1
g/l
Time
0
00
1
0:30
1
1
:
00
1
1
:
3
0
1
2
:
:
0
0
1
2
:
3
0
Process Control
detect and identify
Level Measurement
Uni-Probe LB 490
With All Supplements
User’s Manual
ID no. 38477BA2B
Rev. no.: 05 25.5.09
Embedded Soft. Rev. 100
Device Description 03 HART
Device Description 01 PA
Device Description 02 FF
Volume 1: Safety Manuals
1
Volume 2: Uni-Probe Installation
®
Volume 3: HART
Communicator User Interface
Volume 4: PACTware
™
User Interface FDT/DTM
2
3
4
Volume 5: SIMATIC PDM User Interface HART
®
Volume 6: SIMATIC PDM User Interface Profibus PA
™
Volume 7: FOUNDATION
Fieldbus User Interface
5
6
7
Volume 1-7
General Information
Dear customers Thank you very much for purchasing the level gauging system
Uni-Probe LB 490 made by BERTHOLD TECHNOLOGIES GmbH &
Co. KG.
The scope of supply also includes this User’s Manual. Be sure to
have this User’s Manual always to hand.
To avoid physical injury and property damage, please observe the
warnings and safety instructions provided in this User’s Manual.
They are identified as follows: DANGER, WARNING, CAUTION or
NOTICE. In Volume 1, "Safety Manuals", you find a summary of all
safety hazards and information how to deal with them.
Please read the User’s Manual prior to installation to get acquainted
with the product.
If you do encounter problems despite careful study of the User’s
Manual, please do not hesitate to contact us.
Your Uni-Probe LB 490 team
4 25.5.09
38477BA2B
Table of Contents
Volume 1-7 Contents
Volume 1 Safety Manuals
1 About this User’s Manual .................................................. 1 – 19
1.1 Identification and Warning Messages........................ 1 – 19
1.2 Further Symbols........................................................ 1 – 20
1.3 General Instructions.................................................. 1 – 21
2 Use and Function .............................................................. 1 – 23
3 Qualification of Personnel .................................................1 – 25
3.1 Specialized Persons ................................................... 1 – 25
3.2 Qualified Persons ...................................................... 1 – 26
3.3 Authorized Persons................................................... 1 – 26
4 Transport and Assembly .................................................... 1 – 27
5 Electrical installation.......................................................... 1 – 29
6 Radiation Protection.......................................................... 1 – 31
6.1 General Information and Guidelines ......................... 1 – 31
6.2 General Radiation Protection Instructions.................. 1 – 33
6.3 Mounting the Shielding ............................................ 1 – 34
6.4 Safety Measures ....................................................... 1 – 37
6.5 Protection against Theft............................................ 1 – 37
6.6 Accidents, Loss, Damage, Fire, Theft ......................... 1 – 38
6.7 Shielding and Source ................................................ 1 – 40
6.8 Leak Test .................................................................. 1 – 42
7 Source Replacement ......................................................... 1 – 45
7.1 Point Source Replacement ........................................ 1 – 45
7.2 Rod Source Replacement ..........................................1 – 48
7.3 Point Source Replacement on Rotary Cylinder
Shielding1 – 52
7.4 Radiation Exposure during Source Replacement ........1 – 55
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
8 Source Disposal................................................................. 1 – 57
9 Functional Safety .............................................................. 1 – 61
9.1 Scope of Application ................................................ 1 – 61
9.2 Use and Function...................................................... 1 – 63
9.3 Safety Function......................................................... 1 – 64
9.4 Safety Requirement .................................................. 1 – 64
9.5 Project Planning........................................................ 1 – 65
5
Contents Volume 1-7
9.6 Getting Started......................................................... 1 – 67
9.7 Behavior during Operation and during Malfunctions . 1 – 69
9.8 Recurrent Performance Test ...................................... 1 – 70
9.9 Safety-Technical Data................................................ 1 – 71
9.10 Certificate Functional Safety ..................................... 1 – 73
10 Safety Instructions for the Types of Protection
ATEX / FM / CSA ............................................................... 1 – 83
10.1 Overview Ex-Versions ................................................ 1 – 85
10.2 Type of Protection ATEX............................................ 1 – 87
10.3 Type of Protection FM/CSA ....................................... 1 – 88
10.4 Type of Protection CSA ............................................. 1 – 88
11 Certificates ....................................................................... 1 – 89
11.1 ATEX Certificate ....................................................... 1 – 89
11.2 FM Certificate......................................................... 1 – 108
11.3 CSA Certificate....................................................... 1 – 110
11.4 EG Declaration of Conformity................................. 1 – 112
11.5 Material Safety Data Sheet for Lubricant OKS 217 ..1 – 113
6 25.5.09
38477BA2B
Volume 1-7 Contents
Volume 2 Uni-Probe Installation
1 System Description.......................................................... 2 – 119
1.1 Measuring System .................................................. 2 – 119
1.2 Uni-Probe Hardware ............................................... 2 – 123
1.3 Measuring Principle ................................................ 2 – 125
1.4 Measuring Arrangements ....................................... 2 – 126
1.5 Technical Data ........................................................ 2 – 130
1.6 Detector Codes ...................................................... 2 – 133
1.7 Uni-Probe LB 490 Nomenclature ............................. 2 – 134
1.8 LB 490 Super-Sens Nomenclature ........................... 2 – 135
1.9 LB 490 Tower-Sens Nomenclature...........................2 – 136
2 Installation ...................................................................... 2 – 139
2.1 Transport to the Installation Site.............................. 2 – 141
2.2 Source-Detector Arrangements............................... 2 – 143
2.3 Detector Protection................................................. 2 – 145
2.4 Detector Installation ............................................... 2 – 147
2.5 Mounting the Shielding .......................................... 2 – 160
3 Electrical Installation........................................................2 – 183
3.1 Conduits ................................................................ 2 – 184
3.2 Terminals ................................................................ 2 – 187
3.3 Switch Setting ........................................................ 2 – 189
3.4 Connecting the Uni-Probe .....................................2 – 192
3.5 Uni-Probe with Ex i Current Output ........................ 2 – 195
3.6 Uni-Probe with Signal Output Profibus PA /
FOUNDATION
3.7 Uni-Probe with Intrinsically Safe Signal Output
Profibus PA / FOUNDATION
™
Fieldbus (not intrinsically safe)........2 – 206
™
Fieldbus..................... 2 – 209
4 Repair, Maintenance and Service ..................................... 2 – 213
4.1 General Safety Precautions ..................................... 2 – 213
4.2 Visual Inspection of the Uni-Probe .......................... 2 – 216
4.3 Checking the Connection Box ................................2 – 217
4.4 Trouble Shooting .................................................... 2 – 218
4.5 Replacing the Complete Uni-Probe ........................ 2 – 220
4.6 Replacing the Electronics Module............................2 – 222
4.7 Replacing the Crystal-Multiplier Assembly
(for Point Detector) ................................................. 2 – 225
4.8 Replacing the Multiplier (for Rod Detector) ............. 2 – 227
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
7
Contents Volume 1-7
4.9 Replacing the Plastic Scintillator .............................. 2 – 229
4.10 Replacing the Digital Board..................................... 2 – 231
4.11 Replacing the Power Supply Unit ............................ 2 – 234
4.12 Replacing Fuses ...................................................... 2 – 236
4.13 Updating the Embedded Software in the Uni-Probe 2 – 237
4.14 Check Detector ...................................................... 2 – 242
4.15 Customer Service.................................................... 2 – 245
4.16 Returning Repairs ................................................... 2 – 246
5 Screw Fittings and Accessories ........................................ 2 – 247
5.1 ATEX Cable Screw Fittings ...................................... 2 – 247
5.2 ATEX-Adapter (Ex d IIC) for Screwed Cable Glands . 2 – 249
5.3 Dummy Plug........................................................... 2 – 249
6 Technical Drawings ......................................................... 2 – 251
6.1 Point Detector ........................................................ 2 – 251
6.2 Rod Detector.......................................................... 2 – 254
6.3 Super-Sens ............................................................. 2 – 264
6.4 Tower-Sens............................................................. 2 – 268
6.5 Point Source Shielding LB 744X .............................. 2 – 273
6.6 Point Source Shielding for Rod Detectors ................ 2 – 281
6.7 Rod Source Shielding..............................................2 – 282
6.8 Pneumatic for Rod and Point Source Shieldings ...... 2 – 284
6.9 Pneumatic, Design and Electrical Data for Limit
Switch .................................................................... 2 – 285
6.10 Shielding for Rod Source on Dip Tube.....................2 – 286
6.11 Flange Adapter for Rod Source Shieldings...............2 – 287
7 Cooling Water Curves..................................................... 2 – 289
7.1 Point Detectors....................................................... 2 – 289
7.2 Rod Detector.......................................................... 2 – 289
7.3 Super-Sens ............................................................. 2 – 291
7.4 Tower-Sens............................................................. 2 – 291
8 25.5.09
38477BA2B
Volume 1-7 Contents
Volume 3 HART® Communicator User Interface
1 General Information on the HART
1.1 Connection, Power On and Power Off of the
1.2 Working with the HART
HART
®
Communicator ........................................... 3 – 297
®
Communicator.........3 – 297
®
Communicator ............... 3 – 298
2 Menu Structure............................................................... 3 – 299
2.1 Information on the Menu Structure ........................ 3 – 299
2.2 Menu Overview ...................................................... 3 – 300
2.3 Start Menu ............................................................. 3 – 302
2.4 L
2.5 P
2.6 V
2.7 P
2.8 S
2.9 S
2.10 S
2.11 R
2.12 A
2.13 E
2.14 S
2.15 C
2.16 G
2.17 S
2.18 M
2.19 D
2.20 R
2.21 P
2.22 C
2.23 C
2.24 S
2.25 1-2 P
2.26 M
2.27 C
2.28 I
2.29 C
2.30 D
2.31 S
2.32 T
2.33 I/O T
2.34 S
IVE DISPLAY ...................................................... 3 – 303
ROBE RAW DATA............................................... 3 – 304
IEW PARAMETER ............................................... 3 – 305
ROCESS VARIABLES .......................................... 3 – 305
HOW CAL. CURVE .............................................. 3 – 306
TATUS CONTROL................................................ 3 – 307
HOW ERROR LOG .............................................. 3 – 308
EVIEW ................................................................3 – 309
CCESS TO SETUP ............................................... 3 – 311
NTER PASSWORD............................................... 3 – 312
ETUP ................................................................... 3 – 313
ONFIGURATION .................................................. 3 – 313
ENERAL DATA .................................................... 3 – 314
YSTEM PARAMETER ...........................................3 – 315
EASURE PARAMETER......................................... 3 – 316
AMPING DATA ................................................... 3 – 317
AD. INTERFERENCE ........................................... 3 – 319
ULSE RATE LIMITS ............................................ 3 – 320
ALIBRATION I/O .............................................. 3 – 321
ALIBRATION ....................................................... 3 – 321
AVE & LOAD CURVE .......................................... 3 – 322
OINT CURVE............................................... 3 – 323
ULTI POINT CURVE .......................................... 3 – 324
AL. POINT .......................................................... 3 – 325
NPUT / OUTPUT................................................. 3 – 325
URRENT / OUTPUT............................................ 3 – 326
IGITAL OUT CONFIG ........................................ 3 – 327
ERVICE................................................................ 3 – 328
EST CALCULATION ............................................. 3 – 329
EST ............................................................. 3 – 329
TATUS DIG. INPUT............................................ 3 – 330
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
9
Contents Volume 1-7
2.35 DIG. OUTPUT TEST ............................................. 3 – 330
2.36 C
2.37 P
2.38 HV S
2.39 P
2.40 HART I
URRENT OUTPUT ............................................... 3 – 331
ROBE SETTINGS................................................. 3 – 332
ETTINGS ...................................................... 3 – 334
LATEAU ............................................................... 3 – 335
NTERFACE ............................................... 3 – 336
3 Getting Started via the HART
3.1 Steps for Getting Started ........................................ 3 – 337
3.2 Setup Protocol ........................................................ 3 – 338
®
Communicator................ 3 – 337
4 Calibration...................................................................... 3 – 341
4.1 Preparing Calibration .............................................. 3 – 341
4.2 Operation Modes for Calibration ............................ 3 – 348
4.3 Two-Point Calibration ............................................. 3 – 350
4.4 One-Point Calibration ............................................. 3 – 357
4.5 Multi-Point Calibration ........................................... 3 – 360
5 Functional Processes ....................................................... 3 – 367
5.1 Plateau Measurement ............................................. 3 – 367
5.2 Changing the Uni-Probe Password.......................... 3 – 369
5.3 Set Multi-Detector Mode ........................................ 3 – 371
6 Explanations ................................................................... 3 – 373
6.1 Background............................................................ 3 – 373
6.2 Conditions for Empty Calibration............................ 3 – 375
6.3 Linear and Exponential ...........................................3 – 377
6.4 Multi-Point Calibration ........................................... 3 – 380
6.5 Radiation Interference Detection............................. 3 – 383
6.6 Reading-in Pulse Rates............................................ 3 – 386
6.7 Software Versions................................................... 3 – 388
7 Error Handling ................................................................ 3 – 393
7.1 Device Response to Errors....................................... 3 – 393
7.2 Error Handling Modes............................................. 3 – 394
7.3 Corrective Action.................................................... 3 – 395
7.4 Reset ...................................................................... 3 – 397
7.5 Operation Modes during Measurement .................. 3 – 397
7.6 Error Reset.............................................................. 3 – 398
7.7 Fault Current .......................................................... 3 – 399
8 Setup Protocol ................................................................ 3 – 401
8.1 Parameter List......................................................... 3 – 401
8.2 Calibration Values................................................... 3 – 402
10 25.5.09
38477BA2B
Volume 1-7 Contents
Volume 4 PACTware™ User Interface FDT/DTM
1 PC Connection to the Uni-Probe .....................................4 – 407
2 Installing and Working with DTM .................................... 4 – 409
2.1 Requirements ......................................................... 4 – 409
2.2 FDT Container ........................................................ 4 – 409
2.3 DTM Communication Software............................... 4 – 411
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
11
Contents Volume 1-7
Volume 5 SIMATIC PDM User Interface HART
1 Hardware Configuration ................................................. 5 – 421
2 General Information on SIMATIC PDM ............................ 5 – 423
2.1 Hardware Requirements ......................................... 5 – 424
2.2 Fifo Buffer .............................................................. 5 – 424
3 Getting Started with SIMATIC PDM................................. 5 – 427
3.1 How to Get Started ................................................ 5 – 427
3.2 Installing SIMATIC PDM .......................................... 5 – 427
3.3 Installing the Uni-Probe LB 490 Device Description.. 5 – 432
3.4 Project Setup .......................................................... 5 – 434
3.5 Start SIMATIC PDM................................................. 5 – 438
4 Menu Overview .............................................................. 5 – 439
4.1 F
4.2 D
4.3 V
4.4 O
4.5 H
ILE Menu ............................................................ 5 – 440
EVICE Menu ....................................................... 5 – 448
IEW Menu........................................................... 5 – 480
PTIONS Menu .................................................... 5 – 485
ELP Menu ........................................................... 5 – 489
®
5 Calibration with SIMATIC PDM........................................ 5 – 491
5.1 Preparing Calibration .............................................. 5 – 491
5.2 Operation Modes for Calibration ............................ 5 – 496
5.3 Two-Point Calibration ............................................. 5 – 498
5.4 One-Point Calibration ............................................. 5 – 504
5.5 Multi-Point Calibration ........................................... 5 – 506
6 Functional Processes ....................................................... 5 – 513
6.1 Plateau Measurement ............................................. 5 – 513
6.2 Changing the Uni-Probe Password.......................... 5 – 516
6.3 Set Multi-Detector Mode ........................................ 5 – 519
7 Working with SIMATIC PDM ........................................... 5 – 521
7.1 Start SIMATIC PDM................................................. 5 – 521
7.2 The SIMATIC PDM Main Window ........................... 5 – 522
7.3 Device Icons in SIMATIC PDM ................................. 5 – 525
8 Explanations ................................................................... 5 – 527
8.1 Background............................................................ 5 – 527
8.2 Conditions for Empty Calibration............................ 5 – 529
12 25.5.09
38477BA2B
Volume 1-7 Contents
8.3 Linear and Exponential ...........................................5 – 531
8.4 Multi-Point Calibration ........................................... 5 – 534
8.5 Radiation Interference Detection.............................5 – 537
8.6 Reading-in Pulse Rates............................................ 5 – 540
9 Error Handling ................................................................ 5 – 543
9.1 Device Response to Errors.......................................5 – 543
9.2 Error Handling Modes............................................. 5 – 544
9.3 Corrective Action.................................................... 5 – 545
9.4 Reset ...................................................................... 5 – 546
9.5 Operation Modes during Measurement .................. 5 – 547
9.6 Error Reset.............................................................. 5 – 547
9.7 Fault Current .......................................................... 5 – 548
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
13
Contents Volume 1-7
Volume 6 SIMATIC PDM User Interface Profibus PA
1 Process Operation ........................................................... 6 – 555
1.1 Important Information on the Profibus PA
Operation ............................................................... 6 – 555
1.2 Alternative Operation via HART
1.3 System Overview .................................................... 6 – 556
2 Installation / Program Start.............................................. 6 – 559
2.1 Installing the Device Description (DD)...................... 6 – 559
2.2 Starting SIMATIC PDM............................................ 6 – 560
3 Device-specific Menus..................................................... 6 – 561
®
............................ 6 – 555
3.1 D
3.2 V
EVICE Tab ........................................................... 6 – 562
IEW Menu .......................................................... 6 – 592
4 Calibration with SIMATIC PDM........................................ 6 – 601
4.1 Preparing Calibration.............................................. 6 – 601
4.2 Operation Modes for Calibration ............................ 6 – 606
4.3 Two-Point Calibration ............................................. 6 – 608
4.4 One-Point Calibration ............................................. 6 – 615
4.5 Multi-Point Calibration ........................................... 6 – 618
5 Functional Processes ....................................................... 6 – 625
5.1 Plateau Measurement ............................................. 6 – 625
5.2 Set Multi-Detector Mode ........................................ 6 – 630
6 Explanations ................................................................... 6 – 633
6.1 Background............................................................ 6 – 633
6.2 Conditions for Empty Calibration............................6 – 635
6.3 Linear and Exponential ........................................... 6 – 637
6.4 Multi-Point Calibration ........................................... 6 – 640
6.5 Radiation Interference Detection............................. 6 – 643
6.6 Reading-in Pulse Rates............................................ 6 – 646
7 Error Handling ................................................................ 6 – 649
7.1 Device Response to Errors....................................... 6 – 649
7.2 Error Handling Modes............................................. 6 – 650
7.3 Corrective Action.................................................... 6 – 651
7.4 Reset ...................................................................... 6 – 653
7.5 Operation Modes during Measurement .................. 6 – 653
14 25.5.09
38477BA2B
Volume 1-7 Contents
Volume 7 FOUNDATION
1 Process Operation ........................................................... 7 – 659
1.1 Important Information on the Operation................. 7 – 659
1.2 System Overview .................................................... 7 – 660
2 Installation / Program Start .............................................. 7 – 663
2.1 Installing the Device Description.............................. 7 – 663
2.2 Addressing the Uni-Probe LB 490 Level System ....... 7 – 663
3 Parameter Overview ........................................................ 7 – 665
3.1 Parameters for the Function Block Resource............7 – 665
3.2 Parameters for the Function Block Transducer .........7 – 666
3.3 Parameters for the Function Blocks Analog Input .... 7 – 671
4 Calibration with FOUNDATION
4.1 Preparing Calibration .............................................. 7 – 673
4.2 Operation Modes for Calibration ............................7 – 676
4.3 Two-Point Calibration .............................................7 – 678
4.4 One-Point Calibration ............................................. 7 – 682
4.5 Multi-Point Calibration ........................................... 7 – 684
™
Fieldbus User Interface
™
Fieldbus........................ 7 – 673
5 Functional Processes .......................................................7 – 689
5.1 Plateau Measurement ............................................. 7 – 689
5.2 Multi-Detector Mode.............................................. 7 – 691
5.3 Test Calculation (Test Signal Output) .......................7 – 693
5.4 Damping ................................................................ 7 – 694
5.5 Radiation Interference Detection.............................7 – 696
5.6 Input Configuration ................................................ 7 – 696
5.7 Relay Configuration ................................................ 7 – 697
5.8 Defining the Upper/Lower Pulse Rate Limit.............. 7 – 698
5.9 Protecting Parameters against Modification ............ 7 – 699
5.10 Reading Out the Error Log ...................................... 7 – 699
6 Explanations ................................................................... 7 – 701
6.1 Background............................................................7 – 701
6.2 Conditions for Empty Calibration ............................7 – 703
6.3 Linear and Exponential ...........................................7 – 705
6.4 Multi-Point Calibration ........................................... 7 – 708
6.5 Radiation Interference Detection.............................7 – 711
6.6 Reading-in Pulse Rates............................................ 7 – 714
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
15
Contents Volume 1-7
7 Error Handling ................................................................ 7 – 715
7.1 Device Response in Case of Error............................7 – 715
7.2 Error Handling Modes............................................. 7 – 716
7.3 Operation Modes during Measurement .................. 7 – 716
7.4 Corrective Action.................................................... 7 – 717
7.5 Reset ...................................................................... 7 – 719
16 25.5.09
38477BA2B
1
g/l
Time
0
00
1
0:30
1
1
:
00
1
1
:
3
0
1
2
:
:
0
0
1
2
:
3
0
Volume 1 Safety Manuals
Volume 1
1 – 18 25.5.09
38477BA2B
Volume 1 1 About this User’s Manual
IMPORTANT
Tip
1 About this User’s Manual
1.1 Identification and Warning Messages
The symbols and typefaces used in this User’s Manual have the following meaning:
prompts you to carry out an action.
1, 2, 3, … identifies items in a graphic.
• identifies enumerations.
italic typeface highlights important information.
SMALL CAPS
The term BERTHOLD TECHNOLOGIES in this User’s Manual stands
for the company BERTHOLD TECHNOLOGIES GmbH & Co. KG.
indicate commands or menu items.
1
Please observe the warnings and safety instructions given in this
User’s Manual to rule out physical injury and property damage.
They are identified by the following symbols: DANGER, WARNING,
CAUTION or NOTICE.
Indicates an imminently dangerous condition. Failure to follow the instructions will lead to death or serious injury.
Indicates a potentially dangerous condition. Failure to follow the
instructions may lead to death or serious injury.
Indicates a potentially dangerous condition. Failure to follow the
instructions may lead to slight injury or a medium-degree injury.
Indicates a situation which may cause property damage if the
instructions are not followed.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
Paragraphs with this symbol provide important information on the
product or how to work with the product.
Includes application tips and other useful information.
1 – 19
1 About this User’s Manual Volume 1
1.2 Further Symbols
Warning sign: Never step under hovering loads
Warning sign: Nuclear radiation
Warning sign: Explosion protection
Warning sign: Risk of crushing
Instruction: Disconnect from mains supply
Instruction: Wear hard hat
Instruction: Wear safety shoes
1 – 20 25.5.09
38477BA2B
Volume 1 1 About this User’s Manual
1.3 General Instructions
Volume 1 "Safety Manuals" contains the most important safety
instructions. It supplements the applicable regulations which have
to be studied by the personnel in charge.
Please keep in mind:
– the national safety and accident prevention regulations
– the national installation regulations (e.g. EN 60079)
– the generally accepted engineering rules
– the information on transportation, installation, operation, ser-
vice, maintenance and disposal in this User’s Manual
– the safety instructions and information in this User’s Manual
and the enclosed technical drawings and wiring diagrams
– the characteristic data, limit values and the information on the
operating and environmental conditions on the type labels and
data sheets
– the signs on the devices
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 21
1 About this User’s Manual Volume 1
1 – 22 25.5.09
38477BA2B
Volume 1 2 Use and Function
2 Use and Function
The Uni-Probe LB 490 has been designed as a level gauging system
and may be used only for this purpose. If it is used in any manner
not described in this User’s Manual, the protection of the device is
impaired and all warranty claims are voided.
BERTHOLD TECHNOLOGIES guarantees only that the device complies with the published specifications. The Uni-Probe may be
installed only if it is undamaged, dry and clean. Alteration work and
modification of the system components are not permitted.
Conformance with standards The standards and directives the Uni-Probe complies with are listed
in Volume 1 in section "11.4 EG Declaration of Conformity" on
page 1–112.
Protection type The degree of protection of the Uni-Probe according to IEC 60529
is max. IP 66. It depends on the installed screwed cable glands and
adapters.
1
Limits of use The Uni-Probe LB 490 for HART
“intrinsically safe measurements”.
The following Uni-Probe versions are not qualified as “intrinsically
safe measurements”:
–HART
– with field bus interface connection for FOUNDATION
Misuse warning The following is contrary to the intended use and, therefore, has to
be prevented:
– Use under other conditions and prerequisites than those speci-
– Use after repair by persons who have not been authorized by
– Use in a damaged or corroded state.
– Operation with open or inadequately closed cover.
– Operation with inadequately tightened adapters and screwed
– Operation without observing the safety precautions defined by
– Tampering with or bypassing existing safety installations.
®
with intrinsically safe current output
or Profibus PA.
fied by the manufacturer in the technical documents, data
sheets, operating and installation instructions and in other
specifications.
BERTHOLD TECHNOLOGIES.
cable glands.
the manufacturer.
®
is qualified with an FMEDA for
™
Fieldbus
Maintenance The Level Gauge Uni-Probe LB 490 may only be installed, serviced
and repaired by qualified persons (see section "3.2 Qualified Persons", page 1–26).
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 23
2 Use and Function Volume 1
Explosion hazard!
Spare parts for detectors used in hazardous areas may only be
installed by BERTHOLD TECHNOLOGIES service staff or by persons
authorized by BERTHOLD TECHNOLOGIES. If this is not possible,
you have to replace the complete detector or return it to the manufacturer for repair.
Use only fuses that match the rating specified by BERTHOLD
TECHNOLOGIES.
Parameter settings Never change the parameter settings without a full knowledge of
this User’s Manual, as well as a full knowledge of the behavior of
the connected controller and the possible influence on the operating process to be controlled.
This measuring system employs radioactive sources. The radiation
protection guidelines in this User's Manual and the applicable statutory regulations have to be observed strictly; see also chapter
"6 Radiation Protection", on page 1–31.
1 – 24 25.5.09
38477BA2B
Volume 1 3 Qualification of Personnel
IMPORTANT
IMPORTANT
3 Qualification of Personnel
Reference to the qualification of personnel who can be entrusted
with the various installation and maintenance tasks is made at various points in this User’s Manual.
We distinguished three groups:
1. Specialized persons, see section3.1.
2. Qualified persons, see section 3.2.
3. Authorized persons, see section 3.3.
The following sections explain the meaning of these terms and the
prerequisites for the respective group of people.
At least specialized persons are required for all work on and with
the Uni-Probe LB 490, under the guidance of a qualified or authorized person.
1
3.1 Specialized Persons
Specialized persons are e.g. technicians or welders who can carry
out various tasks in transportation, assembly and installation of the
Uni-Probe LB 490 under the supervision of an authorized person.
This may also be construction site personnel. The respective persons must have experience in the transportation and assembly of
heavy components.
For explosion-protected devices, these persons must in addition
have knowledge on how to handle these devices, e.g. the devices
must not be exposed to mechanic damage (blows etc.).
Specialized persons must always be guided by at least one qualified
person.
The Radiation Safety Officer has to be involved whenever radioactive substances are being handled.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 25
3 Qualification of Personnel Volume 1
3.2 Qualified Persons
Persons are qualified if they have acquired adequate knowledge in
the area concerned in the course of their professional education,
and if they are familiar with the pertinent national occupational
safety regulations, accident prevention regulations, directives and
acknowledged rules of technology. They must be capable of assessing the result of their work safely; moreover, they need to be familiar with the contents of this User’s Manual.
3.3 Authorized Persons
Authorized persons are persons, who are foreseen for certain activities as a consequence of statutory provisions, or who have been
approved by BERTHOLD TECHNOLOGIES for carrying out certain
activities. The Radiation Safety Officer has to be involved whenever
radioactive substances are being handled.
1 – 26 25.5.09
38477BA2B
Volume 1 4 Transport and Assembly
4 Transport and Assembly
The weight of the source shielding may be up to several 100kg,
depending on the version. Please keep in mind:
• The bearing capacity of the container walls or the brackets
must be suitable for installation of the source with the shielding
and of the detector. Otherwise, system parts may fall off and
cause severe injuries or bodily harm with fatal consequences.
• Make sure that the mechanical stability of the fixing devices
matches the weight of the shielding.
Please keep in mind:
– Never step under hovering loads while unloading heavy system
parts!
– Only use tested lifting equipment matching the transport
weights.
1
– Maintain adequate safety margins.
– Wear hard hat and safety shoes.
Explosion hazard!
If the screw thread on the cover or on one of the four screwed
cable glands is damaged, the Uni-Probe cannot be used any more
in ex-protected areas. If the Uni-Probe housing receives a mechanical blow, e.g. because it is dropped, then you have to return the
Uni-Probe to BERTHOLD TECHNOLOGIES GmbH & Co. KG for
inspection.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 27
4 Transport and Assembly Volume 1
1 – 28 25.5.09
38477BA2B
Volume 1 5 Electrical installation
5 Electrical installation
Electrical installations may be carried out only by a specialist electrician.
Electrical shock hazard
Danger, electric shock!
Open the housing only to carry out installation, maintenance and
repair work.
If the housing is open, you may get in contact with live parts if the
power supply is turned on. During installation and servicing on the
hardware of the Level Gauge Uni-Probe LB 490 you have to disconnect the system, possibly connected relay contacts and all in- and
outputs from power to avoid getting in contact with live parts.
1
Danger of explosion when opening the housing in an explosive
atmosphere!
You may open the housing only 30 minutes after switching off the
voltage of all in- and outputs and possibly connected relay contacts
and the power supply.
The cooling-off time of 30 minutes ensures that possibly overheated components have enough time to cool off and cannot ignite
the explosive atmosphere.
The screw threads for the cover, on the housing and also on the
cover, must not be damaged, as otherwise explosion protection is
no longer guaranteed.
Before closing, make sure that the threads are clean and greased
with OKS 217.
Close the housing carefully with the housing cover before turning
on the line voltage. Fix the housing cover completely onto the
housing with screws and tighten it using a torque of 25Nm (reference value).
Unused conduits must be closed by a dummy plug suitable for the
respective type of protection, see chapter "5.3 Dummy Plug" on
page 2–249.
Modifications on the installation may not be carried out without
detailed knowledge of this User’s Manual.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 29
5 Electrical installation Volume 1
Additional information for the type
of protection ATEX
Additional information for the type
Use only EEx d approved screwed cable glands These have to be
installed professionally, see chapter "5 Screw Fittings and
Accessories".
Use only cable cross-sections which are included in the specification of the screwed cable gland used.
Close or seal cable entries at the housing by conduit seals.
of protection FM / CSA
ESD protective measures This measuring system uses electrostatic sensitive
devices.We recommend that you wear an ESD wrist strap
during installation or repair work. Connect this wrist strap
to the ground conductor.
When you open the instrument: Please take precautions
when working with printed circuit boards (ESD). Discharge yourself before touching the components by
touching a grounding point.
Please contact BERTHOLD TECHNOLOGIES if you need any further
information.
1 – 30 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
6 Radiation Protection
6.1 General Information and Guidelines
In order to prevent adverse health effects caused by working with
radioactive substances, limits for the maximum permissible radiation exposure of operating personnel have been agreed upon on an
international level. Appropriate measures in designing the shieldings and arranging the measuring system at the measuring site will
ensure that the radiation exposure of the personnel will remain
below the maximum permissible value of 1 mSv (100mrem) per
year.
To ensure safe operation and compliance with the legal regulations,
the company has to appoint a Radiation Safety Manager who is
responsible for all questions relating to radiation protection. He will
monitor handling of the radiometric measuring system and, if necessary, formalize the safeguards and any special precautions applicable to a given establishment in formal procedural instructions,
which in special cases may serve as a basis for radiation protection
guidelines. This may be necessary, for example, when a container
can be accessed and it has to be ensured, therefore, that access
shall be permitted only after the useful beam on the shielding is
closed. Radiation protection zones outside the shielding must be—if
they are accessible—marked and guarded. These instructions
should also include checks of the shutter device of the shielding
and actions in case of accidents - such as fire or explosion. Any
special event has to be reported to the Radiation Safety Manager
immediately. He will then investigate any damage and immediately
take suitable precautions if he detects defects that may adversely
affect the safe operation of the system.
1
The Radiation Safety Manager has to make sure that the provisions
of the Radiation Protection Regulations are observed. In particular,
his duties include instructing the staff on the proper precautions
when working in the vicinity of radioactive substances.
Radioactive sources that are no longer in use or have reached the
end of their service life must be returned to the national radioactive
waste disposal center or to the manufacturer.
Generally, every member of staff should endeavor to minimize any
radiation exposure—even within the permissible limits—by careful
and responsible action and by observing certain safety standards.
The total sum of the radiation dose absorbed by a body is determined by three factors. On the basis of these factors, certain fundamental radiation protection rules can be derived:
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 31
6 Radiation Protection Volume 1
Distance This means the distance between the radioactive source and the
human body. The radiation intensity (dose rate) decreases - like
light - in proportion to the square of the distance; this means, doubling the distance to the source will reduce the dose rate to one
quarter.
Conclusion:
When handling radioactive substances, maximum distance to the
source should be maintained. This is especially true for persons
that are not directly involved in this work.
Time The total time a person stays in the vicinity of a radiometric mea-
suring system and the body is exposed to radiation. The effect is
cumulative and increases therefore with the duration of the radiation exposure.
Conclusion:
Any work in the vicinity of radiometric measuring system must be
prepared carefully and organized such that it can be carried out in
the shortest time possible. Having the proper tools is of particular
importance.
Shielding The material surrounding the source provides the shielding effect.
As the shielding effect depends, following an exponential function,
on the product of thickness multiplied by the density, it follows that
material with a high specific weight are used for shielding purposes. The device designer usually calculates suitable dimensions.
Conclusion:
Before mounting or dismounting the shielding, make sure that the
radiation exit channel is locked in the closed position.
1 – 32 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
6.2 General Radiation Protection
Instructions
A visual inspection of the Uni-Probe has to be carried out at least
every third year. Please use the visual inspection schedule
(Volume 2) on page 2–216. Take appropriate steps as soon as you
discover any defects during visual inspection; if necessary, separate the device from power immediately.
To determine the inspection intervals, please take the following
issues into consideration:
– ambient conditions (outdoors, rain, sunlight, wind)
– operating conditions (degree of utilization of the facilities,
faulty operation)
– major changes in the overall system (e.g. changes in the zone
classification)
Carry out a visual inspection and check the connection box prior to
the first commissioning and prior to any possibly required repair
where the Uni-Probe housing cover has to be opened. Please use
the visual inspection schedule on page 2–216 and the plan for
checking the connection room on page 2–217 in Volume 2.
Installation, dismantling, relocation, maintenance, testing involving
the radioactive source, or its shielding shall ONLY be performed
under the supervision of the Radiation Safety Officer.
1
Please contact BERTHOLD TECHNOLOGIES if you need any further
information.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 33
6 Radiation Protection Volume 1
6.3 Mounting the Shielding
6.3.1 Safety Instructions
To keep the radiation exposure of the assembling personnel as low
as possible, only licensed personnel who have been trained on how
to handle radioactive substances are allowed to assemble or disassemble the shielding with the source. The work is performed
according to the instructions and under the supervision of the Radiation Safety Manager. It has to be ensured that the lock of the
shielding is closed and secured, so that no unshielded radiation can
exit. Make sure the shielding is not modified or damaged.
Depending on the operation conditions, the function check has to
be repeated at appropriate intervals, and at least every six months.
6.3.2 Radiation Exposure during Installation of the
Shielding
The shieldings of measuring systems are usually designed such
that the limit of the control area is in a given distance (in most
cases less than one meter) around the shielding, and it does not
matter whether point or rod sources are being used and how high
their activity is. A simplified calculation of the radiation exposure
during installation of the shielding is possible with sufficient accuracy using the dose rate data printed on the type plate, measured
in 1m distance from the shielding. The radiation exposure D can be
calculated according to the following formula:
D = DR x t x 4
D = accumulated dose during installation in µSv
DR = dose rate on the type plate of the shielding in µSv/h
t = time needed for the installation with shielding in h
If the work process is prepared well, you may expect a working
time of less than 20 minutes to perform work such as installation of
the shielding or operating the shutter.
Calculation example DR = 3µSv
t = 20min (1/3h)
D = 3 x 1/3 x 4 = 4 µSv/h
If we compare this dose with the permissible annual dose of 1mSv
for persons who are not exposed to radiation on their job, this work
may be carried out 250 times per year by one and the same person.
1 – 34 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
Dosis D
AkT××
r
2
s×
----------- ------------=
μS vm
2
×
h MBq×
------------- ------------
D
350MBq 0.35μ Sv m×
2
0.5h××
0.5m()
2
hMBq× 30××
----------- ------------- ------------- ---------- ------------- ------------- ------------- ------ 8.2μSv==
6.3.3 Radiation Dose Calculations
When preparing work on radiometric measuring systems, it is
important to pre-calculate the radiation exposure to be expected,
since this has consequences on the required safety precautions.
The expected radiation exposure can be calculated quite easily and
with sufficient accuracy, provided you know the isotope and the
activity of the source used. You can take this information from the
source documentation, or from the type label on the shielding.
The radiation exposure to be expected for a shielded source is calculated as follows:
A is the activity of the source and k the respective specific Gamma
radiation constant (see table below). The distance from the measuring point to the source is r and the duration of stay at this point
is T. s is the shielding factor of the shielding used; it is listed in the
shielding brochure or can be calculated. s = 1 when calculating the
dose rate for work with an unshielded source.
Nuclide K Dimensions
Co-60 0.35
Cs -137 0.09
1
Calculation example The dose in a distance of 50cm from a Co-60 source with an activ-
ity of 350MBq and a time of 30minutes has to be calculated. The
source is installed in a shielding with a shielding factor of 30:
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 35
6 Radiation Protection Volume 1
6.3.4 Testing the Shutter Mechanism
This procedure ensures that the shutter mechanism is operating
correctly and that the shutter is closed and the source is completely
shielded when CLOSED is indicated by the device handle or cylinder. This is very important to avoid exposures to radiation if for
some reason (such as a broken shaft in a point source shielding)
the shutter indication is CLOSED but the shutter remains open. The
USNRC and Agreement States make this a mandatory test to be
done at intervals not to exceed 6 months. You may be asked to
provide documentation of previously performed tests and a schedule for the next set of tests on your devices.
Make sure that the process engineer is aware that process
information will be interrupted during the test.
®
Determine the count rate (via the HART
SIMATIC PDM).
Write down the reading.
Move the shutter to the CLOSED position and observe reduction
of displayed counts to zero or to a very low background level.
Write down the reading.
Communicator or
Repeat the sequence 5 times, noting the readings each time.
Ensure that the shutter moves freely, without binding or stick-
ing.
If all is well, disconnect the HART
the SIMATIC PDM and report the result to the process engineer.
If there is a failure or you have doubt, notify the BERTHOLD
TECHNOLOGIES service department.
Document the test, including the date of test, the device model
and serial number, test conclusions and your name. A government inspector may ask you for this information.
®
Communicator or terminate
1 – 36 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
6.4 Safety Measures
When designing the installation of radiometric measuring systems,
the possibility that a fire breaks out must be considered. Please
keep in mind that flammable substances must not be stored in the
proximity of radioactive substances. They should be covered and
protected properly to prevent a possible spreading of the fire to the
radioactive sources. It is mandatory to coordinate all preventive
measures against fire with the local authorities, primarily with the
fire department, which must be informed about the type, scope and
place of application of the radioactive substances used, in order to
be prepared in the event of fire.
When devising alarm plans, possible special features of the radiometric measuring system have to be mentioned; the competent or
authorized personnel (Radiation Safety Manager) to be notified in
the event of an emergency has to be included in those plans as
well, and also the address and phone number of the regulatory
authority.
6.5 Protection against Theft
Radioactive substances or facilities containing radioactive substances must be secured against unauthorized use. Fixed installations are, by their nature, protected against unauthorized use.
1
If facilities working with radiometric measuring systems are taken
out of service for a longer or indefinite period of time, the radioactive sources together with their shieldings should be dismantled
and secured until the facility is taken into operation again.
Portable measuring systems, on the other hand, have to be protected by keeping them under constant supervision, or, if they are
not in operation, by keeping them in a locked room or container
which can be guarded against unauthorized access.
This is especially true for low activity test sources which are used,
for example, to check the function of dose rate measuring instruments.
In the event that radioactive substances are lost, the Radiation
Safety Manager and the regulatory authority have to be notified
immediately.
In case of theft, the police must be informed as well.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 37
6 Radiation Protection Volume 1
6.6 Accidents, Loss, Damage, Fire, Theft
Remember the principles of health and safety in such situations:
time, distance and shielding. In case of one of the above situations:
• Limit access to the area.
• Report the incident to BERTHOLD TECHNOLOGIES; who will
advise what further immediate precautions to take and arrange
for quick support from a licensed person.
In case of loss or theft, notify the regulatory authority.
If the sealed radioactive substances are no longer contained, the
supervisory authority must be notified immediately; moreover,
steps have to be taken to ensure that the contamination cannot be
dispersed.
Proper handling and disposal of possibly leaking radioactive
sources or contaminated parts of the equipment must be coordinated with the supervisory authority.
6.6.1 Malfunctions and Accidents
The Radiation Protection Regulation defines malfunction as an
event which for safety reasons prohibits continuation of the operation of the facility.
Malfunction Malfunction means, that a device necessary to guarantee safe
operation of the facility, e.g. the seal of the active radiation beam of
the shielding, no longer functions properly.
Accident An accident is an event which could expose persons to a radiation
dose which exceeds the permissible limits, or could cause contamination by radioactive substances.
In terms of safety, malfunctions and accidents are very serious
events and appropriate steps must be taken immediately to prevent hazards to persons as well as facilities, or to reduce them as
much as possible.
It is therefore important that the personnel is aware of preventive
measures and is prepared for possible accidents or malfunctions of
the facilities, so that dangerous consequences can be ruled out as
far as possible by a proper reaction of the personnel.
In any case, the Radiation Safety Manager who checks the situation
at site and takes all necessary steps to prevent unnecessary radiation exposure of the personnel must be notified immediately.
The Radiation Safety Manager will then take appropriate measures
and will inform the official authority concerned, and, if necessary,
get further information from the manufacturer.
The necessary steps should be taken in the following order:
Locate source.
Check the function of the shielding.
Check effectiveness of shielding by measuring the dose rate.
38477BA2B
1 – 38 25.5.09
Volume 1 6 Radiation Protection
Guard and mark controlled areas.
Secure source and shielding.
Document the incident and assess possible radiation exposure
of personnel.
In case the source capsule is damaged, the following points have to
be considered:
Avoid contamination.
Handle source with tools (e. g. pincers or tweezers) and put
both (source and tool) in a plastic bag.
Stay behind auxiliary shielding (e.g. concrete, steel, or lead
plate).
Check if vicinity is free of contamination.
Secure radioactive waste properly (deposit at governmental
collection site or return to manufacturer).
If the source is leaking and the dose rate might possibly be
exceeded, the regulatory authority (e.g. trade board) has to be
notified immediately.
In case of an accident or malfunction or any other event which
affects the safety, the regulatory authority has to be informed and
also, if necessary, the authority in charge of public safety. Please
contact BERTHOLD TECHNOLOGIES if you need any further information.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 39
6 Radiation Protection Volume 1
IMPORTANT
1
2
3
4
5
6
7
8
9
1 Source number
2 Isotope
3 Source manufacturing date
4 Shielding material
5 Type of shielding
6 Shielding manufacturer
7 Dose rate in 1m distance
8 Effective shielding thickness
9 Activity
1234 - 11 - 94
6.7 Shielding and Source
Shieldings do not include any wearing parts or mechanically moving parts that under normal operating conditions require maintenance. For safety reasons, however, it should be possible any time
to lock the useful beam. A function check has to be performed in
appropriate intervals of max. six months. The Radiation Protection
Manager has to be informed immediately if any faults on the shielding or a sluggish locking mechanism are detected. If the problem
cannot be solved simply by cleaning, you have to stop working with
the system until it has been repaired.
As long as the shielding does not show any significant mechanical
damage or strong corrosion, the built-in source will be protected.
Refer to the radiation protection guidelines in section 2 to check or
replace the source.
The radioactive sources used and the function area of the measuring system typically permit a service life of more than 10 years. We
recommend replacing a source if the statistical variations which
increase in the course of time become intolerably high and any
compensation by increasing the time constant is not acceptable
any more, e.g. for control-engineering reasons.
Empty calibration has to be performed any time a source is
replaced!
For information on the design of source and shielding please refer
to the technical documentation and the identity plate (Figure 6-1).
Figure 6-1 Identity plate
If the source has to be renewed, you have to include the source
number of the original source in your new order. This number consists of three digits, for example:
1 – 40 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
The first group is a consecutive number, the second group identifies
the month (here: November) and the third the year the source was
manufactured (here: 1994). It is included on the identity plate of
the shielding and also on the seal certificate that comes with every
source.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 41
6 Radiation Protection Volume 1
Alternative test areas,
if accessible
Source
Source holder
Alternative test area
6.8 Leak Test
Depending on the regulatory authority responsible for the sources
employed in their territory, regularly recurring leak tests have to be
carried out. These tests have to be carried out by authorized technical experts. The appropriate documents on the source have to be
provided in order to carry out this test.
6.8.1 Required Documents
• Inventory of the sources to be tested with information on the
previous leak tests.
• Source certificate including the following information:
– Nuclide, activity, purchase date, physical-chemical form
– Description of capsule and type of sealing
– Resistance against mechanical and thermal influences or
classification of the source design
• Information on location, intended use as well as on the typical
operational max. mechanical and thermal stress.
• If the sources are installed in an appliance, a drawing has to be
enclosed which clearly shows the position of the source and of
all parts that are essential for its protection against external
influences. Proposals for the best test method should be available, e.g. through information on alternative test areas and, if
necessary, the required manipulations, how the test can be carried out without adversely affecting the workability of the system or appliance.
• Certificate on an acceptance test by the manufacturer.
Alternative test areas For point source shieldings LB 744X
Figure 6-2 Alternative test area on point source shieldings
Turn lever to horizontal position for testing.
1 – 42 25.5.09
38477BA2B
Volume 1 6 Radiation Protection
Alternative test area
Alternative test area
The alternative test area is the head of the visible edge of the
source holder. If the cover is also accessible then you have to wipe
there as well.
For rod source shieldings The alternative test area is the visible part on the head of the
shielding cylinder.
1
For point source shieldings with
rotary shutter
Figure 6-3 Alternative test area on rod source shieldings
The alternative test area is the visible part on the head of the
shielding cylinder.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
Figure 6-4 Alternative test area on point source shieldings
1 – 43
6 Radiation Protection Volume 1
1 – 44 25.5.09
38477BA2B
Volume 1 7 Source Replacement
IMPORTANT
7 Source Replacement
7.1 Point Source Replacement
This section describes how to replace point sources in the following
shieldings:
– LB 7440
– LB 7442
– LB 7444
–LB7445
–LB7446
The replacement of radioactive sources must be carried out taking
into account the applicable regulations under the supervision of the
Radiation Safety Officer.
1
Hazards due to nuclear radiation!
When replacing a source, you have to work with the unshielded
source for a short time. An increased radiation dose is harmful to
health.
You have to carry a pocket dosimeter during work to measure the
actual radiation exposure. Work has to be coordinated with the
competent Radiation Protection Manager.
For Germany you have to keep in mind:
Source replacement by the customers is possible only when:
1) the respective expertise is available
2) the work required to replace the source has been approved
explicitly by the authorities in charge. Your “License to Handle
Radioactive Substances” states whether you are in possession of
such a license.
Point sources have to be fixed on source holders which are then
screwed into the shielding, positioning the source in the center of
the shielding.
Prerequisite for this work is that the personnel is familiar with the
exact shielding construction; therefore, drawings must be available.
Preparation All necessary work has to be prepared such that it can be carried
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
out quickly, so that exposure to the unshielded source is kept to a
minimum. Using a drawing of the shielding, you should plan the
best procedure and have the following tools handy:
• Allan keys in the required sizes.
• 2 pairs of pliers to take hold of source and source holder.
1 – 45
7 Source Replacement Volume 1
1
2
3
Cordon off an area consistent with the activity of the source. Prevent persons from approaching.
If sufficient space is available, the source can be replaced in the
shielding installed at the measuring site. To this end, bring the new
source in its transport shielding close to the measuring site.
Prepare a suitable, clean space, if possible with an auxiliary shielding (shielding vessel, lead bricks, concrete stones, etc.) and place
the source holder and the source there on a piece of paper to protect it against dirt.
Depending on the construction, you either have to open the lock on
the shielding and turn the lever to center position between ON and
OFF until the hexagon head bolt of the source holders becomes visible, or remove the locking plate, so that you can unscrew the
source holder.
7.1.1 Procedure for Source Replacement
Open the lock of the shielding (1) halfway, so that you can
unscrew the source holder (2) together with the source (3)
using a socket wrench.
Figure 7-1 Situation source holder
Hazards due to nuclear radiation!
Do not remove the source from the shielding!
Do not touch the source to prevent a high partial body dose. Only
touch the source with tools that allow you to grab the source easily
and safely, e.g. a pipe wrench. Do not push the pipe wrench tight
too much to prevent damage to the source. Hold the source far
away from your body and put it down, if possible, behind an auxiliary shielding.
Remove source from shielding Unscrew the source from the source holder using a socket
wrench (size 10 mm). Hold the source holder using a second
socket wrench (size 12 mm).
38477BA2B
1 – 46 25.5.09
Volume 1 7 Source Replacement
IMPORTANT
IMPORTANT
IMPORTANT
For this work, you should use the shielding housing as an auxiliary
shielding between source and body.
Take hold of the source using a pair of pliers and immediately
put it into the transport shielding or another shielding.
Make sure that no mix-up with the new or other sources can occur.
If necessary, clean and grease the thread on the source holder
and the shielding.
Install new source Using a pair of pliers, take the new source out of the transport
shielding and firmly fix it onto the source holder together with
the locking washer.
Put the source holder with the source again into the shielding
and fix it using the socket wrench.
Check the proper ON/OFF function.
Carefully close the transport shielding again, after you have put
the old source into the transport shielding.
Replace type label Replace the type label on the shielding or attach the new source
number.
1
The special regulations regarding labeling and transport of the
shielding back to the manufacturer have to be observed. If in
doubt, please contact BERTHOLD TECHNOLOGIES' Source Transport Manager.
This completes the point source replacement.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 47
7 Source Replacement Volume 1
IMPORTANT
7.2 Rod Source Replacement
This section describes how to replace rod source in the following
shieldings:
– Type 80
– Type 100
– Type 120
– Type 150
– Type 200
– Type 270
Radioactive sources may be replaced only by competent and
licensed persons, taking into account official regulations.
Hazards due to nuclear radiation!
When replacing a source, you have to work with the unshielded
source for a short time. An increased radiation dose is harmful to
health.
You have to carry a pocket dosimeter during work to measure the
actual radiation exposure. Work has to be coordinated with the
competent Radiation Protection Manager.
For Germany you have to keep in mind:
Source replacement by the customers is possible only when:
1) the respective expertise is available
2) the work required to replace the source has been approved
explicitly by the authorities in charge. Your “License to Handle
Radioactive Substances” states whether you are in possession of
such a license.
Prerequisite for this work is that the personnel is familiar with the
exact shielding construction; therefore, drawings must be available.
Preparation All necessary work has to be prepared such that it can be carried
out quickly, so that exposure to the unshielded source is kept to a
minimum. Using a drawing of the shielding, you should plan the
best procedure and have the following tools handy:
• Allan keys, sizes 4, 5, 6, 8 and 10
1 – 48 25.5.09
• 2 pairs of pliers (e.g. polygrip wrench or a pair of combination
or water pump pliers)
Cordon off an area consistent with the activity of the source. Prevent persons from approaching.
Prepare a suitable clean space, if possible with an auxiliary shielding (shielding container, lead bricks, concrete blocks etc.) where
38477BA2B
Volume 1 7 Source Replacement
IMPORTANT
Shielding Rod sources
Top: 1 ring
Bottom: 2 rings
you can later place the source holder and the source temporarily on
a piece of paper to protect it from dirt.
Turn the shieldings to the CLOSED position and secure them. We
recommend placing the individual shielding upright. In particular,
the rotating cylinder has to be secured against tipping over, before
releasing the head flange. Bring the transport shielding containing
the new source close to the measuring site and open it such that
the new source can be taken out and the old rod source put into the
transport shielding as quickly as possible.
Check that the sources are installed in the proper position. Note the
respective marking rings on the source (top = 1 ring; bottom = 2
rings (see Figure 7-2).
1
Figure 7-2 Markings on shielding and rod source
If you are working with several sources, make sure that the
sources cannot be mixed up. Multi-part sources must be set up in
the proper order. The installation pattern of multi-part sources is
indicated by the letters A, B, C etc. from top to bottom (see Figure
7-3 on page 1–50).
With multi-part sources, the rings on the rod source indicate the
installation order and position. It is important to observe these
instructions when replacing a source.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 49
7 Source Replacement Volume 1
Shielding Rod sources
Top: 1 ring
Bottom: 2 rings
1
2
3
4
Figure 7-3 Markings on multi-part sources and shieldings
7.2.1 Procedure for Source Replacement
Figure 7-4 Dismounting rod source shielding
Unscrew the head flange (1) using a suitable Allan key.
Open the locking cover (2).
1 – 50 25.5.09
38477BA2B
Volume 1 7 Source Replacement
IMPORTANT
IMPORTANT
Hazards due to nuclear radiation!
Do not remove the source from the shielding!
Do not touch the source to prevent a high partial body dose. Only
touch the source with tools that allow you to grab the source easily
and safely, e.g. a pipe wrench. Do not push the pipe wrench tight
too much in prevent damage to the source. Hold the source far
away from your body and put it down, if possible, behind an auxiliary shielding.
Remove source from shielding Pull out the rod source (4) using the brass extension bar (3),
hold it with two pairs of pliers and insert it into a transport
shielding. Unscrew the extension bar (3) first using two pairs of
pliers.
If necessary, clean and grease the thread on the source holder
and the shielding.
Pull the new source out of the transport shielding so much that
the brass extension bar can be fixed at the top with screws.
Make sure not to mix up the parts, especially when working
with multi-part sources.
1
Make sure that no mix-up with the new or other sources can occur.
Install new source Pull the new source out of the transport shielding using the pair
of pliers and place it into the working shielding.
Attach the brass cover (2) again after you have checked if the
O-ring seal is clean and undamaged.
Attach head flange again and carefully secure it with screws.
Check the proper ON/OFF function.
Carefully close the transport shielding again, after you have put
the old source into the transport shielding.
Set up the working shieldings as planned. With multi-part
shieldings be sure to observe the correct order.
Replace type label Replace the type label on the shielding or attach the new source
number.
The special regulations regarding labeling and transport of the
shielding back to the manufacturer have to be observed. If in
doubt, please contact BERTHOLD TECHNOLOGIES' Source Transport Manager.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
This completes the source replacement.
1 – 51
7 Source Replacement Volume 1
IMPORTANT
7.3 Point Source Replacement on Rotary
Cylinder Shielding
This section describes how to replace point sources in the following
shieldings:
– Type 80
– Type 100
– Type 120
– Type 150
– Type 200
– Type 270
When replacing a source, you have to work with the unshielded
source for a short time.
The replacement of radioactive source must be carried out taking
into account the applicable regulations under the supervision of the
Radiation Safety Officer.
Hazards due to nuclear radiation!
When replacing a source, you have to work with the unshielded
source for a short time. An increased radiation dose is harmful to
health.
You have to carry a pocket dosimeter during work to measure the
radiation exposure. Work has to be coordinated with the competent
Radiation Protection Manager.
For Germany you have to keep in mind:
Source replacement by the customers is possible only when:
1) the respective expertise is available
2) the work required to replace the source has been approved
explicitly by the authorities in charge. Your “License to Handle
Radioactive Substances” states whether you are in possession of
such a license.
Prerequisite for this work is that the personnel is familiar with the
exact shielding construction; therefore, drawings must be available.
Preparation All necessary work has to be prepared such that it can be carried
out quickly, so that exposure to the unshielded source is kept to a
minimum. Using a drawing of the shielding, you should plan the
best procedure and have the following tools handy:
1 – 52 25.5.09
• Allan keys, sizes 4, 5, 6, 8 and 10
• 2 pairs of pliers (e.g. polygrip wrench or a pair of combination
or water pump pliers)
38477BA2B
Volume 1 7 Source Replacement
12 3
4
Cordon off an area consistent with the activity of the source. Prevent persons from approaching.
Prepare a suitable clean space, if possible with an auxiliary shielding (shielding container, lead bricks, concrete blocks etc.) where
you can later place the source holder and the source temporarily on
a piece of paper to protect it from dirt.
Turn the shieldings to the CLOSED position and secure them. We
recommend placing the individual shielding upright. In particular,
the rotating cylinder has to be secured against tipping over, before
releasing the head flange. Bring the transport shielding containing
the new source close to the measuring site and open it such that
the new source can be taken out and the old source put into the
transport shielding as quickly as possible.
When working with several sources, make sure that the sources
cannot be mixed up.
7.3.1 Procedure for Source Replacement
1
Figure 7-5 Dismantling the rotary cylinder point source shielding
Dismantling the shielding Unscrew the head flange (1) using a suitable Allan key.
Open the locking cover (2).
Hazards due to nuclear radiation!
Do not remove the source from the shielding!
Do not touch the source to prevent a high partial body dose. Only
touch the source with tools that allow you to grab the source easily
and safely, e.g. a pipe wrench. Do not push the pipe wrench tight
too much to prevent damage to the source. Hold the source far
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 53
7 Source Replacement Volume 1
IMPORTANT
IMPORTANT
IMPORTANT
away from your body and put it down, if possible, behind an auxiliary shielding.
Unscrew the source holder (3) with the source (4) from the
shielding using a size 12 socket wrench.
Remove source from shielding Unscrew the source from the source holder using a socket
wrench (size 10 mm). Hold the source holder using a second
socket wrench (SW 13).
For this work, you should use the shielding housing as an auxiliary
shielding between source and body.
Take hold of the source using a pair of pliers and immediately
put it into the transport shielding or another shielding.
Make sure that no mix-up with the new or other sources can occur.
If necessary, clean and grease the thread on the source holder
and the shielding.
Install new source Using a pair of pliers, take the new source out of the transport
shielding and firmly fix it onto the source holder together with
the locking washer.
Put the source holder with the source again into the shielding
and fix it using the socket wrench.
Assemble shielding again Attach the brass cover (2) again after you have checked if the
O-ring seal is clean and undamaged.
Install the head flange (1) again and fix it carefully with
screws.
Check the proper ON/OFF function.
Carefully close the transport shielding again, after you have put
the old source into the transport shielding.
Replace type label Replace the type label on the shielding or attach the new source
number.
1 – 54 25.5.09
The special regulations regarding labeling and transport of the
shielding back to the manufacturer have to be observed. If in
doubt, please contact BERTHOLD TECHNOLOGIES' Source Transport Manager.
This completes the source replacement.
38477BA2B
Volume 1 7 Source Replacement
IMPORTANT
IMPORTANT
7.4 Radiation Exposure during Source
Replacement
It is important to calculate the potential radiation exposure before
mounting or dismantling point or rod sources. An exact calculation
is possible using the equation below.
The anticipated working hours should be split up in work in the
direct vicinity of the shielding during mounting and dismantling the
source holders and work with the unshielded source while fixing
and dismantling the source and the source holder. The dose
obtained while working in the vicinity of the shielding and the dose
obtained while working with the unshielded source have to be calculated separately and added up.
A rather simplified estimation is possible when the work is prepared
well. Based on the assumptions of a mean distance of 0.5m for the
whole body radiation and the time you are working with the
unshielded source of 6 minutes (= 1/10 hour), the radiation exposure can be calculated for different activities (A) as follows:
Dose D = A x 0.15 at Co-60
Dose D = A x 0.04 at Cs-137
Enter the activity in MBq and the dose is calculated in Sv. the dose
is calculated in µSv.
For multi-part rod sources, the estimated radiation exposure has to
be multiplied with the number of source parts.
1
Using a pocket dosimeter with direct reading, measure the accurate radiation exposure during this work, even if the radiation
exposure lies below the detection limit of dosimeters.
Calculation example A single part rod source with an activity of 400 MBq (approx.
11mCi) has to be replaced. Using the above assumptions concerning distance and time and the above equation, we get the following
result:
D = 400 x 0.15 = 60µSv
The radiation exposure in the vicinity of the shielding was already
calculated to be 10µSv. The total exposure including mounting and
dismantling can then be estimated as being 70µSv for a single part
source.
If the above assumptions do not apply, the calculations have to be
corrected accordingly. Actually, it can only be another working time
which has a proportional effect on the result of the calculated dose
rate.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 55
7 Source Replacement Volume 1
1 – 56 25.5.09
38477BA2B
Volume 1 8 Source Disposal
8 Source Disposal
In general, each country has one depot for receiving and disposing
of radioactive material.
However, if you would like to return radioactive material to us for
disposal, the international regulations for transport, labeling and
dose rates of the radioactive material have to be complied with, as
well as the regulations of each country. It is the full responsibility of
the sender to make sure these regulations are complied with.
Please keep in mind:
• Dose rate on the surface of the packing: < 2000µSv/h.
• Dose rate in a distance of 1 m from the surface of the packing:
<100µSv/h.
• Attaching the UN number with the symbol for dangerous cargo
on each package
• Shipping documents with correct description of the contents
and accident procedures sheet in conformance with the ADR
regulations are required.
• Packaging must comply with the valid ADR regulations.
1
For all questions on source transport or source disposal please contact our source disposal and repair department. You will reach
them in the Bad Wildbad headquarters under:
Phone +49 (0)7081 177 228
Fax +49 (0)7081 177 330
Please state the source number to enable the respective person in
charge to quickly identify the source.
Please keep in mind:
• Radioactive materials and their shieldings may not be damaged
in any way and must have a valid seal test certificate. The seal
test certificate may not be older than six months at the time of
arrival in Germany. An exception is possible if a PTB certificate
is available which confirms that the validity of the test dates
has been extended.
• If you plan to return radioactive sources with isotope Am-241
or Cm-244, you have to include the Special Form certificate.
• It is imperative that radioactive material which is returned to us
is adequately labeled with your name and address.If you have
received a quotation from us, please include our quotation
number as well.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
• Radioactive material can be returned only after you have
received permission from BERTHOLD TECHNOLOGIES. We
would be happy to send you a quotation on the disposal costs
to be expected.
1 – 57
8 Source Disposal Volume 1
• The radioactive material has to be shipped to Wildbad carriage
paid. BERTHOLD TECHNOLOGIES does not take over any costs
for customs clearance or transport.
• BERTHOLD TECHNOLOGIES has to be informed in advance
about the return transport. Radioactive material that is shipped
to Berthold without prior notice will not be accepted by
BERTHOLD TECHNOLOGIES. Any warehouse expenses will be
charged to the supplier.
• A copy of the enclosed notification form sheet and the seal test
certificate has to be attached on each shielding. The original
has to be included with the shipping papers. The documents
have to be send in advance via telefax to our source disposal
and repair department.
On the following pages you will find a form sheet that you can use
to return sources or shieldings to us.
1 – 58 25.5.09
38477BA2B
Volume 1 8 Source Disposal
Company / Sender: Person responsible:
Complete address Telephone no.:
Town / Postal code Country:
Source No.
Isotope
Activity
mCi MBq
Notification Form
FOR DISPOSAL OF RADIOACTIVE MATERIALS
Shielding may be disposed off
.................................................................................................
Other instructions (please complete)
Source will be returned for disposal
.................................................................................................
.................................................................................................
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 59
8 Source Disposal Volume 1
a) Sources and shieldings are not contaminated
b) The material to be returned has been packed and
labeled according to the regulations (see ADR)
The sender hereby declares that:
Place and Date Signature and Title:
Return of a shielding on loan from sender
Sender's order no.: ........................./ our order confirmation no.
Any other instructions or remarks:
Shielding to be returned to sender after repair
Sender's repair order no.: ........................./ our order confirmation no.
.................................................................................................
.................................................................................................
.................................................................................................
New sources to be inserted in the shielding(s) according to
sender's order no.: ........................./ our order confirmation no.
Shielding to be returned empty to sender
1 – 60 25.5.09
38477BA2B
Volume 1 9 Functional Safety
Radiation source Measuring path Measuring system Output
Shielded source
- Co-60
- Cs-137
with mechanical locking
mechanism
Uni-Probe LB 490 Current output
4–20mA
9 Functional Safety
The Safety Manual requires that you are familiar with the device
and software description ID no. 38477BA1 (German) or ID no.
38477BA2 (English).
The Safety Manual includes all information required for the safe
operation of the measuring system.
9.1 Scope of Application
This Safety Manual is valid for radiometric measuring systems,
which consists of a radiation source and the Level Gauge Uni-Probe
LB 490.
1
Figure 9-1 Overview measuring system with Uni-Probe LB 490
The information applies to the following device versions:
DEVICE Description Hardware
revision
Level
measuring
system
This FMEDA is not valid for the versions:
– LB 490 HART with intrinsically safe current output
(ID no. 47678-xxx)
– LB 490 with signal output Profibus PA
(ID no. 50040-xxx and 50035-xxx)
– LB 490 with signal output FOUNDATION
(ID no. 50041-xxx and 50036-xxx)
LB 490 with
®
-signal
HART
output, ID no.
38477-xxx
04 and higher 100 and higher
™
Fieldbus
Software
revision
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 61
9 Functional Safety Volume 1
The software revision can be viewed on the Device Description
menu, menu item
The hardware revision (Device Rev.) is indicated on the outside of
the housing and inside the connection box.
REVIEW.
1 – 62 25.5.09
38477BA2B
Volume 1 9 Functional Safety
Measuring system LB 490
Source
9.2 Use and Function
The Level Gauge Uni-Probe LB 490 is employed for continuous level
measurement and monitoring and for the detection of limit levels of
liquids and bulk material in and pipelines.
Figure 9-2 Measuring system
The measuring system can be employed for the detection and indication of maximum levels (overflow protection) and minimum levels (protection against dry running) and fulfills the requirements
regarding:
• Explosion protection (depending on version and category)
1
• Electromagnetic compatibility according to EN 61326 and
Namur NE 21.
If the device is employed in safety-relevant systems (functional
safety according to IEC 61508/61511), all information in this User’s
Manual has to be observed. In particular, the safety-technical data
in section 9.9 apply only to the application of the system in the
operating mode with low demand mode and taking into account the
information in this manual.
Any usage which goes beyond this information is regarded as noncontractual and may cause severe personal injury or property damage.
BERTHOLD TECHNOLOGIES does not assume any liability for this
kind of injuries or damages.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 63
9 Functional Safety Volume 1
9.3 Safety Function
The safety function of the measuring system comprises the measurement and detection of levels caused by the presence of product
being measured in the measuring path between radiation source
and measuring system.
9.4 Safety Requirement
Safety integrity level Operating mode with low
demand rate
SIL PFD PFH
4 ≤10
3 ≤10-4 to <10
2 ≤10-3 to <10
1 ≤10-2 to <10
-5
to <10
-4
-3
-2
-1
Operating mode with high or continuous
demand rate
≤10-9 to <10
≤10-8 to <10
≤10-7 to <10
≤10-6 to <10
-8
-7
-6
-5
Safe failure fraction Hardware fault tolerance
SFF HFT = 0 HFT = 1 HFT = 2
none: <60% not allowed SIL 1 SIL 2
low: 60% to <90% SIL 1 SIL 2 SIL 3
medium: 90% to <99% SIL 2 SIL 3
high: ≤99% SIL 3
1 – 64 25.5.09
38477BA2B
Volume 1 9 Functional Safety
9.5 Project Planning
General instructions and restrictions • Please make sure that the measuring system will be used in
accordance with its designated function.
• The application-specific limits have to be observed and the
specifications must not be exceeded. See also the technical
data and ambient conditions in the User’s Manual.
• The fault tolerance time of the overall system must be greater
than the reaction time of the measuring system.
• The digital inputs 1 and 2 must not be closed in case of a
safety-related application.
• The multidrop mode must be turned off. Set the polling address
in the parameter
NTERFACE", page 3–336).
I
• The error handling function must be set to STOP.
• The 4–20 mA current output has been defined as signal circuit
for safety-related applications.
• Interfering radiation, e.g. due to welding seam tests, is largely
identified and signaled by the measurement. However, in some
situations it is conceivable that the intensity of the interfering
radiation will increase the radiation level at the detector only
slightly, so that no alarm is triggered or not in due time. Therefore, the facility always has to be informed as soon as a welding
seam test is carried out in the environment of the facility in
which the measurement is employed. In this case, suitable
safety precautions have to be taken.
• To ensure the proper function of the Level Gauge Uni-Probe
LB 490, the avoidance of interference radiation and the avoidance of disturbances due to parallel radiometric measurements
have to be taken into account.
POLL ADDR to “0” (see section "2.40 HART
1
Assumptions The FMEDA (Failure Mode Effects and Diagnostics Analysis) is
based on the following assumptions:
• The failure rates are constant over the service life of the device.
• The following is not taken into consideration:
– external power supply failure rates
– multiple errors
• The mean ambient temperature during the operating time is
40°C.
• The environmental conditions correspond those of an average
industrial environment.
• The working life of the components is between 8 and 12 years.
• The time to repair (replacement of the measuring system) after
a fault protected from interference is eight hours (MTTR = 8h).
• In the operating mode with low demand rate the reaction time
of the LB 490 to dangerous detected faults is max. 15 minutes.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 65
9 Functional Safety Volume 1
• In the operating mode with high demand rate the reaction time
of the LB 490 to dangerous apparent faults is max. 1 day.
If the demand rate is not more than once a year, the measuring
device may be operated as a safety-relevant sub-system in the
operating mode with low demand rate (IEC 61508-4, 3.5.12).
If the ratio of the internal diagnostic test rate of the measuring system to the demand rate exceeds the value 100, the measuring system can be treated as if were executing a safety function in the
operating mode with low demand rate (IEC 61508-2, 7.4.3.2.5).
Diagnostic rate: once every 5 minutes + 15 minutes = 20 minutes
The associated parameter is the value PFD
of dangerous Failure on Demand). The value is dependent on the
test interval T
tive function.
Numerical values see section "9.9 Safety-Technical Data".
between the function checks of the PLT protec-
Proof
(average Probability
avg
Safe state The intrinsically safe state is reached when the current output indi-
cates the following values:
< 3.6mA
> 21.5mA.
A safe failure is defined as a failure that causes the measuring system to go to the defined intrinsically safe state without a demand
from the process.
A dangerous undetected failure is present if the measuring system,
following a demand from the process, does not go to the defined
intrinsically safe state.
1 – 66 25.5.09
38477BA2B
Volume 1 9 Functional Safety
9.6 Getting Started
The conditions at the facility affect the safety of the measuring system. Therefore, the mounting and installation instructions in the
User’s Manual have to be observed.
In particular, the correct setting of the parameters via the HART
Communicator has to be ensured. For more information on the
parameters and on getting started, please refer to the User’s Manual LB 490, ID no. 38477BAx.
Minimum setting for the safety function are the calibration and current output parameters.
The information below refers to the operation with the HART
Communicator. If you are using another user interface to set up the
Uni-Probe parameters, e.g. Siemens SIMATIC PDM, please consult
the relevant chapter in the respective User’s Manual.
Prerequisite for the following sequence of operation is:
• that the shielding or the radiation source have not yet been
installed
• the Uni-Probe has been installed
• the Uni-Probe is supplied with power
• that communication with the Uni-Probe has been established
via an operating device, e.g. a HART
Probe
®
Communicator. Uni-
®
®
1
• that a two-point calibration is carried out. If another type of
calibration is selected, you have to carry it out in accordance
with the User’s Manual, parameter basic setting!!
See User’s Manual ID no. 38477BAx, Volume 3, chapter
"4.1 Preparing Calibration" and "4.2 Operation Modes for Calibration".
Further settings
– “Error Handling” function
– Digital inputs function DISABLED
Measuring the background
– See Volume 3, chapter "4.3.1 Measure Background" and
explanations in chapter "6.1 Background".
Install shielding with radiation source and then open the radia-
tion channel!
– See Volume 2, chapter "2 Installation".
Empty calibration
The level must be below the measuring range.
– Empty calibration has to be carried out as described in the
User’s Manual. See Volume 3, chapter "4.3.2 Empty Calibration".
Full calibration
The level must be above the measuring range. If this is not
possible, you may also close the source shielding. If only the
STOP
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 67
9 Functional Safety Volume 1
source shielding is closed to carry out the full calibration, then
you have to keep in mind:
Make sure that the absorption of the closed shielding nearly
corresponds to the absorption of the product. If in doubt,
please contact BERTHOLD TECHNOLOGIES or your local representative.
– Full calibration has to be carried out as described in the
User’s Manual. See Volume 3, chapter "4.4.3 Full Calibration".
TEST
– Write down the empty and full count rate. Enter the empty
count rates under S
In this manner, you can simulate the two states Empty /
Full and check if the displayed levels, 0% / 100%, are correct. If not, please check the calibration.
Function check
The tank on which the measurement is carried out is in the normal operating mode, the level is below the measuring range.
The measured value has to fluctuate around 0%.
– Increase level above the measuring range (if not possible:
close shielding).
The measured value has to fluctuate around 100%.
– The alarm output must indicate an alarm and must not
switch back anymore.
Password
– Enter a password as described in the User’s Manual, see
Volume 3, "2. 13 E
rules out data manipulation by unauthorized persons.
ERVICE MENU / TEST CALCULATION.
NTER PASSWORD", on page 3–312. This
The calibration is now finished and the measurement has
been taken into operation.
1 – 68 25.5.09
38477BA2B
Volume 1 9 Functional Safety
9.7 Behavior during Operation and during
Malfunctions
• Do not change the parameters during operation.
• The following parameter are automatically adjusted in the
course of operation relative to the decay compensation; therefore, their values may change: count rate of all calibration data
points.
• If the operation is changed, please observe the safety functions.
• Malfunctions that may occur are described in the User’s Manual.
• If failures have been detected or malfunctions are reported,
you have to take the entire measuring system out of service
and keep the process in a safe state through other measures.
• Replacement of the measuring system is rather simple; it is
described in the User’s Manual.
• If parts are replaced as a result of a detected failure, please
inform BERTHOLD TECHNOLOGIES accordingly (including failure description).
• If modifications in the product, the gas pressure, or the construction of the tank in the area of the radiation path are carried out, the measurement has to be calibrated again.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 69
9 Functional Safety Volume 1
IMPORTANT
9.8 Recurrent Performance Test
The recurrent performance test is used to check the safety function
to uncover possibly undetected dangerous failure. The operational
capability of the measuring system has to be checked in adequate
intervals.
It is in the responsibility of the operator to select the type of test
and the proof test interval. The intervals are dependent on the
PFD
Technical Data” (see also FMEDA report).
The test has to be carried out such that the proper safety function
will be proven through interaction of all components.
This is the case when the level is controlled within the scope of a
filling. If a filling is not feasible, the measuring system has to be
triggered to respond by suitable simulation of the level or of the
physical measurement effect.
The methods and procedures used in the tests have to be named
and their degree of suitability has to be specified. The tests have to
be documented.
If the function check is negative, you have to take the entire measuring system out of service and keep the process in a safe state
through other measures.
value defined in the table and chart in the section “Safety-
avg
During the test, the person in charge of the test has to ensure the
safety-technical monitoring of the process through other technical
and organizational measures.
1 – 70 25.5.09
38477BA2B
Volume 1 9 Functional Safety
Shielding with
source
Ta nk
2 Uni-Probes
General data
9.9 Safety-Technical Data
The failure rates of the electronics were determined through
FMEDA according to EC 61508. The calculations are based on the
component failure rates according to SN 29500. All numerical values refer to an average ambient temperature of +40°C (104°F).
The calculations are further based on the information given in the
chapter “Project Planning”.
λ
sd
λ
su
λ
dd
λ
du
SFF >96% Safe Failure Fraction
DC
S
DC
D
(Fit = failure in time = 10
Failure react io n time T
max. service life of the measuring system for the safety
function
783 Fit Safe detected failure
174 Fit Safe undetected failure
427 Fit Dangerous detected failure
74 Fit Dangerous undetected failure
82% Safe Diagnostic Coverage
85% Dangerous Diagnostic Coverage
-9
failures per hour)
1.5sec
Reac tio n
10 years
1
Single channel architecture 1001
HFT = 0 (Hardware Fault Tolerance)
PFD
T
T
T
Proof
Proof
Proof
avg
= 1 year
= 2 years
= 5 years
<0.032 x 10
<0.064 x 10
<0.160 x 10
-2
-2
-2
Two-channel architecture 1002 HFT = 1 (Hardware Fault Tolerance)
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 71
9 Functional Safety Volume 1
PFD
avg
T
Proof15 10
1
3
2
1. For common cause ß = 2%
PFD
PFD
avg
T
Proof
T
Proof
T
Proof
2. For common cause ß = 5%
PFD
avg
T
Proof
T
Proof
T
Proof
= (PFD
1002
= 1 year
= 2 years
= 5 years
= 1 year
= 2 years
= 5 years
)2 + ß x PFD
1001
<6.5 x 10
<13.2 x 10
<34.5 x 10
<1,6 x 10
<3,2 x 10
<8.2 x 10
1001
-6
-6
-6
-5
-5
-5
Time-dependent trend of PFD
avg
The time trend of PFD
is nearly linear to the operating time in
avg
the period up to 10 years. The above mentioned values apply only
to the T
interval, according to which a recurrent performance
Proof
check has to be carried out.
Time-dependent trend of PFD
1 PFD
2 PFD
3 PFD
= 0
avg
after 1 year
avg
after 5 years
avg
avg
It is in the interest of the operator of a facility to verify the safety
function quantitatively.
38477BA2B
1 – 72 25.5.09
Volume 1 9 Functional Safety
The document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in
any event for incidental or consequential damages in connection with the application of the document.
© All rights on the format of this technical report reserved.
Failure Modes, Effects and Diagnostics Analysis
Project:
Level Transmitter LB490 Uni-Probe
Customer:
Berthold Technologies GmbH & Co. KG
Bad Wildbad
Germany
Contract No.: Berthold Technology 04/08-10
Report No.: Berthold Technology 04/08-10 R003
Version V1, Revision R3, Apr. 2007
Rainer Faller
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 2 of 18
Management summary
This report summarizes the results of the hardware assessment according to IEC 61508 carried
out on the Level Transmitter LB490 Uni-Probe. For safety applications only level measurement
and the 4..20mA output is considered. The HART™ communication shall not be used for safety
applications. The configuration set up using HART™ shall be checked by functional testing.
The hardware assessment consists of a Failure Modes, Effects and Diagnostics Analysis
(FMEDA). A FMEDA is one of the steps taken to achieve functional safety assessment of a
device per IEC 61508. For full assessment purposes all requirements of IEC 61508 must be
considered.
From the FMEDA, failure rates are determined and consequently the Safe Failure Fraction
(SFF) is calculated for the device. A dangerous failure is defined as a failure that does not
correctly respond to a demand from the process outside a measurement band of more than 5%
full span at ambient temperature. Failure rates used in this analysis are basic failure rates from
the Siemens standard SN 29500. For the photo-multiplier field failure evaluations from Berthold
Technologies and the manufacturer (Photonis) were used. For the mechanical design of the
detector unit field failure evaluations from Berthold Technologies were used.
The Level Transmitter LB490 Uni-Probe is considered to be a Type B sub-system with a
hardware fault tolerance of HFT=0.
It is assumed that the current output signal is fed to a SIL compliant analog input of a safety
PLC (programmable logic controller). The analog input and the application program of the
connected safety PLC shall be configured according to NAMUR NE43 to detect under-range
and over-range failures. Under the assumptions described in section 4 the following table shows
the failure rates according to IEC 61508. Additional to the FMEDA, fault injection tests have
been executed to confirm the effectiveness of the fault detection mechanisms.
Table 1 Summary for the Level Transmitter LB490 Uni-Probe incl. photomultiplier – IEC 61508
Failure rates
O
sd
O
su
O
dd
O
du
SFF DC
S
1
DC
D
783 fit 535 fit 427 fit 74 fit 96% 59% 85%
These failure rates are valid for operating stress conditions typical of an industrial field
environment similar to IEC 60654-1, class C (sheltered location) with an average temperature
over a long period of time of 40ºC. For a higher average temperature of 60°C, the failure rates
should be multiplied with an experience-based factor of 2.5. A similar multiplier should be used
if frequent temperature fluctuation must be assumed.
The failure rates do not include failures resulting from incorrect use of the transmitter, in
particular high vibration at the photomultiplier tube and humidity entering through incompletely
closed housings or inadequate cable feeding through the PG inlets.
A user of the Level Transmitter LB490 Uni-Probe can utilize these failure rates in a probabilistic
model of a safety instrumented function (SIF) to determine suitability in part for safety
instrumented system (SIS) usage in a particular safety integrity level (SIL). A full table of failure
rates is presented in section 5.1 along with all assumptions in section 4.
1
DC means the diagnostic coverage (safe or dangerous).
9.10 Certificate Functional Safety
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 73
9 Functional Safety Volume 1
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 3 of 18
The failure rates are valid for the useful life of the instrument. The circuits of the Level
Transmitter LB490 Uni-Probe evaluation unit do not contain any components with limited useful
lifetime which are contributing to the dangerous undetected failure rate. For typical applications,
the photomultiplier tube has a useful lifetime of more than 7,5 years with 60Co radiation source
and more than 21 years with 137Cs radiation source. When plant conditions and experience
indicate a shorter useful lifetime than indicated in this appendix, the number based on plant
experience shall be used.
The PFD
AVG
was calculated for three different proof test intervals.
Table 2 Summary for the Level Transmitter LB490 Uni-Probe incl. photomultiplier – PFD
AVG
values
T[Proof] = 1 year T[Proof] = 2 years T[Proof] = 5 years
PFD
AVG
= 3,2E-04 PFD
AVG
= 6,4E-04 PFD
AVG
= 1,6E-03
The boxes marked in green mean that the calculated PFD
AVG
values are within the allowed
range for SIL 2 according to table 2 of IEC 61508-1 and table 3.1 of ANSI/ISA–84.01–1996 and
do fulfill the requirement to not claim more than 35% of this range, i.e. to be better than or equal
to 3,5E-03.
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 4 of 18
Table of Contents
Management summary....................................................................................................2
1 Purpose and Scope ................................................................................................... 5
2 Project management..................................................................................................6
2.1 exida.com .....................................................................................................................6
2.2 Roles of the parties involved..........................................................................................6
2.3 Standards / Literature used............................................................................................6
2.4 Reference documents....................................................................................................7
2.4.1 Documentation provided by the customer............................................................7
2.4.2 Documentation generated or reviewed by exida.com ..........................................7
3 Description of the analyzed modules.........................................................................8
3.1 System description .........................................................................................................8
3.2 Measuring principle ........................................................................................................9
4 Failure Modes, Effects, and Diagnostics Analysis ...................................................10
4.1 Description of the failure categories.............................................................................10
4.2 Methodology – FMEDA, Failure rates ..........................................................................11
4.2.1 FMEDA...............................................................................................................11
4.2.2 Failure rates .......................................................................................................11
4.2.3 Assumption ........................................................................................................11
5 Results of the assessment.......................................................................................13
5.1 Level Transmitter LB490 Uni-Probe .............................................................................13
6 Terms and Definitions.............................................................................................. 15
7 Status of the document............................................................................................ 16
7.1 Liability .........................................................................................................................16
7.2 Releases ......................................................................................................................16
7.3 Release Signatures ......................................................................................................16
Appendix 1: Possibilities to reveal dangerous undetected faults during proof test ........17
Appendix 2: Impact of lifetime of critical components on the failure rate .......................18
1 – 74 25.5.09
38477BA2B
Volume 1 9 Functional Safety
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 5 of 18
1 Purpose and Scope
Generally three options exist when doing an assessment of sensors, interfaces and/or final
elements.
Option 1: Hardware assessment according to IEC 61508
Option 1 is a hardware assessment by
exida
according to the relevant functional safety
standard(s) like IEC 61508 or EN 954-1. The hardware assessment consists of a FMEDA to
determine the fault behavior and the failure rates of the device, which are then used to calculate
the Safe Failure Fraction (SFF) and the average Probability of Failure on Demand (PFD
AVG
).
Fault injection testing will be used to confirm the effectiveness of any self-diagnostics.
This option for pre-existing hardware devices shall provide the safety instrumentation engineer
with the required failure data as per IEC 61508 / IEC 61511 and does not include an
assessment of the software development process
Option 2: Hardware assessment with proven-in-use consideration according to IEC 61508 /
IEC 61511
Option 2 is an assessment by
exida
according to the relevant functional safety standard(s) like
IEC 61508 or EN 954-1. The hardware assessment consists of a FMEDA to determine the fault
behavior and the failure rates of the device, which are then used to calculate the Safe Failure
Fraction (SFF) and the average Probability of Failure on Demand (PFD
AVG
). Fault injection
testing will be used to confirm the effectiveness of any self-diagnostics. In addition this option
consists of an assessment of the proven-in-use documentation of the device and its software
including the modification process.
This option for pre-existing programmable electronic devices shall provide the safety
instrumentation engineer with the required failure data as per IEC 61508 / IEC 61511 and may
help justify the reduced fault tolerance requirements of IEC 61511 for sensors, final elements
and other PE field devices when combined with plant specific proven-in-use records.
Option 3: Full assessment according to IEC 61508
Option 3 is a full assessment by
exida
according to the relevant application standard(s) like IEC
61511 or EN 298 and the necessary functional safety standard(s) like IEC 61508 or EN 954-1.
The full assessment extends option 1 by an assessment of all fault avoidance and fault control
measures during hardware and software development.
This assessment shall be done according to option 1.
This document shall described the results of the assessment carried out on the Level
Transmitter LB490 Uni-Probe with Software Revision V2.00.
This document does neither consider any systematic software design failures nor calculations
necessary for proving intrinsic safety.
The information in this report can be used to evaluate whether a sensor meets the average
Probability of Failure on Demand (PFDavg) requirements and the architectural constraints, i.e.,
the minimum hardware fault tolerance and safe failure fraction requirements per IEC 61508.
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 6 of 18
2 Project management
2.1 exida.com
exida is one of the world’s leading knowledge companies specializing in automation system
safety and availability with over 200 years of cumulative experience in functional safety.
Founded by several of the world’s top reliability and safety experts from assessment
organizations like TUV and manufacturers, exida is a partnership with offices around the world.
exida offers training, coaching, project oriented consulting services, internet based safety
engineering tools, detail product assurance and certification analysis and a collection of on-line
safety and reliability resources. exida maintains a comprehensive failure rate and failure mode
database on process equipment.
2.2 Roles of the parties involved
Berthold Technologies Manufacturer of the Level Transmitter LB490 Uni-Probe
exida Performed the hardware assessment according to option 1 (see
section 1).
Berthold Technologies contracted exida.com GmbH in August 2004 with the FMEDA of the
above mentioned device.
2.3 Standards / Literature used
The services delivered by exida were performed based on the following standards / literature.
[N1] IEC 61508-2:2000 Functional Safety of
Electrical/Electronic/Programmable Electronic
Safety-Related Systems
[N2] ISBN: 0471133019
John Wiley & Sons
Electronic Components: Selection and Application
Guidelines by Victor Meeldijk
[N3] FMD-91, RAC 1991 Failure Mode / Mechanism Distributions
[N4] FMD-97, RAC 1997 Failure Mode / Mechanism Distributions
[N5] NPRD-95, RAC Non-electronic Parts – Reliability Data 1995
[N6] SN 29500 Failure rates of components
[N7] NSWC-98/LE1 Handbook of Reliability Prediction Procedures for
Mechanical Equipment
[N8] IEC 60654-1:1993, 2
nd
edition Industrial process measurement and control
equipment – Operating conditions – Part 1:
Climatic conditions
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 75
9 Functional Safety Volume 1
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 7 of 18
2.4 Reference documents
2.4.1 Documentation provided by the customer
[D1] Circuit Diagram 36134SP, Rev 05;
Power Supply UniProbe 24V AC/DC
AC wide range
Circuit Diagram Power Supply, AC wide range
[D2] PMA30 D 5/24 und PMA15 S24 Kalkulation MTBF nach MIL HDBK 217F,
Notice 2, Ground Benign, Temperatur 25°C
MTM Power Mellenbach
[D3] Circuit Diagram 21324SP, Rev 04
Voltage Divider
Circuit Diagram Voltage Divider
[D4] Circuit Diagram 48631SP, Rev 04,
5 pages, Digital Board UniProbe
(35966SP übergangen in 48631SP)
Circuit Diagram Digital Board UniProbe
[D5] Circuit Diagram 40998SP, Rev 01,
Pre-Amplifier / H.V.
Circuit Diagram Pre-Amplifier / High Voltage
[D6] MTTF_XP3230_2b.xls; 20.4.2005 Berthold Technologies, Process Control /
Estimation of useful lifetime XP3230
[D7] FMEDA Berthold UniProbe Gesamt
040927_Ergebnisse_2 Silva
Kommentare (2).xls; 25.8.2006
Documenation of the fault insertion tests
[D8] 15.821 (Report DAG437BE to Req for
MTTF of XP3230, XP3240,
Berthold Technologies).pdf; 8.9.2004
XP3230B and XP3240B PMTs - MTBF
[D9] Sicherheitshandbuch, Rev 00
Id 38477BA15, SW-Version 2.0
Safety Manual LB490
2.4.2 Documentation generated or reviewed by exida.com
[R1] FMEDA Berthold UniProbe ACDC-DC V654 061010.xls; 10.10.2006
[R2] FMEDA Berthold UniProbe Process Output Neu V654 061010.xls; 10.10.2006
[R3] FMEDA Berthold UniProbe Digital+Amplifier Neu V654 061010.xls; 10.10.2006
[R4] Failure rate Photo Multiplier: Field failure analysis V002.xls; 10.10.2006
[R5] FMEDA Berthold UniProbe Gesamt 061010.xls; 10.10.2006
[R6]
Safety Manual Checklist V1 R1.1.doc of 16.12.04
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 8 of 18
3 Description of the analyzed modules
3.1 System description
The analyzed system is the Level Transmitter LB490 Uni-Probe.
This transmitter is designed to perform measurements for fluids or bulk material level. The
measurement is based on the physical law of the attenuation of Gamma radiation as it passes
through medium. The Level Transmitter LB490 Uni-Probe combines long years of experience by
Berthold Technologies with the Gamma measurement technology.
The Level Transmitter LB490 Uni-Probe is considered to be a Type B sub-system with a
hardware fault tolerance of HFT=0.
See Figure 1 for a system overview.
Figure 1: System Overview
The pulse reading is converted via the evaluation unit into a 4..20mA signal. The HART™
communication is not considered safety-related and not subject of this report.
1 – 76 25.5.09
38477BA2B
Volume 1 9 Functional Safety
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 9 of 18
3.2 Measuring principle
Figure 2 gives an overview of the measuring principle of the Level Transmitter LB490 Uni-Probe.
Figure 2: Measuring principle of the Level Transmitter LB490 Uni-Probe
Explanation of terms:
Strahlenquelle: Capsulated and shielded Gamma radiation source mounted outside the vessel
at the level to be monitored
Messsystem: Radiation detector mounted opposite to the source
Ausgang: 4..20mA NAMUR NE43 compliant output
The Level Switch system is based on the physical law of the attenuation of Gamma radiation as
it passes through medium. Product in between the source and the corresponding detector
decreases the detected radiation by a related extent. This effect corresponds to the relative
product's presence and therewith it signalizes the level of the product in the container (vessel,
pipe, etc.).
As it is a contact-less measurement with external mounting without modification of the existing
vessel, the measurement is independent of:
x High temperature with water-cooling
x High pressure or vacuum
x Volatile & biohazard material
x Corrosive material
x Agitators, baffles, coils etc.
x Build up on vessel walls
x Physical and chemical properties of the product and the process
Berthold Technologies main detector properties are designed according to the patented method
of automatic drift stabilization for radiometric applications, this method uses the energy loss of
natural cosmic radiation for readjustment of the amplification for measurement result
corrections. (See also Patent scripture DE 41 14030 C1)
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 10 of 18
4 Failure Modes, Effects, and Diagnostics Analysis
The Failure Modes, Effects, and Diagnostic Analysis was done together with Berthold
Technology and is documented in [R1] to [R3]. When the effect of a certain failure mode could
not be analyzed theoretically, the failure modes were introduced on component level and the
effects of these failure modes were examined on system level (see [D7] – Fault insertion tests).
This resulted in failures that can be classified according to the following failure categories.
4.1 Description of the failure categories
In order to judge the failure behavior of the Level Transmitter LB490 Uni-Probe, the following
definitions for the failure of the product were considered.
Fail-Safe State The fail-safe state is defined as the current contact reaching the
NAMUR NE43 Alarm ranges, i.e., I < 3,6mA or I > 21mA.
Fail Safe A safe failure (S) is defined as a failure that causes the transmitter
to go to the defined fail-safe state without a demand from the
process. Safe failures are divided into safe detected (SD) and safe
undetected (SU) failures.
Fail Dangerous A dangerous failure (D) is defined as a failure that does not
correctly respond to a demand from the process outside a band of
more than 5% full span at ambient temperature.
Fail Dangerous Undetected Failure that is dangerous and that is not being diagnosed by
internal diagnostics.
Fail Dangerous Detected Failure that is dangerous but is detected by internal diagnostics or
a connected logic solver (These failures may be converted to the
selected fail-safe state).
Annunciation Failure, e.g. in a diagnostic circuit, that does not directly impact
safety but impacts the ability to detect a future fault. Annunciation
failures are divided into annunciation detected (AD) and
annunciation undetected (AU) failures. For the calculation of the
Safe Failure Fraction (SFF), they are treated like dangerous
failures. This is a worst-case interpretation.
No Effect failures Failure of a component that is part of the safety function but has
no effect on the safety function within a band of not more than 5%
full span. For the calculation of the Safe Failure Fraction (SFF), it
is treated like a safe undetected failure.
The failure categories listed above expand on the categories listed in IEC 61508 which are only
safe and dangerous, both detected and undetected. The reason for this is that not all failure
modes have effects that can be accurately classified according to the failure categories listed in
IEC 61508.
“No Effect” and “Annunciation” failures are provided for those who wish to do reliability modeling
more detailed than required by IEC 61508. In IEC 61508:2000, “No Effect” failures are defined
as safe undetected failures even though they will not cause the safety function to go to a safe
state. Therefore they need to be considered in the Safe Failure Fraction calculation.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 77
9 Functional Safety Volume 1
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 11 of 18
4.2 Methodology – FMEDA, Failure rates
4.2.1 FMEDA
A Failure Modes and Effects Analysis (FMEA) is a systematic way to identify and evaluate the
effects of different component failure modes, to determine what could eliminate or reduce the
chance of failure, and to document the system in consideration.
An FMEDA (Failure Mode Effect and Diagnostic Analysis) is an FMEA extension. It combines
standard FMEA techniques with extension to identify online diagnostics techniques and the
failure modes relevant to safety instrumented system design. It is a technique recommended to
generate failure rates for each important category (safe detected, safe undetected, dangerous
detected, dangerous undetected, fail high, fail low) in the safety models. The format for the
FMEDA is an extension of the standard FMEA format from MIL STD 1629A, Failure Modes and
Effects Analysis.
4.2.2 Failure rates
The failure rate data used by exida in this FMEDA are from the Siemens SN 29500 failure rate
database. The rates were chosen in a way that is appropriate for safety integrity level
verification calculations. The rates were chosen to match operating stress conditions typical of
an industrial field environment similar to IEC 60654-1, class C. It is expected that the actual
number of field failures will be less than the number predicted by these failure rates.
The user of these numbers is responsible for determining their applicability to any particular
environment. Accurate plant specific data may be used for this purpose. If a user has data
collected from a good proof test reporting system that indicates higher failure rates, the higher
numbers shall be used. Some industrial plant sites have high levels of stress. Under those
conditions the failure rate data is adjusted to a higher value to account for the specific
conditions of the plant.
4.2.3 Assumption
The following assumptions have been made during the Failure Modes, Effects, and Diagnostic
Analysis (FMEDA) of the Level Transmitter LB490 Uni-Probe with 4..20mA NAMUR NE43
compliant current output.
x Failure rates are constant, wear out mechanisms are not included.
x Propagation of failures is not relevant.
x The HART™ communication is not used for safety applications. The correct configuration
set up using HART™ shall be checked by functional testing.
x Only the NAMUR NE43 compliant current output is used for safety application.
x The current output signal is fed to a SIL compliant analog input of a safety PLC. The safety
PLC analog input and the application program are configured according to NAMUR NE43 to
detect under-range and over-range failures.
x The stress levels are average for an industrial environment and can be compared to the
Ground Fixed classification of MIL-HNBK-217F. Alternatively, the assumed environment is
similar to:
o IEC 60654-1, Class C (sheltered location) with temperature limits within the
manufacturer’s rating and an average temperature over a long period of time of 40ºC.
Humidity levels are assumed within manufacturer’s rating.
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 12 of 18
x The Level Transmitter LB490 Uni-Probe is operated in the low demand mode of operation or
is operated in high demand mode of operation with a demand rate of less than once per day.
x Internal power supply failure rates are included in the FMEDA, but not external power supply
failures.
1 – 78 25.5.09
38477BA2B
Volume 1 9 Functional Safety
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 13 of 18
5 Results of the assessment
exida did the FMEDAs together with Berthold Technology.
For the calculation of the Safe Failure Fraction (SFF) the following has to be noted:
O
total
consists of the sum of all component failure rates. This means:
O
total
= O
safe
+ O
dangerous
+ O
no effect
+ O
annunciation
O
du total
= O
du
+ O
annunciation undetected
SFF = 1 – O
du total
/ O
total
For the FMEDAs failure modes and distributions were used based on information gained from
[N3] to [N5].
5.1 Level Transmitter LB490 Uni-Probe
The FMEDA carried out on the Level Transmitter LB490 Uni-Probe leads under the
assumptions described in section 4.2.3 to the following failure rates:
Failure category Failure rates [FIT:=10
-9
/h]
Pre-amplifier, voltage
divider and digital board
Fail Safe Detected 752
Fail Safe Undetected 97
Fail Dangerous Detected 261
Fail Dangerous Undetected 45
Annunciation Detected 7
Annunciation Undetected 5
No Effect 313
Safe Failure Fraction 96,6%
4..20mA Output - new Fail Safe Detected 31
Fail Safe Undetected 22
Fail Dangerous Detected 92
Fail Dangerous Undetected 1,3
Annunciation Detected 43
Annunciation Undetected 17
No Effect 31
Safe Failure Fraction 92,3%
AC/DC-DC converter Fail Safe Detected 0
Fail Safe Undetected 55
Fail Dangerous Detected 3
Fail Dangerous Undetected 0
Annunciation Undetected 3
No Effect 18
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 14 of 18
Failure category Failure rates [FIT:=10
-9
/h]
Safe Failure Fraction 95,9%
Photomultiplier Fail Dangerous Detected 21
Fail Dangerous Undetected 2,4
Safe Failure Fraction 90%
The failure rates for the photo multiplier were evaluated from the field experience report of the
manufacturer Photonis.
Remark: Due to the isolated mounting of the contacts in the Ex-D housing, the PG inlet and the
O-ring to the connector room of the photo multiplier were not considered.
Under the assumptions described in section 4.2.3 the following table shows the failure rates
according to IEC 61508:
O
sd
O
su
Total
=
O
su
+ O
no effect
O
dd
Total
=
O
dd
+ O
ad
O
du
Total
=
O
du
+ O
au
SFF DC
S
DC
D
783 fit 535 fit 427 fit 74 fit 96% 59% 85%
These failure rates are valid for operating stress conditions typical of an industrial field
environment similar to IEC 60654-1, class C (sheltered location) with an average temperature
over a long period of time of 40ºC (see chapter 4.2.3). For a higher average temperature of
60°C, the failure rates should be multiplied with an experience-based factor of 2.5. A similar
multiplier should be used if frequent temperature fluctuation must be assumed.
Note that the “no effect” and “annunciation” failures on its own will not affect system reliability or
safety, and should not be included in spurious trip calculations.
The PFD
AVG
was calculated for three different proof test intervals.
T[Proof] = 1 year T[Proof] = 2 years T[Proof] = 5 years
PFD
AVG
= 3,2E-04 PFD
AVG
= 6,4E-04 PFD
AVG
= 1,6E-03
The boxes marked in green mean that the calculated PFD
AVG
values are within the allowed
range for SIL 2 according to table 2 of IEC 61508-1 and table 3.1 of ANSI/ISA–84.01–1996 and
do fulfill the requirement to not claim more than 35% of this range, i.e. to be better than or equal
to 3,5E-03.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 79
9 Functional Safety Volume 1
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 15 of 18
6 Terms and Definitions
DC
S
Diagnostic Coverage of safe failures (DC
S
= O
sd
/ (O
sd
+ O
su
)
DC
D
Diagnostic Coverage of dangerous failures (DC
D
= O
dd
/ (O
dd
+ O
du
)
FIT Failure In Time (1x10
-9
failures per hour)
FMEDA Failure Mode Effect and Diagnostic Analysis
HART Highway Addressable Remote Transducer
HFT Hardware Fault Tolerance
Low demand mode Mode, where the frequency of demands for operation made on a safety-
related system is no greater than one per year and no greater than twice
the proof test frequency.
PFD
AVG
Average Probability of Failure on Demand
SFF Safe Failure Fraction summarizes the fraction of failures, which lead to a
safe state and the fraction of failures which will be detected by
diagnostic measures and lead to a defined safety action.
SIF Safety Instrumented Function
SIL Safety Integrity Level
Type B component “Complex” component (using micro controllers or programmable logic);
for details see 7.4.3.1.3 of IEC 61508-2
T[Proof] Proof Test Interval
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 16 of 18
7 Status of the document
7.1 Liability
exida prepares FMEDA reports based on methods advocated in International standards. Failure
rates are obtained from a collection of industrial databases. exida accepts no liability
whatsoever for the use of these numbers or for the correctness of the standards on which the
general calculation methods are based.
7.2 Releases
Version History: V0, R1: Initial version; Aug. 16, 2005
V0, R2: Results from fault insertion tests integrated
Comments from FMEDA reviews integrated; Oct. 10, 2006;
Safety Manual added
V1, R0: Released version
V1, R1: 4 additional EMC capacitors on 48631SP, Rev 04
V1, R3: Editorial changes, Apr. 12, 2007
Authors: Rainer Faller
Review: V0, R2: Stephan Aschenbrenner (exida), Sept. 18, 2006;
Dr. Briggmann, Mr. Silva, Berthold Technologies, Oct. 2006
V1, R3: Mr. Silva, Berthold Technologies, April 2007
Release status: Released
7.3 Release Signatures
Dipl.-Ing. (Univ.) Rainer Faller, Principal Partner
Dipl.-Ing. (Univ.) Stephan Aschenbrenner, Partner
1 – 80 25.5.09
38477BA2B
Volume 1 9 Functional Safety
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 17 of 18
Appendix 1: Possibilities to reveal dangerous undetected faults during
proof test
According to section 7.4.3.2.2 f) of IEC 61508-2 proof tests shall be undertaken to reveal
dangerous faults which are undetected by diagnostic tests.
This means that it is necessary to specify how dangerous undetected faults which have been
noted during the FMEDA can be detected during proof testing.
Table 3 shows an sensitivity analysis of the most critical dangerous undetected faults and
indicates how these faults can be detected during proof testing.
Table 3: Sensitivity Analysis of dangerous undetected faults of the evaluation unit
Component
% of total O
du
Detection through
IC1 – CPU 21% Functional test by closing the radiation source
IC31 – EEPROM 13% Functional test by closing the radiation source
IC2 – OpAmp 11% Functional test by closing the radiation source
Q1 7% Calibration
IC32 3% Functional test by comparing the measured pulse
rate with the expected “empty” pulse rate.
IC39 – Pulse shaping 3% Empty tank calibration
IC43 3% Empty tank calibration
Table 4: Sensitivity Analysis of dangerous undetected faults of the 4..20mA process output
Component
% of total O
du
Detection through
IC19 – Opto-coupler 35% Functional test by comparing the measured pulse
rate with the expected “empty” pulse rate.
IC32 – OpAmp 23% Functional test, see above
IC14 – DAC 17% Functional test, see above
IC23 – DAC driver 15% Functional test, see above
R112 – Measurement 5% Functional test, see above
The proof tests referenced in table 3 and 4 are described in detailed in the Safety Manual.
© exida.com GmbH berthold 0408-10 r003 v1r3.doc, Apr. 12, 2007
Rainer Faller Page 18 of 18
Appendix 2: Impact of lifetime of critical components on the failure rate
Although a constant failure rate is assumed by the probabilistic estimation method (see section
4.2.3) this only applies provided that the useful lifetime of components is not exceeded. Beyond
their useful lifetime (i.e. as the probability of failure significantly increases with time) the results
of the probabilistic calculation method is therefore meaningless. The useful lifetime is highly
dependent on the component itself and its operating conditions – temperature in particular (for
example, electrolyte capacitors can be very sensitive).
This assumption is based on the bathtub curve, which shows the typical behavior for electronic
components.
Therefore it is obvious that the PFD
AVG
calculation is only valid for components which have this
constant domain and that the validity of the calculation is limited to the useful lifetime of each
component.
It is assumed that early failures are detected to a huge percentage during the installation period
and therefore the assumption of a constant failure rate during the useful lifetime is valid.
The circuits of the Level Transmitter LB490 Uni-Probe evaluation unit do not contain any
components with limited useful lifetime which are contributing to the dangerous undetected
failure rate. For typical applications, the photomultiplier has a useful lifetime of more than 7,5
years with 60Co radiation source and more than 21 years with 137Cs radiation source.
When plant conditions and experience indicate a shorter useful lifetime than indicated in this
appendix, the number based on plant experience shall be used.
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 81
9 Functional Safety Volume 1
1 – 82 25.5.09
38477BA2B
Volume 1 10 Safety instructions ATEX/FM/CSA
Safety instructions ATEX/FM/CSA
10 Safety Instructions for the
Types of Protection ATEX /
FM / CSA
Safety instructions ATEX/FM/CSA
When working in areas in danger of explosion, the safety of personnel and facilities is dependent on the observance of all relevant
safety regulations. The assembly and service personnel, therefore,
carries a special responsibility and must have appropriate expertise
with regard to explosion protection or has to be authorized by
BERTHOLD TECHNOLOGIES. Prerequisite for working in these areas
is that the personnel knows all applicable rules and regulations.
Users have to keep in mind:
– the characteristic data, limit values and the information on
operating and environmental conditions indicated on the type
labels and data sheets
1
– the signs on the devices
– that damage to the devices may undo the ex-protection
– that the Uni-Probe may be operated only if the housing is com-
pletely closed.
In areas in danger of explosion, the Uni-Probe is intended only for
stationary installation.
The temperature range that is valid for all types of protection lies
between -20°C and +50°C. Most types of protection, however,
offer a larger temperature range. This is stated on the respective
certificate (see Volume 1, chapter 11).
Do not open the housing while it is energized, or in a potentially
explosive atmosphere. Please keep in mind that you have to disconnect the relay contacts in addition to the supply line.
The thread for the housing cover, on the housing and also in the
housing cover, must not get damaged, as otherwise explosion protection is no longer ensured. Using the Uni-Probe in areas endangered of explosion is not permitted when:
– the screwed cable glands are corroded
– the screw threads at the housing cover is corroded
– dummy plugs are heavily corroded
– the Uni-Probe housing is heavily corroded
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
– the Uni-Probe housing is damaged
– the Uni-Probe housing has received a mechanical blow, e.g. by
dropping it on the floor.
Cleaning of corroded screw threads on the housing cover, on the
screwed cable glands or the 3/4" cable bushing using abrasives or
steel brushes is not permitted.
1 – 83
10 Safety instructions ATEX/FM/CSA Volume 1
Close the housing carefully with the housing cover before turning
on the line voltage. Fix the housing cover completely onto the
housing with screws and tighten it using a torque of 25Nm (reference value).
Before closing, make sure that the threads are clean and greased
with OKS 217.
Unused conduits must be closed by a dummy plug which is suited
for the respective type of protection.
Modifications on the installation may not be carried out without
detailed knowledge of these operating instructions.
Ground conductor The ground conductor has to be connected to the internal ground-
ing screw via a fairly short cable.
Equipotential bonding Connect the detector to an equipotential busbar. The cable to this
bar has to be fairly short.
Screened cable Cable screens can be connected to the internal grounding screw
using a fairly short cable. Exception: The screened cables for the
RS-485 connection cable. These have to be connected to
terminals 56.
For installation, please keep in mind • Connect the cables with special care. The connection line must
comply with the applicable regulations and must have the
required cross-section. The cross-section must match the information stated on the cable conduit.
• Through appropriate selection of the cables and the type of
installation, make sure that maximum permissible wire temperatures will not be exceeded.
• While installing the cable, make sure that mechanical damage
of the wire isolation caused by sharp-edged or mobile metal
parts is ruled out. If necessary, the cable has to be installed
protected, e.g. in conduit pipes.
• Install the connecting cables in the connection room such that
– dirt and humidity in the connection room will be ruled out.
– the cable is not damaged during stripping.
– the wire isolation reaches up to the terminals during strip-
ping.
– you will not fall below the minimum bending radius for the
respective wire cross-section.
– the cable are installed strain-relieved and abrasion-free.
Repair and spare part exchange Spare parts for measuring devices used in the ex-area may only be
installed by the BERTHOLD TECHNOLOGIES service or by service
engineers authorized by BERTHOLD TECHNOLOGIES. If this is not
possible, the complete detector has to be returned to the manufacturer for repair.
Repairs on electronic circuits or on the printed circuit boards of the
Uni-Probe may only be carried out in the manufacturer's plant.
38477BA2B
1 – 84 25.5.09
Volume 1 10 Safety instructions ATEX/FM/CSA
Replacement of the Uni-Probe or
relocation of the measuring point
Please keep in mind that devices that are used in non hazardous
areas cannot be used anymore in hazardous areas. Intrinsically
safe devices whose intrinsically safe signals are connected to nonintrinsically safe electric circuits may not be connected to intrinsically safe electric circuits: Since devices that are used in non-hazardous areas are not subject to the supervision and attendance of
explosion protection experts, it is not ensured that e.g. for repair or
assembly the same care is used as measuring site required for
devices in hazardous areas. Explosion protection safety, therefore,
cannot be guaranteed any more. The same holds true for the intrinsic safety of devices.
10.1 Overview Ex-Versions
Please refer also to the LB number code in Volume 2, chapter
"1.8 LB 490 Super-Sens Nomenclature", page 2–135.
i
1
LB 490Type
Communication
Uni-Probe ID no. 38477-XXX
HART
Super-Sens ID no. 53214-005 … 007
®
Ex protection
Approval according to ATEX
Device group,
category
Inspection
document
Zone
Type of
protection
Signal output
intrinsically safe
Ex temp. range
IIC
EEx d IIC T6
IP66 T80°C
no yes yes no yes no
-40 … +60°C -20 … +50°C -20 … +60°C -40 … +60°C -20 … +60°C -40 … +60°C
Tower-Sens ID no. 50250-005 … 007
Uni-Probe ID no. 47678-XXX
Super-Sens ID no. 53214-009 … 016
Tower-Sens ID no. 50250-009 … 016
®
HART
EEx d [ia]
IIC/IIB T6
IP66 T80°C
Uni-Probe ID no. 50040-XXX
Super-Sens ID no. 53214-057 … 064
Tower-Sens ID no. 50250-057 … 064
Profibus PA Profibus PA
pressure-resistant casing
DMT 02 ATEX E 132
can be used in zones 1, 2, 21, 22
EEx d [ia]
IIC/IIB T6
IP66 T80°C
Uni-Probe ID no. 50035-XXX
Super-Sens ID no. 53214-049 … 056
II 2GD
EEx d IIC T6
IP66 T80°C
Tower-Sens ID no. 50250-049 … 056
FOUNDATION
Uni-Probe ID no. 50041-XXX
Super-Sens ID no. 53214-033 … 040
Tower-Sens ID no. 50250-033 … 040
Fieldbus
EEx d [ia]
IIC/IIB T6
IP66 T80°C
™
FOUNDATION™
EEx d IIC T6
Uni-Probe ID no. 50036-XXX
Super-Sens ID no. 53214-025 … 032
Tower-Sens ID no. 50250-025 … 032
Fieldbus
IP66 T80°C
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 85
10 Safety instructions ATEX/FM/CSA Volume 1
LB 490Type
Ex temp. range
IIB
Operat. temp.
range
Uni-Probe ID no. 38477-XXX
Super-Sens ID no. 53214-005 … 007
Tower-Sens ID no. 50250-005 … 007
-40 … +80°C -20 … +50°C -20 … +60°C -40 … +80°C -20 … +60°C -40 … +80°C
-40 … +50°C -20 … +50°C -20 … +50°C -40 … +50°C -20 … +50°C -40 … +50°C
Approval according to FM / CSA
FM / CSA
Approval
Signal output
Ex temp. range
Operat. temp.
range
Cl.I Div1&2
Gr.A,B,C,D
Cl.II Div1&2
Gr.E,F,G
passive, can
be switched
to active
-50 … +50°C – – -50 … +50°C – -50 … +50°C
-40 … +50°C – – -40 … +50°C – -40 … +50°C
Special device
Second current
output
no no no no no no
Uni-Probe ID no. 47678-XXX
Super-Sens ID no. 53214-009 … 016
Tower-Sens ID no. 50250-009 … 016
––
passive passive passive passive passive
Uni-Probe ID no. 50040-XXX
Super-Sens ID no. 53214-057 … 064
Tower-Sens ID no. 50250-057 … 064
Uni-Probe ID no. 50035-XXX
Super-Sens ID no. 53214-049 … 056
Tower-Sens ID no. 50250-049 … 056
Cl.I Div1&2
Gr.A,B,C,D
Cl.II Div1&2
Gr.E,F,G
Uni-Probe ID no. 50041-XXX
Super-Sens ID no. 53214-033 … 040
Tower-Sens ID no. 50250-033 … 040
–
Uni-Probe ID no. 50036-XXX
Super-Sens ID no. 53214-025 … 032
Cl.I Div1&2
Gr.A,B,C,D
Cl.II Div1&2
Gr.E,F,G
Tower-Sens ID no. 50250-025 … 032
1 – 86 25.5.09
38477BA2B
Volume 1 10 Safety instructions ATEX/FM/CSA
10.2 Type of Protection ATEX
The Uni-Probe is licensed for operation in areas in danger of explosion, zones 1 and 2. See also ATEX certificate in Volume 1, chapter
11.1 on page 1–89.
The Uni-Probe housing corresponds to the type of protection „d“
pressure-resistant casing. The connection room is inside the pressure-resistant casing.
The designation with the ID of the types of protection is supplemented by the respective ID [ia] on the type label.
Screwed cable glands and adapters The requirements according to EN 60079-14 and EN 60079-1 apply
to installations of the pressure-resistant entry points (screwed
cable glands, adapters).
Use only ATEX-approved screwed cable glands for the respective
type of protection (see Volume 2, section "5 Screw Fittings and
Accessories"). The pressure-resistant screwed cable glands must
be suitable for volumes of >2 liters. Depending on the type of protection, this screw fitting has to be approved for gas or dust ex. The
approved type of protection is printed on the screw fitting. The
screwed cable glands have to be installed professionally and must
be suitable for the working temperature range, the cable type (not
armoured, armoured, …) and the cable cross section.
Use only cable cross-sections which are included in the specification of the screwed cable gland used.
1
Please keep in mind that only one adapter may be used per cable
entry. It is not permitted to screw together several adapters.
The connected cables must not be exposed to any tensile stress,
but have to be installed strain-relieved. We suggest that you make
a cable loop before inserting the cable into the housing.
If there is any danger that the cable may be misused as a stepladder, then the cables have to be installed properly protected, for
example in conduit pipes. Make sure that the cables that are connected to the Uni-Probe will be installed without chafing, strainrelieved and without bending.
For screwed cable glands with metric male screw thread you need
ATEX-approved adapters “NPT / metric”.
BERTHOLD TECHNOLOGIES is offering the following adapters:
• ¾" NPT male thread to M16 female thread
• ¾" NPT male thread to M20 female thread
Non-armoured cables
Pass the connection cable with the complete outer insulation
through the cable bushing into the connection box. Pull the hexagon nuts of the cable bushings tight to ensure the connection box is
leak tight and the connection points will be strain relieved. The
tightening torques for the screwed cable glands supplied by
BERTHOLD TECHNOLOGIES are listed in the technical documents in
chapter 5, page 2–247.
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 87
10 Safety instructions ATEX/FM/CSA Volume 1
Armoured cables
Special screwed cable glands are needed for armoured cables. How
to install these cables is described in the installation instructions for
the cable conduits used.
10.2.1 Characteristic Features of Versions with Intrin-
sically Safe Current Output
• The Uni-Probe is provided with a 20 m long cable tail. The cable
has to be terminated in accordance with the valid setup regulations.
• The connecting cable has to be installed firmly.
• If intrinsically safe signal lines are passed through areas with
potentially explosive dust atmosphere or through zone 0, then
they must be protected against electrostatic charge.
10.3 Type of Protection FM/CSA
The Uni-Probe has been approved for Class 1+2 and Division 1+2.
See also certificates in Volume 1, chapter 11.2 and 11.3, on
page 1–108.
A conduit seal has to be installed directly behind the respective
cable duct for every cable duct with connected conduit.
10.4 Type of Protection CSA
The Uni-Probe may only be used in the following range limits:
• Pollution Degree: 2
• Installation Category: III
• Altitude: up to 2000 m
• Humidity: 90 % or less
• Temperature: 50°C maximum
• Electrical supply, rated: 95…250V
18…32V
, 15VA max.
DC
or 24VAC, 47…63Hz or
AC
1 – 88 25.5.09
38477BA2B
Volume 1 11 Certificates
11 Certificates
11.1 ATEX Certificate
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 89
11 Certificates Volume 1
1 – 90 25.5.09
38477BA2B
Volume 1 11 Certificates
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 91
11 Certificates Volume 1
1 – 92 25.5.09
38477BA2B
Volume 1 11 Certificates
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 93
11 Certificates Volume 1
1 – 94 25.5.09
38477BA2B
Volume 1 11 Certificates
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 95
11 Certificates Volume 1
1 – 96 25.5.09
38477BA2B
Volume 1 11 Certificates
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 97
11 Certificates Volume 1
1 – 98 25.5.09
38477BA2B
Volume 1 11 Certificates
1
Uni-Probe LB 490
BERTHOLD TECHNOLOGIES GmbH & Co. KG
1 – 99
11 Certificates Volume 1
1 – 100 25.5.09
38477BA2B
Loading...