67 83 26 51
for Norway and Iceland

Aerzen Cz s.r.o.
Namesti TGM 729/7
69002 Breclav
Czech Republic
Tel. + 42 05 19 32 66 57
Fax + 42 05 19 32 66 58

Aerzen Svenska AB
Nakskovvej 28
2500 Valby / Denmark
Tel. + 45 36 16 40 48
Fax + 45 36 16 40 48

HAFI Engineering & Consulting Gesellschaft m.b.H.


Mhletorplatz 4-6
6800 Feldkirch / Austria
Tel. + 43 55 22-7 79 24-0
Fax + 43 55 22-7 49 38
for the remaining countries in
Eastern Europe

Aerzen Austria
Handelsges. m.b.H.
Gewerbepark Tresdorf II/1
2111 Tresdorf / Austria
Tel. + 43 22 62 7 43 88
Fax + 43 22 62 7 43 99

Brasil, Mexico, USA,


Canada and Asia
Aerzen do Brasil Ltda.
Rua Howard Archibaldi
Acheson Jr. N 615
Jardim da Glria, Cep 06711
280 Cotia, SP / Brasil
Tel. + 55 11-46 12 40 21
Fax + 55 11-46 12 02 32
Aerzen Mxico
Av. San Rafael 31
Fraccionamiento Industrial
Lerma
Lerma 52000 Estado de
Mxico (Toluca) / Mxico
Tel. + 52 72 82 82 55 08
Fax + 52 72 82 82 51 97
Aerzen USA Corporation
645 Sands Court
Coatesville, PA 19320 /USA
Tel. + 1 610-3 80 02 44
Fax + 1 610-3 80 02 78
Aerzen Canada Blowers
Compressors Inc.
1995 Monte Labossire
Vaudreuil, Quebec J7V8P2
Canada
Tel. + 1 450-4 24- 39 66
Fax + 1 450-4 24- 39 85
Aerzen Asia Pte. Ltd.
38 Woodlands
Industrial Park E1
#04-01 Singapore 757700
Tel. + 65 6254 5080
Fax + 65 6254 6935
Aerzen International Trading
(Shanghai) Co. Ltd.
No. 519 Tong Li Road
Jiu Ting Town
Song Jiang District
201615 Shanghai / P.R.China
Tel. + 86 21 5109 7767
Fax + 86 21 5109 7768
Aerzen Machines (India)
Private Limited
301-1 A Square Building
82-Urmi Society
Productivity Road
Vadodara - 390007 / India
Tel. + 91 265 2324306
Tel. & Fax + 91 265 2324307
We would be pleased to
provide the addresses of
our representatives in the
remaining continents, upon
request.

Aerzener Maschinenfabrik GmbH


Reherweg 28 . 31855 Aerzen / Germany P.O. Box 1163 . 31849 Aerzen / Germany
Phone ++ 49 51 54 / 8 10 . Fax ++ 49 51 54 / 8 11 91 . www.aerzen.com . info@aerzener.de