IndustrialHydraulics

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Modern Explosion ProtectionProduct Solutions for IndustrialHydraulics

ATEX Directive 94 / 9 / EG

Explosion Protection Directive 94 / 9 / EG – ATmosphère EXplosible

Directive 94/9/EC of the European Parliament, that lays down minimum requirements for the improvement of health and safety at work for employees working in areas with an explosion hazard, came into force on 01.07.2003.

Since that day, all products thathave been placed on the market,or put into service must complywith this new directives, because since this date both old directives and national regulations became invalid in all EU member states.

The member states must transposethe European regulations intonational law!

This ensures total harmonizationregulations regarding explosion protection, free trade and uni- form requirements for qualityassurance and additional monito-ring of quality assurance for thedevelopment and production ofsuch components within the EU.

Since 01.07.2003 Rexroth has exclusively supplied products for these specific applications that comply with this directive and areaccompanied by the relevant docu-mentation.It is no longer permitted in the EU to sell new components that are in manufactured in accordance with old standards.

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The Directive is valid for:

• Equipment (devices, protective systems and components) intended for use in a potentially explosive atmospheres.

• Safety devices, controlling devices and regulating devices intended for use outside potentially explosive atmospheres but required for or contributing to the safe functioning of equipment.

• Equipment capable of causing an explosion through its own potential source of ignition.

• Electrical equipment, which source of ignition could be electricity and all related effects such as heat, sparks and radi- ation.

• Non-electrical equipment, which source of ignition could be hot surfaces, friction and mechanically generated sparks.• Equipment intended for use in areas with a potentially explosive atmosphere caused by dust.

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It is required to assign equipment tocertain zones of hazard, equipmentgroups and categories. This classi-fication must be in accordance withthe following table:

Group I (mines, firedamp / combus-

tible dusts)

Group II(explosive atmospheres consisting of gas/air or dust/air mixtures, mists or vapors)

Category M Category 1 Category 2 Category 3

1 2G (gas) Zone 0

D (dust)Zone 20

G (gas) Zone 1

D (dust)Zone 21

G (gas) Zone 2

D (dust)Zone 22

For equip-ment that ensures a very highlevel ofprotection.Operationis ensuredalso in the rare case of incidents.

For equip-ment thatensures ahigh level ofprotection.Shutdownpossible inthe event ofan explosiveatmosphere.

For equipment that ensures a very high level ofprotection.Intended for the case of an expected permanent, frequent or longterm explosiv atmosphere.

For equipment thatensures a high level ofprotection.Intended for the occasional occurrence of an explosive atmosphere.

For equipment that ensures the normal level ofprotection.Intended for the rare case that explosive atmospheres are unlikely to occur, or if they do occur are likely to do so far a short period only.

Two inde-pendentmeans ofprotection,or function-ing ensuredif two faultsoccur de-pendentlyof each other.

Suitable fornormal operationand more severeoperatingconditions.

Two independent meansof protection, or functioning ensured if two faults occur independently of each other.

Protection during normaloperation and faults whichnormally have to be takeninto account.

Protection during normaloperation.

Classification and Identificationof Potentially Explosive Atmospheres

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Be on the Safe Side with Rexroth as yourPartner for Industrial Hydraulics

Our products are designed, manu-factured and delivered strictly inaccordance with the ATEX Direc-tive.Thanks to in-depth analyses, risksoccurring in the design and pro-duction phases and during opera-tion can be recognized at an earlystage and ruled out right from thestart. For this reason, our productsmeet the high safety and healthrequirements laid down in Direc-tive 94/9/EC.To ensure compliance with thesehigh standards, new processeswere integrated in our production sequence, or existing ones were revised and modernized, as appro-priate.

• Risk analysis and conformity assessment procedure

• Type tests

• Quality assurance with process representation and assurance of traceability of products

• Issue of a declaration of conformity, CE marking and Ex marking

• Preparation and supply of operating instructions for components, devices and power units

• Presentation of design documents to notified bodies

• Nomination of an officer for explosion protection

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To meet the exacting demandsplaced on health and safety of emp-loyees and to guarantee quality,comprehensive technical docu-mentation has been produced. Each component is accompanied by a documentation package that includes the following items.

• Written operating instructions in four languages and a CD-ROM with all further EU languages

• General information about the use of equipment in potentially explosive atmospheres

• Product data sheet

• Product specific instructions together with compulsory declaration of conformity

Labour intensive and costly processes of this type can only be handled by a manufacturer such as Rexroth. Benefit from our know-how and experience of our Product Units.

The required technical productdata sheets are, of course, alsoavailable online.

Servicing and repair of equipmentaccording to the old Directiveis still permitted in the EU andworldwide. This is carried outquickly and competently by ourService Centers.

Safety, Healthand Quality

The Conformity Assessment Procedure

Category to 94/9/EG

Type ofproduct

Procedure Storing of ducumentation

IM1 / II1G / II1D Electrical andnon-electrical

EC type testing by noti-fied body

Rexroth + to notified body withconfirmation

IM2 / II2G / II2D Electrical EC type testing by noti-fied body

Rexroth + to notified body withconfirmation

IM2 / II2G / II2D non-electrical Conformity assessmentby manufacturer

Rexroth + to notified body

II3G / II3D Electrical andnon-electrical

Conformity assessmentby manufacturer

Rexroth

Depending on the category and equipment group, the following requirements must be met:

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Our product spectrum ranges from simple isolator valves trough to highly dynamic servo-valves.The required type of explosionprotection of, for example on/offvalves, can be selected dependingon the application at hand. Somevalves are also available as cart-ridge type valves. Due to the strin-gent demands that Rexroth places on its ATEX valves, potential risks during design, production and operation of the components have been eliminated.

Industrial Controlsin Accordance with the ATEX Directive

We offer a comprehensive andapplication-oriented product rangeof on/off and high-response, servoand proportional valves in accor-dance with the ATEX Directive.

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Hydraulic Cylindersin Accordance with the ATEX Directive

Hydraulic cylinders from Rexrothallow you, as a manufacturer ofplant and machinery intended foruse in potentially explosive atmos-pheres, to employ tie rod cylinders of our preferred product range with bores of 25 to 320 mm in different pressure stages and with stroke lengths of up to 6000 mm.

On the basis of our ATEX-compli-ant cylinders you can equip your plant and machinery with hydrau-lic cylinders from Rexroth to meet the requirements set out in EU Directive 94/9/EC.

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Hydraulic power units intendedfor use in potentially explosiveatmospheres are developed in closecooperation with the client and inaccordance with the new ATEXDirective. The modular designprinciple offers a high level of flexibility for a wide performance spectrum – in spite of the res-rictions imposed by Directive 94/9/EC.

System Technology in Accordancewith the ATEX Directive

Of course, Rexroth also develops complete drive and control soluti-ons in accordance with the ATEXDirective and in close cooperation with the customer. We offer appli-cation-related system solutions andturnkey systems for potentiallyexplosive atmospheres.

Hydraulic Power Unitsin Accordance with the ATEX Directive

All of our hydraulic power unitswhich are intended for use inpotentially explosive atmospheresare subjected to an ignition risk as-sessment according to the relevantrequirements. This procedureresults in safe hydraulic powerunits without any source of igniti-on in gas and dust atmospheres.

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Escaping gases• Foundry machines• Core-shooting machines• Chemical plant• Firedamp in mines

Formation of vapors from fluids• In foaming systems• On drilling platforms• In chemical plant• In tank systems

Formation and sedimentation of dusts• Plastics processing machines• Woodworking machines• Mills• Mining machines• Machines for the production of animal feed

ATEX-compliant equipmentfrom Rexroth is used in manyhazardous environments

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The Drive & Control CompanyRexroth offers a unique andcomprehensive range of pro-ducts and services acrosstechnologies in its six business units and service areas in high-quality individual technologies and combined with highest ap-plication-specifi c competence in system packages with integrated complete solutions.

You can rely on service across technologies Rexroth integrates all services for the entire product spectrum in the fi eld of factory and indus-trial automation into a single organization: from immediate support, spare parts service, fi eld and repair service, retro-fi t/modernization through to training.

Intelligent Hydraulicsin New Dimensions

Wherever forces need to be utilizedeconomically, the advantages of in-dustrial hydraulics are obvious –whether it is required to lift and lo-wer loads smoothly, perform linearor rotary movements, achieve con-stant acceleration, maintain givenspeeds, approach positions exactly,transmit powers or interlink se-quences.

Rexroth is the technology andmarket leader in industrial hydrau-lics with a comprehensive productrange and distinct applicationexpertise.

At Rexroth you can select from theworld‘s largest standard productrange in the fi eld of hydraulics,application and customer-specifi c

system solutions of high quality.With advanced micro-electronicsRexroth has made hydraulics evenmore powerful.

For you, Rexroth is the ideal partnerfor developing highly effi cientmachines and production facilities– from the fi rst point of contact tocommissioning and throughout theentire life cycle. Teams that operateworldwide carry out the completeengineering of your systems and,if requested, up to the hand-overof turnkey systems and beyond –service included.

Thanks to the use of hydraulicdrive and control technology fromRexroth you will be more competi-tive than ever.

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IndustrialHydraulics

Electric Drives and Controls

LinearMotion andAssemblyTechnologies

Pneumatics

ServiceAutomation

Mobile Hydraulics

Bosch Rexroth AGIndustrial HydraulicsZum Eisengießer 197816 Lohr, GermanyTel.: +49(0)9352/18 - 0Fax: +49(0)9352/18 - 32 41

www.boschrexroth.com

Printed in GermanyRE 00837/01.04