Page 1
12/01
Addition to the
Electromagnetic
flowmeter in 2-wire
technology
ALTOFLUX 2W
IFM 4042 K-EEx
Compact flowmeter
installation and
operating
instructions
7.xxxxx.xx.xx
Page 2
WARNING !
No changes may be made to the devices. Unauthorized changes
might affect the explosion safety of the devices.
These additional instructions are an extension to the Installation and Operating
Instructions and only applies for the EEx version of the IFM 4042 K electromagnetic
compact flowmeter. All technical information described in the Installation and
Operating Instructions are applicable, when not specifically excluded or replaced by
the instructions in these additional instructions.
CONTENTS
1. SYSTEM COMPONENTS...............................................................................................................2
1.1 General information...................................................................................................................2
1.2 Primary head...............................................................................................................................2
1.3 IFC 040-EEx signal converter ..................................................................................................3
1.3.1 Electronics compartment....................................................................................................3
1.3.2 Terminal compartment........................................................................................................3
1.3.3 Cable or conduit entries......................................................................................................4
2. ELECTRICAL CONNECTION........................................................................................................4
2.1 Detailed description of the output circuits..............................................................................5
2.2 Safety-technical data.................................................................................................................6
2.3 Connection examples................................................................................................................6
3. OPERATION OF THE SIGNAL CONVERTER...........................................................................8
4. REPLACEMENT OF ELECTRONICS UNIT................................................................................9
5. EQUIPOTENTIAL BONDING SYSTEM.....................................................................................10
6. TECHNICAL DATA .........................................................................................................................10
7. MAINTENANCE..............................................................................................................................10
8. CONNECTION DIAGRAM.............................................................................................................11
9. ORDERING INFORMATION.........................................................................................................12
10. DATA PLATES.............................................................................................................................12
11. EC-TYPE EXAMINATION CERTIFICATE...............................................................................15
Be sure to follow these instructions !
IMPORTANT !
• 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 (equivalent of IEC 364, e.g. VDE 0100), especially
the regulations in EN 60079-14 "Electrical installations in hazardous locations" or
equivalent national standard (e.g. DIN VDE 0165) must be followed.
• Installation, establishment, utilization and maintenance are only allowed to be
executed by personnel with an education in explosion safety !
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1. SYSTEM COMPONENTS
1.1 General information
The Altoflux 2W IFM 4042 K-EEx electromagnetic compact flowmeter in 2-wire technology is
in accordance with European Directive 94/9 EG (ATEX 100a) and approved for hazardous
classified locations of Zone 1 and 2 by the KEMA conform to the European Standards of the
EN 500xx series. The IFM 4042 K-EEx has the following approval number.
KEMA 01 ATEX 2200 X
The IFM 4042 K-EEx compact flowmeter is designed for ambient temperatures in the range
of -40°C up to +60°C.
The allowed process liquid temperature is a.o. limited by the combustible atmosphere that
(possibly) surrounds the apparatus, which again is determined by the temperature class of
the atmosphere (first column of the tables). See table 1 and 2 below for details.
For dusts the second column of the two below listed tables is applicable.
Max. surface
class
(for gases)
T6 T85°C 75°C 70°C 70°C
T5 T100°C 95°C 90°C 75°C
T4 T135°C 130°C 115°C 75°C
T3 T180°C 150°C 115°C 75°C
Table 1: Temperature classification DN10…20 and DN200 and larger.
class
(for gases)
T6 T85°C 70°C 70°C 70°C
T5 T100°C 85°C 85°C 85°C
T4 T135°C 120°C 120°C 115°C
T3 T180°C 180°C 180°C 115°C
Use heat-resistant cables above - - 50°C
Table 2: Temperature classification DN25…150 with PFA liner.
The IFM 4042 K-EEx flowmeter consists of the IFC 040-EEx signal converter unit, which is
screwed on top of the primary head (i.e. the measuring unit). The compact flowmeter is
marked with one of the codes below, depending on the meter size:
• DN10-20: II 2GD EEx dme [ib] IIC T6…T3.
• DN25-150: II 2GD EEx de [ib] IIC T6…T3 ("EEx e" or "EEx d" terminal compartment).
• DN200 and up: II 2GD EEx de [ib] IIC T6…T3.
temperature
(for dusts)
Max. surface
temperature
(for dusts)
Maximum process liquid temperatureTemperature
Ta ≤ 40°C Ta ≤ 50°C Ta ≤ 60°C
Maximum process liquid temperatureTemperature
Ta ≤ 40°C Ta ≤ 50°C Ta ≤ 60°C
For details see the EC-type examination certificate in Section 10 of these instructions.
1.2 Primary head
The primary head is the measuring unit of the IFM 4042 K-EEx compact flowmeter and
contains two field coils (see table 3 on the next page for the type of protection) and two
electrodes in type of protection intrinsic safety category "ib" according to EN 50020.
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Meter size Type of protection
Field coils: Increased safety "e" according to EN 50019
DN10 up to DN20
Electrodes: Intrinsic safety "ib" according to EN 50020
DN25 up to DN150
DN200 and larger
NOTE:
The intrinsically safe electrode circuits of the IFM 4042 K-EEx compact flowmeter are
only internal circuits and not accessible for the customer.
Housing: Flameproof enclosure "d" according to EN 50018
Electrodes: Intrinsic safety "ib" according to EN 50020
Field coils: Increased safety "e" according to EN 50019
Electrodes: Intrinsic safety "ib" according to EN 50020
Table 3: Types of protection of primary head.
Encapsulation "m" according to EN 50028
1.3 IFC 040-EEx signal converter
The IFC 040-EEx signal converter consists of a cylindrical housing of die-casted aluminum,
which 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 contains a
flameproof cable feed-through. The signal converter housing is on both ends closed by a
cylindrical threaded cover with O-ring sealing. The housing has an ingress protection degree
of at least IP65 conform to EN 60529.
1.3.1 Electronics compartment
The electronics compartment accommodates the pre-certified IFC 040-EEx electronics unit
with approval number PTB 00 ATEX 2213 U. The compartment is designed with type of
protection flameproof enclosure "d" according to EN 50018. It is closed by a flameproof
display cover with glass window.
1.3.2 Terminal compartment
The terminal compartment has seven terminals for connection of the current output (I, I⊥ ),
the additional power supply or "Power Booster" (1L=, 0L=) and binary pulse/status outputs
(B1, B⊥ , B2). Chapter 2 shows the terminal arrangement of the IFC 040-EEx. There are two
versions possible with a different explosion protection according to the European Standards,
which is dependent on the safety-technical maximum voltage Um of the mains power supply
system to which the flowmeter is connected.
Version A: Terminal compartment in type of protection "EEx de [ib]" with Um = 60 V.
The connections of the output circuits can be ordered by the customer in one of the following
types of explosion protection:
• EEx [ib] (intrinsic safety, category "ib") or
• EEx e (increased safety) or
• EEx d (flameproof enclosure).
Version B: Terminal compartment in type of protection "EEx de" with Um = 250 V.
The customer can order the connections of the output circuits in one of the following types of
explosion protection:
• EEx e (increased safety) or
• EEx d (flameproof enclosure).
The two versions (A and B) of the terminal compartment as well as their requirements are
described in more detail in section 2.1 of these additional instructions.
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1.3.3 Cable or conduit entries
⊥
⊥
Dependent on the explosion protection type that the terminal compartment is configured with,
(see description on the previous page), can the terminal compartment be equipped with
cable entries or conduit adapters. The used cable entries (glands and/or blind plugs) must
have a ATEX approval in accordance with the type of protection of the terminal compartment.
Type of protection Intrinsic Safety category "ib" is only applicable for mains power supply
systems with a maximum voltage of Um = 60 V. In this case "EEx ib" approved cable entries
must be used, which are marked by a blue color.
The cable entry holes can be provided with a screw-thread size of Pg13.5, Pg16 or M20x1.5.
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.
ATEX approved "EEx d" cable glands, screw-threaded adapters as well as blind plugs are no
integral part of the delivery package and must be purchased by the customer himself or can
be ordered through their (local) Krohne representative as special parts !
2. ELECTRICAL CONNECTION
To connect external devices to the signal output terminals, the wiring requirements for the
type of protection of the compartment must also be conform to the international or national
standard involved (e.g. EN 60079-14). The terminal arrangement is shown by figure 1 below.
I
I B1 B
B2 1L= 0L=
CURRENT BINARY
OUTPUT OUTPUTS
PE (Protective Earth) terminal
Figure 1: Terminal arrangement in terminal compartment.
The following outputs are available for connection to external circuits (see figure above):
• Current output (terminals I, I⊥ )
This circuit constitutes a passive 4-20 mA current loop and includes the HART protocol of
the communication device (the polarity is free to choice).
• Additional power supply (terminals 1L=, 0L=)
These terminals are connected to provide the 2x2 wire mode (choice of polarity is free).
• Binary outputs (terminals B1, B⊥ , B2)
Terminals B1 and B⊥ can be configured as pulse or status output through software.
Terminals B2 and B⊥ can be configured as pulse or status output to NAMUR.
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Galvanical separation of circuits:
• The internal electrode circuit with type of protection "EEx ib" is galvanically connected to
the aluminum signal converter housing (i.e. PE potential).
• The current output, the additional power supply and the internal field current circuit are
galvanically connected to each other.
2.1 Detailed description of the output circuits
The terminal compartment of the IFM 4042 K-EEx is, with respect to the explosion protection,
available in two versions. The version can be identified by the information that is listed on the
data plate, which is mounted on the signal converter housing.
Version A: Terminal compartment in "EEx de [ib]" with Um = 60 V.
The customer can decide in which type of explosion protection the output circuits - current
output, additional power supply and binary outputs (i.e. pulse and/or status outputs) - can be
driven; in type of protection "EEx ib", "EEx e" or "EEx d".
The safety-technical maximum voltage Um (maximum effective AC or DC voltage) of the
mains power supply system for the terminal compartment in type of protection EEx de [ib] is
restricted to 60 V. With this maximum voltage it is guaranteed that the protective components
on which the intrinsic safety of these circuits depends are not overloaded. This condition is
met if the mains power supply system satisfies the PELV requirements in accordance with
IEC 364 / IEC 536.
RESTRICTION !
• It is not allowed to mix two different types of protection (e.g. current output in
type of protection "EEx ib" and pulse/status outputs in "EEx e" or "EEx d").
Version B: Terminal compartment in "EEx de" with Um = 250 V.
This version is intended for applications were the mains power supply system provides a
maximum safety-technical voltage of Um = 250 V. The terminals can either be provided with
type of protection increased safety "EEx e" according to EN 50019 or flameproof enclosure
"EEx d" conform to EN 50018. Type of protection intrinsical safety "EEx ib" is not allowed for
this version.
IMPORTANT NOTES (applicable for both versions)
• The intrinsically safe "EEx ib" internal electrode circuit is supplied by the IFC 040-EEx
signal converter electronics unit inside the electronics compartment. This circuit is
separated from all other circuits up to a maximum voltage of Um = 250 V according to En
50020. The internal electrode circuit with type of protection intrinsic safety "ib" is
galvanically connected with the PE (housing potential).
• The IFM 4042 K-EEx compact flowmeter must be incorporated within the equipotential
bonding system of the installation in the hazardous area in accordance with the standard
EN 60079-14. Therefore the internal or external M5 clamp terminal (i.e. PE) must be used.
Disconnection of the equipotential bonding system is only allowed when the flowmeter is
not energized.
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• The current output (terminals I, I⊥ ) and the additional power supply (terminals 1L=, 0L=)
must be galvanically separated connected and driven from each other. To avoid voltage or
current summation, at least one of the two circuits must be isolated from earth potential. It
is not allowed to drive both circuits at the same time with grounded zener barriers. Both
current circuits, including all connection cables, must be galvanically separated at all times
according to the valid regulations.
• Also in case of non-intrinsically safe connections, it is absolutely necessary to maintain a
galvanic separation between the current output circuits and the additional power supply
connections. Without a galvanic separation, the IFC 040-EEx signal converter electronics
will be damaged, because these two circuits are internally connected to each other.
• A safe connection of the IFC 040-EEx signal converter electronics with the equipotential
bonding system is achieved through the zinc-plated mounting frame, which must be
securely screwed to the aluminum signal converter housing (PE potential) by means of
two long-shafted screws. To access the two long-shafted screws it is necessary to
unscrew the display unit and fold it aside. The screws must be tightly secured with a
torque of 1.3 Nm (a 2 Pt. Phillips screwdriver is recommended).
2.2 Safety-technical data
The safety-technical data are listed in the table below.
Important: The functional-technical must also be regarded, therefore see the standard
installation and operating instructions.
Terminal
designation
Circuit 1
I, I⊥
Circuit 2
1L=, 0L=
Circuit 3
B1, B⊥
B2, B⊥
Function
Current output, passive
(2-wire connection)
4-20 mA, HART = possible
Additional power supply
(4-wire connection)
additional to circuit 1 (optional)
Passive pulse/status output 1
Passive pulse/status output 2
Table 4: Safety-technical data of output circuits.
Ui = 30 V, Ii = 100 mA,
Pi = 1.0 W
Ci = 20 nF, Li = 0
Um = 60 V
Maximum values:
Ui = 30 V, Ii = 100 mA,
Pi = 1.0 W
Ci = 0, Li = 0
Um = 60 V
Electrical data (per circuit)
Type of protection
"EEx ib"
Maximum values:
Type of protection
"EEx e"
Un= 14…36 Vdc
In= 4…20 mA
Um= 250 V
Un= 14…36 Vdc
In= 22 mA
Um= 250 V
Maximum values:
U = 36 V
I = 100 mA
Um= 250 V
2.3 Connection examples
In this section two examples for connection of the IFM 4042 K-EEx compact flowmeter are
described for operation in the 2-wire mode (figure 2) as well as in the 2x2-wire mode (figure
3).
See figure 2 on the next page. It shows an IFM 4042 K-EEx with the terminal compartment in
version A (EEx de [ib] with Um = 60 V). The flowmeter is connected through a so-called
transmitter power supply ("EEx i" approved) in 2-wire mode. If data communication with the
flowmeter through the HART protocol is required, the transmitter power supply unit must be
HART compatible. Terminals I, I⊥ are not polarity sensitive.
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⊥
Hazardous Area
⊥
1L=
Safe Area
IFM 4042 K-EEx
(MGM 4042 K-EEx)
4-20 mA
Transmitter Power
Supply (EEx i)
4-20 mA
Process/
Display Unit
I
I
⊥
Vs
HTT
Figure 2: Connection of IFM 4042 K-EEx in 2-wire mode.
The entity parameters of the "EEx i" approved transmitter power supply, including the cable
capacitances and inductances, must fit the entity parameters of the IFM 4042 K-EEx
compact flowmeter, namely Uo ≤ 30 V, Io ≤ 100 mA. Suitable HART compatible transmitter
power supplies that can be used in combination of the Altoflux 2W IFM 4042 K-EEx are:
• Phoenix PI/Ex-ME-RPSS-I/I;
• CEAG 6/420.
Hazardous Area
IFM 4042 K-EEx
(MGM 4042 K-EEx)
I
I
⊥
0L=
Transmitter Power
Supply (EEx i)
Vs
Zener Barrier
Safe Area
Process/
Display Unit
4-20 mA4-20 mA
HTT
+
22 mA
_
External
Power Supply
Figure 3: Connection of IFM 4042 K-EEx.
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Figure 3 on the previous page shows an example of the connection of the IFM 4042 K-EEx in
2x2-wire mode. As in the previous example (figure 2), the terminal compartment of the IFM
4042 K-EEx is performed as version A, which means that it is providfed with type of
protection "EEx de [ib]".
The additional power supply (terminals 1L=, 0L=) of the IFM 4042 K-EEx is supplied by an
external power supply unit through a ATEX approved "EEx i" zener barrier with a linear
output load. The connection of the current output (terminals I, I⊥ ) and the additional power
supply (terminals 1L=, 0L=) is insensitive for polarity reversal.
IMPORTANT !
Only one of the two connected circuits of the IFM 4042 K-EEx, namely the "currrent
output" or the "additional power supply" may be earthed to maintain the required
galvanic separation between the two circuits !
The voltage of the external power supply unit must be carefully chosen to keep it within the
allowed limits. The upper limit is determined by the maximum working voltage of the zener
barrier, which in general lies a few volts below the maximum open voltage value Uo of the
used zener barrier. The lower limit is determined by the sum of the minimum working voltage
of the additional power supply of the IFM 4042 K-EEx flowmeter of 14 V and the voltage drop
over the zenerbarrier that is caused by the end-to-end resistance of the barrier. This voltage
drop can be significant. The above described determination of the external power supply
voltage is explained by the following example.
Example with typical parameters:
Zener barrier data: Uo = 28 V
Io = 93 mA
Maximum working voltage = 25.5 V.
End-to-end resistance = 340 Ω.
The voltage drop across the end-to-end resistance of the zener barrier is:
22 mA x 340 Ω = 7.5 V
This means that the external power supply must supply an output voltage to the zener barrier
that lies in the range somewhere between 21.5…25.5 V. The voltage over the terminals of
the additional power supply of the IFM 4042 K-EEx is in that case between the required
14.0…18.0 V.
3. OPERATION OF THE SIGNAL CONVERTER
The IFM 4042 K-EEx contains the IFC 040-EEx signal converter electronics unit, which is
equipped with a display unit that contains magnetic Hall sensors. These Hall sensors enable
the settings of the IFC 040-EEx electronics unit to be set respectively reset with the help of
the with the apparatus delivered bar magnet without opening the flameproof signal converter
housing in the hazardous area.
Consult the standard Installation and Operating Instructions for the program functions of the
software of the IFC 040-EEx electronics unit.
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4. REPLACEMENT OF ELECTRONICS UNIT
IMPORTANT !
The following instructions must be followed carefully, when the IFC 040-EEx signal
converter housing has to be opened respectively closed again !
Before opening:
♦ Make absolutely sure that there is no explosion hazard !
♦ If necessary provide a "Gas-free certificate" !
♦ Make sure that all connecting cables are safely isolated from the power supply !
♦ Allow the prescribed waiting time to elapse before opening the housing:
20 minutes for temperature class T6
11 minutes for temperature class T5
When the instructions above are strictly followed, the display cover (with the glass window)
can be removed. First unscrew the recessed head screw of the interlocking device by a
hollow-head screw wrench size 3, until the cover can rotate freely. Unscrew the cover with
the special plastic wrench (black) that is supplied with the apparatus.
Then continue as follows:
1. Remove the display cover of the electronics compartment.
2. Unscrew the two screws of the display unit and turn it carefully aside.
3. Carefully disconnect the 12 pin connector (for field coil and electrode circuits connection)
from the electronics unit.
4. Unscrew the two mounting screws of the electronics unit, which fixes the zinc-plated
frame to the back of the signal converter housing. A screwdriver with a long shaft like the
screwdriver type 2 Pt. Phillips is most suitable.
5. Carefully remove the electronics unit of the converter housing (see the Remark below).
6. Reassemble in reverse order with the replacement of the IFC 040-EEx electronics unit.
After opening:
♦ The zinc-plated frame of the IFC 040-EEx electronics unit must be securely screwed to
the housing (back-end of electronics compartment) by the two non-removable fastening
screws. Screw them with a tightening torque of 1.3 Nm. These two screw-connections
also establish the safety-technical connection of the electronics unit to the signal converter
housing and equipotential bonding system. Before the two screws can be accessed, the
display unit must be removed via their two screws.
♦ Before the cover is screwed back into the housing, the screw-thread must be clean and
well-greased with an acid and resin-free grease, e.g. silicone grease.
♦ Screw the display cover as tight as possible into the housing by hand, so that the gasket
of the cover must be clamped to provide the required Ingress Protection (IP) degree.
♦ Screw the recessed head screw of the interlocking device tight.
Refer to the standard Installation and Operating Instructions for detailed information about
resetting and reprogramming the new electronics unit after replacement.
REMARK !
Carefully keep the connecting cables of the field coil and electrode circuits to the side of
the housing, while removing respectively inserting the electronics unit into the signal
converter housing. This is to prevent damaging of the connecting cables !
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5. EQUIPOTENTIAL BONDING SYSTEM
The IFM 4042 K-EEx electromagnetic compact flowmeter must be incorporated into the
equipotential bonding system. Therefore the bonding conductor with a maximum crosssectional area of 4 mm2 (AWG 10) must be connected to the external U-clamp terminal M5
that is press-fitted in the connecting flange at the bottom of the neck of the flameproof signal
converter housing.
The U-clamp terminal is made of nickel-plated brass to prevent it for corrosion. When the
IFM 4042 K-EEx is incorporated in the equipotential bonding system, make sure that the core
of the bonding wire is properly mounted under the U-clamp and that the screw is tightly fixed.
6. TECHNICAL DATA
See also the standard installation and operating instructions of the Altoflux 2W magneticinductive compact flowmeter type IFM 4042 K-EEx.
Ambient temperature: -40°C…+60°C.
Process liquid temperature: See EC-type Examination Certificate of the IFM 4042 K-EEx
with No. KEMA 01 ATEX 2200 X or the two tables below.
Max. surface
class
(for gases)
T6 T85°C 75°C 70°C 70°C
T5 T100°C 95°C 90°C 75°C
T4 T135°C 130°C 115°C 75°C
T3 T180°C 150°C 115°C 75°C
Table 5: Temperature classification DN10…20 and DN200 and larger.
class
(for gases)
T6 T85°C 70°C 70°C 70°C
T5 T100°C 85°C 85°C 85°C
T4 T135°C 120°C 120°C 115°C
T3 T180°C 180°C 180°C 115°C
Use heat-resistant cables above - - 50°C
NOTES:
• Ta represents the maximum ambient temperature.
• The maximum process liquid temperatures listed in the above tables apply for measuring
tubes that have a PFA liner and are absolute safety-technical limits. Due to functiontechnical reasons (e.g. different lining material) lower process liquid temperatures can be
in effect.
temperature
(for dusts)
Max. surface
temperature
(for dusts)
Table 6: Temperature classification DN25…150.
Maximum process liquid temperatureTemperature
Ta ≤ 40°C Ta ≤ 50°C Ta ≤ 60°C
Maximum process liquid temperatureTemperature
Ta ≤ 40°C Ta ≤ 50°C Ta ≤ 60°C
7. MAINTENANCE
The IFM 4042 K-EEx electromagnetic compact flowmeters are maintenance free with regard
to the flowmetering properties. Within the scope of the periodical inspections, which are
required for electrical apparatus that are installed and used in hazardous classified locations,
it is recommended to check the flameproof enclosure(s).
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8. CONNECTION DIAGRAM
of Zone 1 and 2
E
Increased safe field coil circuit
Coil
CURRENT BINARY ADD. POWER
PE
SIGNAL IN-/OUTPUTS 1L= 0L= PE
≥
2
B
A
E
Coil
IFC 040-EEx
Signal Converter
(OPTIONAL)
4 mm
I ⊥ I B2 B⊥ B2 1L= 0L=
OUTPUT OUTPUTS SUPPLY
TERMINAL COMPARTMENT
ELECTRONICS COMPARTMENT (always "EEx d")
Intrinsically safe ("ib") Increased safe ("e")
electrode circuits field coil circuits
(No. "2", "3", "1") (No. "7", "8")
FE
Flameproof (EEx d)
terminal feed-through
Flameproof (EEx d) cable
feed-through LC-2/EEx
Hazardous locations
Field coil wires - green/blue
(PTFE insulated copper)
EQUIPOTENTIAL BONDING CONDUCTOR
Electrode cables - white/pink
(PTFE insulated shielded copper)
Intrinsically safe electrode circuits
Flow tube
IFS 4000…-EEx
Primary Head
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9. ORDERING INFORMATION
In case of questions about spare or replacing parts contact your local Krohne representative.
The part number of the IFC 040-EEx electronics unit is 2.12896.01.00.
10. DATA PLATES
Figure 4: Data plate of IFM 4042 K-EEx, type "EEx de [ib]".
Figure 5: Data plate of IFM 4042 K-EEx, type "EEx de".
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Figure 6: Data plate IFM 4042 K-EEx, type EEx e [ib].
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11. EC-TYPE EXAMINATION CERTIFICATE
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