KROHNE IFC-090F User Manual

Variable area flowmeters

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©KROHNE12 / 2002 7.30923.31.00

Addition to the installation and operating instructions

IFC 090 F-EEx IFC 090 F / i-EEx

Signal converters for electromagnetic flowmeters

WARNING !

Be sure to follow these instructions !

IMPORTANT !

These additional instructions are an extension to the Installation and Operating Instructions and only apply to the EEx version of the IFC 090 F - EEx or IFC 090 F / i -EEx signal converter. All technical information described in the “Installation and Operating Instructions” are applicable, when not specifically excluded, completed or replaced by the instructions in these additional instructions.

No changes regarding safety may be made to the devices. Unauthorized changes might affect the explosion safety of the devices.

• The prescriptions and regulations as well as the electrical data described in the EC-type examination certificate must be obeyed.

• Beside the instructions for electrical installations in non-hazardous locations according to the applicable national standard (e.g. IEC 364), especially the regulations in EN 60079-14 "Electrical installations in hazardous locations" or equivalent national standard must be followed.

• Installation, establishment, utilization and maintenance are only allowed to be executed by personnel with an education in explosion safety!

Contents

1 System components 3

1.1 General information 3

1.2 IFS x000 F-EEx primary head 3

1.3 IFC 090 / … -EEx signal converter 4

1.3.1 Electronic compartment 4

1.3.2 Terminal compartment 4

1.4 Data plates 5

1.5 Electronic unit 5

2 Electrical connection 7

2.1 Equipotential bonding system 7

2.2 Intermediate junction box ZD-EEx 7

2.3 Connecting cables 7

2.4 Connecting diagram 9

2.5 regular IFC 090 - EEx electronic unit 11

2.6 MODIS version IFC 090 I - EEx electronic unit 12

2.7 Connecting diagrams MODIS 13

3 Operation of the signal converter 20 4 Maintenance 20

5 Service 21

5.1 General information for replacements 21

5.2 Replacement of electronic unit 22

5.3 Repalcement of power fuses 24

5.4 Changing power supply voltage 27

6 Ordering information 28 7 Declaration of conformity 29 8 EC-type examination certificates 30

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 2

1 System components

1.1 General information

The ALTOFLUX IFC 090 F/…-EEx signal converter complies with the European Directive 94/9/EC (ATEX 100a) and has been approved for hazardous classified locations of Zone 1 and 2 by the KEMA conform the European Standards of the EN 500xx series. The IFC 090 F/…-EEx has the following EC-type examination Certificate number:

KEMA 01 ATEX 2234

The signal converter is available in two types, namely: IFC 090 F-EEx regular explosion protected version; IFC 090 F/i-EEx, MODIS version. This type has intrinsically safe signal output circuits, which are pro-vided by two installed MODIS modules (see Sect. 1.5 for details). The regular IFC 090 F-EEx signal converter is designed for ambient temperatures in the range of –40°C up to +60°C, the so-called MODIS version type IFC 090 F/i-EEx is rated for ambient temperatures from -20°C up to +60°C. Both types of signal converters are in remote design, which means that they are installed on a certain distance of the measuring unit, the IFS x000 F-EEx series of primary heads. The primary heads are approved according to the European Directive 94/9/EC (ATEX 100a) as well. Due to the installation on a distance from the primary head, the signal converter is independent of the process liquid temperature and therefore rated for temperature class T6 and a T85ºC for dusts.

The IFC 090 F / … EEx signal converter is marked with the following code below: Regular version II 2GD EEx de [ib] IIC T6 MODIS version II 2GD EEx de [ia] [ib] IIC T6

Also see the EC-type Examination Certificate in Sect. 8 of these instructions.

1.2 IFS x000 F-EEx primary head

The IFS x000 F-EEx series primary head is the measuring unit of the IFC 090 F/…-EEx signal converter and contains two field coils and two electrodes in type of protection intrinsic safety category "ib" according to EN 50020. The type of protection of the field coils depends on the meter type and size, see the additional installation and operating instructions of the primary head concerned.

The electrode circuits are wired by separate shielded cables and marked by the sheath color (white and purple). The intrinsical safe "ib" electrode circuits inside the IFS x000 F-EEx primary head have the following maximum values (entity parameters):

Maximum input voltage U Maximum output current I Maximum internal capacitance C Maximum internal inductance L

The two field coils inside the primary head are connected in series and provided with the type of protection increased safety “e” conform to EN 50019 and additionally flameproof enclosure “d” in accordance with EN 50018 or encapsulation “m” according to EN 50028. The coils have a maximum resistance below 90 Ω per coil with a wire diameter of at least 0.25 mm and insulation class H (T

≥ 180°C) according to IEC 85. The field coils are supplied with a square-wave signal

max

with a peak voltage of 60 V maximum and a nominal current of 125 mA. The coil circuit is protected by two series fuses in the IFC 090 …-EEx electronics unit. The fuses are rated for a maximum voltage of 250 Vac @ 50-60 Hz, have a breaking capacity of at least 35 A and switching characteristics fast (F) to time-lag (T).

= 20 V

max

= 170 mA

max

= 0

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 3

1.3 IFC 090/…-EEx signal converter

The IFC 090/…-EEx signal converter consists of the pre-certified cylindrical housing of die-casted aluminum (type AX/P-EEx with KEMA No. Ex-99.E.8128 U). It has two separate compartments, divided from each other by an integrated wall with casted flameproof terminal feed-through. The neck at the bottom of the housing that is connected to the wall-mounting bracket with junction box, contains flameproof cable feed-through type LC-2/EEx, which is approved by KEMA under No. Ex-01.E.2036 U. The wall-mounting bracket and junction box are also made of die-casted aluminium. The signal converter housing is on both ends closed by a cylindrical cover with M115x2-6H6g screw-thread and O-ring sealing. The signal converter has an ingress protection degree of IP 65 / IP 67 conform to EN 60529.

1.3.1 Electronics compartment

The electronics compartment accommodates the pre-certified IFC 090…-EEx electronics unit with approval number PTB 98 ATEX 2012 U. The compartment is designed with type of protection flameproof enclosure "d" according to EN 50018 and closed by a threaded flameproof display cover. The IFC 090…-EEx unit is inserted into the electronics compartment via two sliding rubbers that position and fixate it at the front in the housing. Two M4 screws mount the unit and a third M4 screw fixates the copper earth strip at the back-end of the safety barrier printed circuit board. The three screws are screwed to the integrated aluminium wall in-between terminal and electronics compartment. The safety barrier provides the electrodes inside the primary head with type of protection intrinsic safety “ib” according to EN 50020.

See tables on the next pages for the electrical data of the available power supplies (e.g. mains voltages, etc.). The safety barrier has the following maximum values (entity parameters):

= 9 V = 38 mA = 4.9 µF = 23 mH

Maximum output voltage U Maximum output current I Maximum allowed external capacitance C Maximum allowed external inductance L

1.3.2 Terminal compartment

The terminal compartment has seven M4 clamp terminals for connection of the power supply and signal output circuits (binary and current outputs). Section 2 shows the terminal arrangement for the regular and MODIS version of the IFC 090/…-EEx signal converter. The terminals are separated from each other by insulation plates (nine in total, one at each end). The terminal arrangement of the MODIS version (i.e. IFC 090i-EEx) is shown in Sect. 2.6. Two of the terminals are used for connection of the non-intrinsically safe power supply and four terminals (marked with "*") for the intrinsically safe, category "ia" signal outputs (i.e. current, pulse resp. status output) of the MODIS modules. The non-intrinsically and intrinsically safe terminals are separated from each other by a metal dividing plate, which is screwed to the remaining (not connected) M4 terminal. The two non-intrinsically safe power supply terminals are covered by an insulating plate.

The terminal compartment (with standard type of protection increased safety "e") is standard equipped with two ATEX or E-generation approved "EEx e" cable glands. The terminal compartment can also be provided as a flameproof enclosure "d", in which case ATEX or Egeneration approved "EEx d" cable glands of size Pg13.5, Pg16 or M20x1.5 are factory installed or must be installed by the customer. For flameproof conduit systems, the terminal compartment must have type of protection flameproof enclosure "d" according to EN 50018. The conduits must be sealed by "EEx d" approved (within the ATEX 100a directive) sealing devices (i.e. stopping box) directly at the conduit entrances of the as flameproof enclosure performed terminal compartment. All used cable glands, blind plugs and sealing devices for conduit systems must have an ingress protection degree of IP65 or better.

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 4

1.4 Data plates

IFC 090 F-EEx IFC 090 F / i-EEx

1.5 Electronics unit

The IFC 090 F/…-EEx signal converter can be equipped with the regular IFC 090-EEx electronics unit or with the IFC 090i-EEx electronics unit with intrinsically safe signal outputs (i.e. MODIS version). The regular signal converter design has type designation IFC 090 F-EEx and the MODIS version is designated as IFC 090 F/i-EEx.

Regular IFC 090-EEx electronics unit

The IFC 090-EEx can be equipped with one of the following power supplies, which depends on the mains supply voltage in area of application.

Electrical data of power supply Power supply Terminal Description Supply voltage Tolerance Power AC-versions

AC/DC-version

L N PE 1L 0L FE

Live Neutral Protective Earth Live Neutral Functional Earth

115/230 Vac 100/200 Vac

24V ac/dc

-15%/+10% 10 VA

AC: -15%/+10% DC: -25%/+30%

AC: 10 VA DC: 8 W

The above listed power supplies are protected by a mains fuse rated according the next table.

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 5

Mains fuses Power supply Mains fuse Type Nominal voltage Rating Specifications AC-versions

DC-version

100/115 Vac 200 mA Switching char.: fast (F) to time-lag (T) 200/230 Vac 125 mA 24 Vac Switching char.: fast (F) to time-lag (T)

1.25 A

24 Vdc

Breaking capacity: ≥ 1500 A @ 250 V

Breaking capacity: ≥ 300 A @ 65 V

The IFC 090-EEx electronics unit is equipped with the following in-/output circuits. Terminals B1, B⊥ and B2 can be configured as status or pulse outputs or as control inputs via the software. See the table below for the electrical data of these in-/output circuits.

Electrical data of in-/output circuits Terminals Description

B1, B⊥, B2

Pulse, status, control in-/outputs 32 V 150 mA

Nominal voltage Maximum current

I+, I Current output 15 V 22 mA

The difference between 115/230 Vac version and the 100/200 Vac version is the number of the primary windings of the mains transformer.

The terminals indicated as B1, B⊥ and B2 can be configured as pulse in-/outputs by jumpers. The IFC 090-EEx electronics unit is provided with an extension module that is used for data communication (e.g. SMART, HART or RS485). In that case, the current output signal (I+, I) is superposed with a sinusoidal voltage signal of 0.5 V. The extension module does not significantly influence the nominal voltage Un, the nominal current In or the power dissipation.

Overheating protection

The mains transformer is protected against overheating by a temperature breaker in series with the primary winding. The temperature breaker is casted within the compound of the transformer and has an opening temperature of 125 °C (± 5 K).

IFC 090i-EEx unit with MODIS modules

The IFC 090i-EEx electronics unit is equipped with two MODIS-modules. It is equipped with one of the following power supplies.

Electrical data of IFC 090i-EEx electronics unit Power supply Terminal Function Electrical data AC-version

L N PE

Live Neutral Protective ground

= 100…230 Vac –15%/+10%

= approx. 15 VA

Primary fuse: Rated current: 1.6 A Design conform IEC 127-2 Breaking capacity: 1500 A

AC/DC-version

1L  0L  FE

Live Neutral Functional ground

= 24 V ac / dc

AC: -15%/+10% or 20.4…26.4 V ac DC: -25% / +30% or 18…32 V dc In = approx. 490…630 mA for AC approx. 310…550 mA for DC Pn = approx. 10 W

Primary fuse: Rated current: 1.25 A Design conform IEC 127-2 Breaking capacity: 1500 A

NOTE:

The mains fuses for both electronics units are listed in Sect. 6 of this manual.

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 6

2 Electrical connection

2.1 Equipotential bonding system

The IFC 090 F/…-EEx signal converter must always be incorporated into the equipotential bonding system of the hazardous area. This connection can be achieved through the PE/FE conductor connected to the PE terminal in the terminal compartment (see figure of terminal arrangement) or through a separate PE conductor, cross sectional area at least 4 mm to the external PE clamp, placed below the converter housing.

2.2 Intermediate junction box ZD-EEx

For safety reasons, standard cables with a rubber or thermoplastic insulation sheath may only be used up to a continuous operating temperature of 70°C at the cable entry and 80°C at the branching point of the connecting cables. In case that the temperature at the above mentioned parts exceed the maximum values, heat-resistant cables must be installed at the IFS x000 F-EEx primary head in remote design. Also see the EC-type examination certificate of the primary head.

The table below summarizes the conditions for use of heat-resistant cables for the IFS x000 FEEx primary head.

Use of heat-resistant cables

Primary head Meter size Ambient temperature Process liquid temperature

IFS 4000 F-EEx

IFS 5000 F-EEx DN2.5 - 100

IFS 6000 F-EEx DN2.5 - 80

DN25 - 150

≤ 40°C ≤ 50°C ≤ 60°C

≥ DN200 ≤ 40°C

≤ 50°C ≤ 60°C ≤ 40°C ≤ 50°C ≤ 60°C ≤ 40°C ≤ 50°C ≤ 60°C

not required

≥ 155°C ≥ 105°C

not required

≥ 145°C ≥ 110°C

≥ 165°C ≥ 130°C ≥ 100°C

not required

≥ 160°C ≥ 115°C

In case that heat-resistant cables are required, install the intermediate junction box ZD-EEx at a distance of approximately 5 m from the primary head. Connect heat-resistant cables (see cables D and E in the next section) between the primary head’s junction box and the intermediate junction box ZD-EEx. The standard cables (types B and C) can be used between the IFC 090 F/…-EEx signal converter and intermediate junction box. See connection diagram 2.

The silicone rubber insulated connection cable for the magnetic field coils must be protected against mechanical damages between the primary head and intermediate junction box by a conduit system with edge protections. Intermediate box ZD-EEx has terminals with type of protection increased safety “e” conform to EN 50019. The intermediate box is incorporated in the equipotential bonding system of the installation via its external clamp terminal.

2.3 Connecting cables NOTE:

The following described cables are shown in the next connection diagrams.

Cable A

Signal cable for current output and binary outputs (pulse and status output): The cable parameters must be in accordance with the regulations in the EN 60079-14 "Electrical installations in hazardous locations" or an equivalent national standard. For the MODIS version with IFC 090iEEx electronics unit (right detail in connection diagram 1) the signal cable for the intrinsically safe signal in-/outputs must also conform the requirements as specified in the relevant standard national code of practice for the installation of electrical apparatus with type of protection Intrinsic Safety "i".

, connected

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 7

Cable B

Power supply cable: The cable parameters must be in accordance with the regulations of the EN 60079-14 "Electrical installations in hazardous locations" or an equivalent national standard.

The PE terminal must be connected to the protective ground conductor of the mains supply.

Rated voltage

≥ 500 V Cross-sectional area of core 1.5 to 2.5 mm2 Examples H07...-., H05...-.

Cable C

Type DS blue

Intrinsical safe, with double shielding

2 3 4 5 6 7 8

3 3

1 Stranded drain wire, 1st shield, 1.5 mm 2 Insulation 3 Stranded wire, 0.5 mm2 4 Special foil, 1st shield 5 Insulation 6 Mu-metal foil, 2nd shield 7 Stranded drain wire, 2nd shield, 0.5 mm 8 Outer sheath (flame-retardant)

Cable constants (typical values at Ta = 20°C)

C’3/3 60 pF/m (1 kHz) C’3/4 110 pF/m (1 kHz) C’4/6 290 pF/m (1 kHz)

L’3/3 0.85 µH/m (1 kHz) L’3/4 0.60 µH/m (1 kHz)

R’3 37 mΩ/m R’4+1 12 mΩ/m

Cable D Intrinsical safe, with single shielding. Heat-resistant conform to VDE 0165/02.91.

Properties

Continuous service temperature Test voltage Capacitance:

Inductance: Cable length Single-wire-Ø: Cross-sectional area of core 0.5 to 1.5 mm

≥ 120°C ≥ 500 V ≤ 200 pF/m ≤ 200 pF/m ≤ 1µH/m ≤ 5 m ≥ 0.1 mm

Sheath light-blue or in other way color-coded as intrinsical safe,

flame-retardant.

Example Silicone rubber insulated, shielded control cable.

Cable E Non-intrinsical safe, 2-core without shielding. Heat-resistant conform to VDE 0165/02.91.

Properties

Continuous service temperature Test voltage Cross-sectional area of core 1.5 mm

≥ 120°C ≥ 500 V

Bonding conductor

Cross-sectional area Max. 4 mm

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 8

2.4 Connection diagrams

Connection diagram 1: Standard cables

SIGNAL IN-/OUTPUTS L N PE 100-230 Vac L

 L

FE 24 Vac/dc

INTRINSICALLY SAFE SIGNAL IN-/OUTPUTS L N PE 100-230 Vac (i.e. MODIS) L

FE 24 Vac/dc

 L

IFC 090-EEx

Signal Converter

B1 B⊥ B2 I+ I L N

BINARY CURRENT MAINS

OUTPUTS OUTPUT SUPPLY

TERMINAL COMPARTMENT Standard "EEx e" (Optional "EEx d")

ELECTRONICS CO MPAR TMENT (a lways "EEx d" )

electrode circuits field coil circuits

(OPTIONAL)

4 mm

≥

Coil

B A

PE FE

Flameproof (EEx d) cable

feed-through

Field coil wires

x x x x

IFC 090i-EEx

Signal Converter

Flameproof (EEx d)

terminal feed-through

Hazardous locations

of Zone 1 and 2

B A

1L 0L

OPTION: MODIS

PE FE

Unused terminal

Separation plate

Flow tube

EQUIPOTENTI AL BONDING CONDUCTOR

Electrode cables

Coil

IFS x000…-EEx

Primary Head

Intrinsically safe electrode circuits

Increased safe field coil circuit

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 9

Connection diagram 2: Use of heat-resistant cables

Signal Converter

IFC 090 F/…-EEx

ELECTRONICS COMPARTMENT (always "EEx d")

Intrinsical safe ("ib") Increased safe ("e")

electrode circuits field coil circuits

(No. "3", "2", "1") (No. "7", "8")

2x fuse 160mA

Flameproof (EEx d) cable

feed-through LC-2/EEx

3 2 1 7 8

Hazardous locations

of Zone 1 and 2

3 2 1 7 8

ZD-EEx intermediate

(OPTIONAL)

4 mm

≥

junction box

3 2 1 7 8

Coil

EQUIPOTENTIAL BONDING CONDUCTOR

Flow tube

Electrode cables - white/pink

Coil

(PTFE insulated shielded copper)

IFS x000 F-EEx

Primary Head type

E = electrode

Field c oil wires - green/bl ue

(PTFE insulated copper)

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 10

2.5 Regular IFC 090-EEx electronics unit

The field cables that enter the terminal compartment of the IFC 090-EEx signal converter unit (i.e. power supply, current and binary outputs) are non-intrinsically safe. To connect external devices to the signal output terminals, the wiring requirements for the type of protection of the compartment (standard: increased safety "e", optional: flameproof "d") must be conform to the international or national standard involved (e.g. EN 60079-14).

Terminal arrangement in terminal compartment

pulse and status outputs or control inputs

binary

outputs

current

output

100 - 240 V AC / 48 - 63 Hz

24 V AC / DC

PE Protective earth FE Functional earth

Active current output

≤ 500 Ω

Passive pulse/status output

I ≤ 150 mA

electronic or electro mechanical totalizer

I ≤ 150 mA

≤ 32 V DC

ext

≤ 24 V AC

e.g. signal indicator

Note:

The binary outputs (terminals B1, B⊥ and B2) can only be configured as passive outputs, the current output (terminals I+ and I) can only be configured as active output.

For power supply versions with the nominal voltage in the range of 100 to 230 Vac the PE conductor must always be connected to the M5 clamp terminal marked with the safety earth symbol that is press-fitted in the dividing aluminium wall of the signal converter housing. For the 24 Vac/dc power supply, the PE conductor may be connected, but it not required for the safety of tthe flowmeter. The terminal arrangement is shown above.

ALTOFLUX IFC 090 F-EEx and ALTOFLUX IFC 090 F / i-EEx 11

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