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Proteus ATEX Zone 1 Original User Instruction Manual

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ZONE 1
Original
User Instruction Manual
Version A
To be used in conjunction with
Proteus Original Instruction Manual

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Summary of Contents for Proteus ATEX Zone 1

  • Page 1 ZONE 1 Original User Instruction Manual Version A To be used in conjunction with Proteus Original Instruction Manual...
  • Page 3 IMPORTANT! Do not use the Mini-Cam equipment for ATEX inspections if: • You have not been trained in the use of Mini-Cam equipment • You are not competent in conducting ATEX inspections • You do not have the correct equipment •...

  • Page 5: Disclaimer

    This instruction manual is applicable to the Proteus ATEX Zone 1 Inspection ™ System. A standard system and available options are covered by this document. Depending on your system configuration you may lack some of the features mentioned in this document.

  • Page 7: Table Of Contents

    Contents Disclaimer Warranty Limited Warranty Extent of the Limited Warranty Conditions of the Limited Warranty Warranty Limitations Introduction Scope of this Operators Manual Use of this Operators Manual If Anything is not Clear Text Conventions Bold Font Lists Procedure Lists Symbols Used in this Manual EC Declaration of Conformity CE Declaration...
  • Page 8 Identifying ATEX System Components ATEX Components Markings CCU208-ExZ1 Control Unit for ATEX-1 VCU500-ExZ1 Desktop Controller for ATEX-1 System Overview Crawler System ATEX Hazardous and NON-Hazardous Environment Equipment Power Control Steps for Powering ON Step 1: Turning on the System Power Step 2: Decide if to use OVERRIDE to Keep Power ON Step 3: Turning on the Inspection Equipment Power Override Lock...
  • Page 9 Using CGP01 Cable Guide Pulley During the Inspection Pressure and Compliance Monitoring Pressure Warnings Advisory Warning Cautionary Warning ATEX-1 Pressure Uncompliant Manually Monitoring the Inspection Equipment At the End of the Inspection Removing the Inspection Equipment from the Site Powering the Inspection Equipment OFF Checking the Equipment If you Noticed any Problems Storage and Transportation...
  • Page 10 Mini-Cam Proteus ExZ1 Version A...

  • Page 11: Warranty

    Warranty Limited Warranty Congratulations on the purchase of your new Proteus™ Hazardous Environment Inspection System. Our products are the result of many years experience and continuous developments. Conscientious manufacturing and checking are essential objectives in our company. Nevertheless failures cannot be excluded totally. If this occurs, you are covered by our generous warranty.

  • Page 12: Introduction

    ATEX-1 is approved for use in ATEX Zone 1 (and Zone 2) Hazardous Environments. The equipment is self-monitoring, and provides warnings to the user, and will automatically remove inspection equipment power in the case of a problem.

  • Page 13: Text Conventions

    Lists are marked as follows: • Item 1 • Item 2 Procedure Lists Procedures that must be performed in a specific order appear in numbered lists like this: 1 Perform this step first. 2 Perform this step second. Version A Mini-Cam Proteus ExZ1...

  • Page 14: Symbols Used In This Manual

    NOTE Notes give important information or guidance. CARE Highlights the recommended care regime required to maintain the long life of the equipment, but also importantly for ensuring compliance with the ATEX requirements. Mini-Cam Proteus ExZ1 Version A...

  • Page 15: Ec Declaration Of Conformity

    EC Declaration of Conformity CE Declaration We Mini-Cam Ltd. Unit 4 Yew Tree Way, Stonecross Park, Golborne, Warrington, WA3 3JD hereby declare that the Proteus ATEX System Components to which this ™ declaration refers are in compliance with the following standards or standardizing...
  • Page 16 Mini-Cam Proteus ExZ1 Version A...

  • Page 17: Overview Of Atex Equipment

    NON-Hazardous. The system cannot detect if an Environment is Hazardous or not. You must only pressurise, or perform maintenance, or change of equipment in a NON-Hazardous Environment. You must NEVER open, disconnect, or reconnect inspection equipment in a Hazardous Environment. Version A Mini-Cam Proteus ExZ1...

  • Page 18: Atex Zones

    NON-ATEX equipment, even when pressurised, can never be classed as being Compliant, as it does not meet the other design regulations required for full ATEX compliance. If any attached ATEX equipment becomes Uncompliant, then the whole system is deemed Uncompliant. Mini-Cam Proteus ExZ1 Version A...
  • Page 19 So for example where a crawler and camera are used together, if only the crawler becomes Uncompliant but the camera is still Compliant, the whole system is deemed Uncompliant. You must only use ATEX equipment that is all Compliant when it is in use in Hazardous Environments. Version A Mini-Cam Proteus ExZ1...

  • Page 20: Use Of The Equipment

    Explosive atmospheres - Part 0: Equipment - General requirements IEC 60079-2 2015 Explosive atmospheres - Part 2: Equipment protection by pressurized enclosure “p” IEC 60079-7 2015 Explosive atmospheres - Part 7: Equipment protection by increased safety “e” Mini-Cam Proteus ExZ1 Version A...

  • Page 21: Permitted Use Of The Equipment

    Permitted Use of the Equipment Use of the Proteus™ ExZ1 pipeline inspection system in Hazardous Environments is only permitted providing, at minimum, ALL of the following are adhered to (this is not a complete list): • Operators have been trained in use of the equipment.

  • Page 22: General Equipment Usage

    • Use only the approved wheels and accessories. • Use only the approved lowering device (for crawlers). • Check condition of all connectors and ensure they are firmly attached before use. • Visually inspect all equipment before use. Mini-Cam Proteus ExZ1 Version A...
  • Page 23 • Do not attach any unapproved components, materials or devices to the equipment. • Never begin using damaged or malfunctioning equipment, however slight. • Don't use Mini-Cam equipment near sensitive other electrical equipment. REMEMBER: • ATEX equipment is only serviceable by a Mini-Cam certified Service Centre. Version A Mini-Cam Proteus ExZ1...

  • Page 24: Operator Responsibilities

    • Ensure that the equipment is undamaged and in working order before commencing the inspection. • Stop the inspection if you have any reason to believe there is a system fault or damage. • Assess the safety of the inspection site and any prevailing weather conditions. Mini-Cam Proteus ExZ1 Version A...

  • Page 25: Care And Maintenance

    ATEX equipment. Care and Maintenance For general care and maintenance, refer to the Proteus Original Instruction Manual. On ATEX equipment the care and maintenance procedures are essential not only for promoting long life of the equipment, but also importantly for ensuring compliance with the ATEX requirements.

  • Page 26: Identifying Atex System Components

    Identifying ATEX System Components Equipment for use in ATEX Zone 1 Hazardous Environments has at least one of these markings: An ExZ1 Serial Number An ATEX-1 Specific Marking Only ATEX markings containing "2G" are for use in ATEX-1 Environments. No other marking is permitted.

  • Page 27: Atex Components Markings

    . You must not ™ use any other system components for ATEX. CCU208-ExZ1 Control Unit for ATEX-1 ATEX Identification CCU208-ExZ1 EX Logo & OVERRIDE Key VCU500-ExZ1 Desktop Controller for ATEX-1 ATEX Identification VCU500-ExZ1 EX Logo & OVERRIDE Key Version A Mini-Cam Proteus ExZ1...

  • Page 28: System Overview

    System Overview Crawler System The Proteus ATEX Zone 1 Inspection System consists of the following main ™ components: • Control Unit / Desktop Controller • Cable Reel • Crawler • Camera A typical configuration is shown in this illustration: *not to scale The actual extent of the Hazardous Environment for each inspection will be defined by the nature of the inspection itself.

  • Page 29: Atex Hazardous And Non-Hazardous Environment Equipment

    Hazardous Environment. Examples of such equipment are the control panel, screens, and cable reel - this is NOT a complete list – always assume that if equipment is NOT marked as ATEX then it MUST NOT enter the Hazardous Environment. Version A Mini-Cam Proteus ExZ1...

  • Page 30: Power Control

    ATEX-1 inspection equipment to report its pressures when you need to re-pressurise it to the correct values. For this reason the OVERRIDE Key can be used to force ATEX-1 inspection equipment power to remain ON even when pressures are low. Mini-Cam Proteus ExZ1 Version A...

  • Page 31: Step 3: Turning On The Inspection Equipment Power

    OVERRIDE. Step 3: Turning on the Inspection Equipment Power If the inspection requires ATEX, you must ensure that the inspection equipment is in a NON-Hazardous Environment before you apply power to the inspection equipment. Version A Mini-Cam Proteus ExZ1...
  • Page 32 In all other cases, you are shown a warning message like this: You might need to enter a pass-code to confirm that you authorise the inspection equipment power ON. Enter the pass-code if you are asked to (the pass-code is not required on all systems). Mini-Cam Proteus ExZ1 Version A...
  • Page 33 The system then shows you the ATEX Zone mode that it has selected based on the detected capabilities of the attached equipment. From then on, the power to the equipment remains ON until one of the conditions occurs to remove the power. Version A Mini-Cam Proteus ExZ1...
  • Page 34 Conditions under which the system will keep power ON the inspection equipment: • Whenever the key is in OVERRIDE position. • When operating in ATEX-1, and all ATEX-1 inspection equipment is Compliant. Mini-Cam Proteus ExZ1 Version A...
  • Page 35 • ATEX-1 inspection equipment becomes Uncompliant and the key is NOT in OVERRIDE. • The main power supply to the system is lost. • A cable becomes detached. • The system detects a malfunction within itself. Version A Mini-Cam Proteus ExZ1...

  • Page 36: Override Lock

    Override Lock The Proteus CCU208-ExZ1 and VCU500-ExZ1 both feature an OVERRIDE Lock as shown below. See page 37 for instructions on how to use the OVERRIDE Lock. CCU208-ExZ1 OVERRIDE Lock VCU500-ExZ1 OVERRIDE Lock Mini-Cam Proteus ExZ1 Version A...

  • Page 37: During Inspection Surveying

    NOT be cut off. You cannot remove the key when it is in the ATEX Mode position. You must ONLY use OVERRIDE Mode if you are certain that the equipment is NOT in a Hazardous Environment. Version A Mini-Cam Proteus ExZ1...

  • Page 38: Powering Off The Inspection Equipment Power

    Manually Powering OFF the Inspection Equipment Power You can choose to power OFF the inspection equipment at any time by pressing the PowerON or (on Proteus) the ALLSTOP key STOP! When conducting an ATEX inspection, if the inspection equipment has been powered OFF, you or a qualified person MUST ensure that the inspection equipment is in a NON-Hazardous Environment before you power it back on again.

  • Page 39: Preparing For The Inspection

    You need to select and use the correct inspection equipment components for the Environment requirements of the inspection. Generally this will be one of: • ATEX-1 is required • ATEX-2 is required • There is no requirement for ATEX Version A Mini-Cam Proteus ExZ1...
  • Page 40 Equipment that is suitable for use in Hazardous Environments will have a label or marking to say so. Generally this is limited to the inspection equipment such as the camera, crawler, sonde, rod, cable, and other devices that are approved by Mini-Cam to use with the inspection equipment. Mini-Cam Proteus ExZ1 Version A...
  • Page 41 • If the Environment does NOT require ATEX, you can use ATEX-1, or ATEX-2, or NON-ATEX equipment. Never use NON-ATEX equipment for ATEX inspections, or when there is a chance of encountering a Hazardous Environment. Version A Mini-Cam Proteus ExZ1...

  • Page 42: Connecting The System Components Together

    Only connect and disconnect components with the system power OFF. For ATEX inspections, only connect and disconnect components in a NON- Hazardous Environment. Connect the components, paying attention to connector orientation and ensuring that all connections are robust. Mini-Cam Proteus ExZ1 Version A...
  • Page 43 5 The position of the Locking Grub 4 Use a 3mm T-Bar to screw and tighten Screw should now be at the top (12 the Locking Grub Screw. DO NOT o'clock). over-tighten the Locking Grub Screw. Version A Mini-Cam Proteus ExZ1...
  • Page 44 DO NOT over-tighten the Lock Screw as this can damage the connector. 3 Use a 3mm T-Bar to tighten the Lock Screw, turning in a clockwise direction as shown. DO NOT over-tighten the Lock Screw. Mini-Cam Proteus ExZ1 Version A...

  • Page 45: Powering The System And Inspection Equipment On

    Before commencing an inspection you should check that the pressures of the inspection equipment are adequate for the duration of the entire inspection. If pressure runs low during the inspection you may have to abandon the inspection. Version A Mini-Cam Proteus ExZ1...

  • Page 46: Pressurising Components

    Only pressurise components in a NON-Hazardous Environment. You may need to use the OVERRIDE Key to maintain power ON while pressurising, see Power Control page 30. Illustrated instructions on how to pressurise Proteus ExZ1 components can be found as follows: • CRP140-ExZ1 Crawler page 48 •...

  • Page 47: Pressure Bar

    For ATEX it is essential that the equipment pressure is not in the RED area - indicating pressure is too low and non-compliant. Version A Mini-Cam Proteus ExZ1...

  • Page 48: Pressurising Crp140-Exz1

    4 Ensure the camera pressure is within the acceptable range by checking the pressure bar on the control unit (see page 47). Refer to the CCU section of the Original Proteus Instruction Manual for specific instructions on how to access the pressure bars. Completely remove the pressure again afterwards, by releasing through the pressure valve.

  • Page 49: Pressurising Cam026L-Exz1

    4 Ensure the camera pressure is within the acceptable range by checking the pressure bar on the control unit (see page 47). Refer to the CCU section of the Original Proteus Instruction Manual for specific instructions on how to access the pressure bars. Completely remove the pressure again afterwards, by releasing through the pressure valve.

  • Page 50: Pressurising Cam028L-Exz1

    4 Ensure the camera pressure is within the acceptable range by checking the pressure bar on the control unit (see page 47). Refer to the CCU section of the Original Proteus Instruction Manual for specific instructions on how to access the pressure bars. Completely remove the pressure again afterwards, by releasing through the pressure valve.

  • Page 51: Testing The Pressure Monitoring

    Follow the procedures for pressurising the inspection equipment (see Pressurising Components page 46). The Help screen should now say that all attached equipment is Compliant and of adequate pressure. The system is now ready for testing. Version A Mini-Cam Proteus ExZ1...

  • Page 52: Steps For The Slow Leak Test

    • Ensure the OVERRIDE key is in the ATEX position. • Turn up the camera illumination (see section "Camera Function Keys" in the Proteus Original Instruction Manual) such that the camera lights are visibly ON. • Manually cause a release of the inspection equipment pressure, by opening the purge valve slowly on the device.
  • Page 53 After performing these tests, the OVERRIDE key must be returned to the ATEX position before using the inspection equipment for ATEX-1 inspections. After manually releasing the inspection equipment pressure, it MUST be re-pressurised again before use. Version A Mini-Cam Proteus ExZ1...

  • Page 54: Testing The System Operation Before Use

    Risk of disorientation and temporary blindness! The illumination on the PROTEUS inspection system uses high power LED lighting with narrow angle secondary optics. During the testing and use of the system never look directly at the camera or auxiliary module illumination.

  • Page 55: Introducing The Inspection Equipment Into The Site

    Take care when lowering the crawler to avoid contact with the inspection chamber walls. Lowering Rope Inspection Cable Hook You must never lower the crawler into the chamber using the inspection cable. Version A Mini-Cam Proteus ExZ1...

  • Page 56: Cable Guide Pulley

    To extend the life of the inspection cable, and help prevent kinks and chaffing agaist the chamber edge, the CGP01 Proteus Cable Guide Pulley should be used. The Pulley also assists in the smooth guiding of inspection cable during the survey.

  • Page 57: Using Cgp01 Cable Guide Pulley

    5 Lower the guide pulley down the cable and position into the invert of the pipe. 6 Tie-off the rope (C) to secure into place. Version A Mini-Cam Proteus ExZ1...

  • Page 58: During The Inspection

    The warning tells you which inspection equipment is getting low on pressure. You must press OK to acknowledge this warning. The inspection equipment can still be used as the pressure is still Compliant. Mini-Cam Proteus ExZ1 Version A...

  • Page 59: Cautionary Warning

    Press OK to acknowledge the alert, and then choose whether to continue using the Uncompliant inspection equipment by switching to OVERRIDE and powering ON again, or whether to abandon the survey and remove the inspection equipment manually without power. Version A Mini-Cam Proteus ExZ1...

  • Page 60: Manually Monitoring The Inspection Equipment

    • Press the PowerON key or the ALLSTOP key STOP! Mini-Cam Proteus ExZ1 Version A...

  • Page 61: At The End Of The Inspection

    Mini-Cam approved Service Centre as soon as possible, so that the equipment is immediately usable again the next time it is needed. Version A Mini-Cam Proteus ExZ1...

  • Page 62: If You Noticed Any Problems

    Mini-Cam approved Service Centre for attention. Storage and Transportation Store the inspection equipment securely during transportation to minimise the possibility of damage during transit. Mini-Cam Proteus ExZ1 Version A...

  • Page 63: Appendices

    Appendices Version A Mini-Cam Proteus ExZ1...

  • Page 64: Atex Approved Wheels

    ATEX Approved Wheels For operation in hazardous environments with potentially explosive atmospheres, only specially designated Proteus ExZ1 wheels may be integrated into a ™ Proteus ExZ1 system. In the case of non-compliance, e.g. when combining ExZ1 ™ components with components without ATEX certification, Mini-Cam and its Service Partners declines any responsibility and shall not be held liable for any claim.

  • Page 65: Maximum Ratings

    Degrees C Operating atmospheric pressure* 1060 Millibars Control System operating IP45 IP rating environment Inspection Equipment operating IP67 IP rating environment *Though the system may operate outside of these pressures, ATEX-1 compliance cannot be guaranteed. Version A Mini-Cam Proteus ExZ1...

  • Page 66: Troubleshooting

    Power supply. Check system power supply is connected and operating. Leak. Visually check for signs of leaks or damage. Inspection Equipment will not pressurise Purge valve not tight. Check tightness of purge valves. Mini-Cam Proteus ExZ1 Version A...

  • Page 67: Weee Statement

    For disposal contact Mini-Cam or the Mini-Cam partner in your country. Information on Disposal for Business Users Your Proteus CCU is marked with the symbol shown above. It means that used electrical and electronic products should not be disposed of in with general household waste.
  • Page 68 Useful Information UK Customers For service and repair contact Mini-Cam Ltd Tel: 01942 444555 Email: service@minicam.co.uk International Customers For service and repair contact your local Mini-Cam Approved Dealer To view “How To” Videos visit www.minicam.co.uk Mini-Cam Proteus ExZ1 Version A...
  • Page 69 Notes Version A Mini-Cam Proteus ExZ1...
  • Page 70 Notes Mini-Cam Proteus ExZ1 Version A...
  • Page 71 Version A Mini-Cam Proteus ExZ1...
  • Page 72 ©2020 Mini-Cam Ltd. All rights reserved. Mini-Cam and Proteus names/logos are trademarks of Mini-Cam Ltd. Specifications subject to change without notice. Mini-Cam Ltd is a Halma Company. DESIGN 0320...

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