KROHNE IFM4042KEEx-ATEX User Manual

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Addition to the installation and operating instructions

ALTOFLUX 2W IFM 4042 K/EEx

2-wire compact electromagnetic flowmeter

Variable area flowmeters Vortex flowmeters Flow controllers

Electromagnetic flowmeters

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Warning!

• No safety technical 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 magnetic-inductive 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 3

1.1 General information 3

1.2 Data plates 4

1.3 Primary head 4

1.4 IFC 040-EEx signal converter 5

1.4.1 Electronics compartment 5

1.4.2 Terminal compartment 5

1.5 Cable or conduit entries 5

2 Electrical connection 6

2.1 Equipotential bonding system 6

2.2 Terminal arrangement 6

2.3 Description of the output circuits 6

2.4 Connection diagram 8

2.5 Safety-technical data 9

2.6 Connection examples 9

2.6.1 Example of IFM 4042 K in 2-wire mode 9

2.6.2 Example of IFM 4042 K in 2×2-wire mode (4-wire) 10

3 Operation of the signal converter 11 4 Maintenance 11 5 Ordering information 11 6 Technical data 11

7 Replacement of electronic unit 12

7.1 Removal of the electronics unit 12

7.2 Inseration of the electronics unit 12

8 EC Declaration of conformity 13 9 EC-Type examination certificate 14

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 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

General information The Altoflux 2W IFM 4042 K-EEx electromagnetic compact flowmeter in 2wire technology is in accordance with European Directive 94/9/EC (ATEX 100a) and approved for hazardous classified locations of Zone 1 and 2 under:

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 tables below for details.

For dusts the second column of the two below listed tables is applicable.

Temperature classification DN 25 - 150 with PFA liner

Temperature class

(for gases) (for dusts) 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 no no yes

Temperature classification DN 10 - 20 and >DN 200

Temperature class

(for gases) (for dusts) 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

Max. surface temperature

T180°C

Maximum process liquid temperature

≤ 40°C Ta ≤ 50°C Ta ≤ 60°C

Maximum process liquid temperature

≤ 40°C Ta ≤ 50°C Ta ≤ 60°C

150°C 115°C 75°C

* T 150 °C for DN 10-20 and > DN 200

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:

• DN 10 - 20 II 2GD EEx dme [ib] IIC T6…T3 ("EEx e and d" terminal compartment)

• DN 25 - 150 II 2GD EEx de [ib] IIC T6…T3 ("EEx e and d" terminal compartment)

• DN 200 - 300 II 2GD EEx dqe [ib] IIC T6…T3 ("EEx e and d" terminal compartment)

• DN 350 and up II 2GD EEx de [ib] IIC T6…T3

("EEx e" and "EEx d" terminal compartment) For details see the EC-type examination certificate in Section 9 of these instructions.

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1.2 Data plates

IFM 4042 K-EEx, type "EEx de [ib]"

IFM 4042 K-EEx, type "EEx de"

1.3 Primary head

The primary head is the measuring unit of the IFM 4042 K-EEx compact flowmeter and contains two field coils (see table below for the type of protection) and two electrodes in type of protection intrinsic safety category "ib" according to EN 50020.

Meter size Type of protection

DN 10 up to DN 150 Housing: Encapsulation "m" according to EN 50028 and

increased safety “e” according to EN 50 019 Electrodes: Intrinsic safety "ib" according to EN 50020

DN 200 up to DN 300 Housing: Powder filling “q” according to EN 50017 and

increased safety “e” according to 50 019 Electrodes: Intrinsic safety "ib" according to EN 50020

DN 350 and larger Field coils: Increased safety "e" according to EN 50019

Electrodes: Intrinsic safety "ib" according to EN 50020

NOTE

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The intrinsically safe electrode circuits of the IFM 4042 K-EEx compact flowmeter are only internal circuits and not accessible for the customer.

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1.4 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 IP67 conform to EN 60529.

1.4.1 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.

1.4.2 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 "EEx de [ib]" with Um = 60 V

The connections of the output circuits can be configured by the customer in one of the following types of explosion protection:

• EEx [ib] (intrinsic safety, category "ib") or

• EEx e (increased safety) or when the precaution in section 1.5 is obeyed

• EEx d (flameproof enclosure)

•

Version B Terminal compartment "EEx de" with Um = 250 V The customer can configure the connections of the output circuits in one of the following types of explosion protection:

• EEx e (increased safety) or when the precaution in section 1.5 is obeyed

• 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 2.3 of these additional instructions.

1.5 Cable or conduit entries

The used cable entries (glands and/or blind plugs) must be ATEX certified. Standard the IFM 4042 K-EEx flow-meter is delivered with an EEx e cable gland and EEx e blind stop. (see also the EEx code on cable gland and blind stop). The cable gland and blindstop are suitable for connections in EEx e and EEx ib, but not for EEx d.

Safty technical note

Therefore, when connection in EEx d is planned a special EEx d certified conduits, gland(s) or blindstops must be used! 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 ! Note that for a correct choice of the EEx d cable gland the precise cable type and cable dimensions (e.g. outside diameter) must be given.

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2 Electrical connection

2.1 Equipotential bonding system

The IFM 4042 K-EEx magnetic-inductive compact flowmeter must be incorporated into the equipotential bonding system through the internal of external PE-clamp. Latter clamp is suitable for wires till 4 mm2 cross section. Disconnection from the equipotential bonding system is only allowed when the flowmeter is not in contact with power supplies or ground voltages outside the hazardous area.

2.2 Terminal arrangement

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 the following figure.

Terminal arrangement in terminal compartment

I⊥ I B1 B⊥ B2 1L= 0L=

current binary power booster output outputs (additional power supply)

PE protective ground FE functional ground

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 (choice of polarity is free).

Additional power supply or Power Booster (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.

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.

2.3 Description of the output circuits

The terminal compartment of the IFM 4042 K-EE 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.

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Version A Terminal compartment "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".

If type of protection EEx e or EEx d is used, the markings for "Intrinsically safe" - that are blue oring around the cable gland and the blue sticker in the connection compartment - should be removed.

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.

Safety technical note

• 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").

• The end-user is allowed to change the type of protection of the terminal compartment by the afterwards a random times, when it is garuanteed that the maximum voltage U

of the mains

power supply system is always limited at 60 V!

Version B Terminal compartment "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 versions A and B)

• 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 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.

• 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 longshafted 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).

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2.4 Connection diagram

signal outputs 1L= 0L= PE

(optional)

IFC 040-EEx

signal converter

I ⊥ I B1 B⊥ B2 1L= 0L=

current binary power output outputs booster

terminal compartment

electronic compartment (always "EEx d")

electrode circuits field coil circuits

B (optional)

PE FE

flameproof (EEx d)

terminal feed-through

Hazardous locations

of Zone 1 and 2

coil

flow tube

equipotential bonding conductor ≥ 4 mm

coil

IFS 4002…-EEx

primary head

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2.5 Safety-technical data

Important The functional-technical data must also be regarded,

therefore see the standard installation and operating instructions.

Safety-technical data of output circuits Terminal Function Electrical data (per circuit) designation Circuit 1 I, I ⊥

Circuit 2 1L=, 0L=

Type of protection "EEx ib" Type of protection "EEx e" Current output, passive

(2-wire connection) 4 - 20 mA, HART = possible Additional power supply or Power Booster, (4-wire connection)

Maximum values: Ui = 30 V, Ii = 100 mA, P

= 1.0 W

= 20 nF, Li = 0

= 60 V

= 14 - 36 Vdc

= 4 - 20 mA

= 250 V

Un = 14 - 36 Vdc I

= 22 mA

= 250 V

additional to circuit 1 (option)

Circuit 3 B1, B⊥ B2, B⊥

Passive pulse/status output 1 Passive pulse/status output 2

Maximum values:

= 30 V, Ii = 100 mA,

= 1.0 W

= 0, Li = 0

= 60 V

Maximum values: U = 36 V I = 100 mA

= 250 V

2.6 Connection examples

In the following sections examples for connection of the IFM 4042 K-EEx compact flowmeter are described for operation in the 2-wire mode as well as in the 2x2-wire mode.

2.6.1 Example of IFM 4042 K in 2-wire mode

The diagram 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 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. 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-EEx compact flowmeter, namely Ui = 30 V, Ii = 100 mA, Ci = 200 nF, Li = 0. 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

Safe Area

IFM 4042 K-EEx

4-20 mA

Transmitter Powe

Supply (EEx i)

4-20 mA

Process

Display Unit

I ⊥

HTT

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2.6.2 Example of IFM 4042 K in 2×2-wire mode (4-wire)

The diagram shows an example of the connection of the IFM 4042 K-EEx in 2x2-wire mode. As in the previous example (see Sect. 2.6.1), the terminal compartment is again version A.

The additional power supply (terminals 1L=, 0L=) of the IFM 4042 K-EEx is supplied by an external power supply unit through an "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 notes!

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! It is strictly interdicted to use the IMoCOM adapter with the IFC040-EEx unit!

Hazardous Area

Safe Area

IFM 4042 K-EEx

4-20 mA

Transmitter Power

Supply (EEx i)

4-20 m

Process/

Display Unit

I ⊥

HTT

1L=

0L=

22 mA

Zener Barrier

External

Power Supp ly

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 caused by the end-to-end resistance of the barrier and (if not neglectable) the serie cable resistance. 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: U I

= 28 V

= 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.

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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.

4 Maintenance

The IFM 4042 K-EEx magnetic-inductive 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 enclosures on signs of damage or corrosion. This concerns the converter housing and for sizes DN25 till DN150 also the primary head housing.

5 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.

6 Technical data

Safty technical note

The following maximum safty technical process liquid temperatures are absolute safety-technical limits. Due to function-technical reasons (e.g. measuring accuracy) lower process liquid temperatures can be in effect, see also the standard installation and operating instructions of the Altoflux 2W electromagnetic compact flowmeter type IFM 4042 K-EEx!

Ambient temperature Ta -40°C…+60°C

Maximum saftety technical process liquid temperature see EC-Certificate of the IFM 4042 K-EEx with No. KEMA 01

ATEX 2200 X in Sect. 9 and the Tables in Sect. 1.1

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7 Replacement of electronic 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!

When the instructions above are strictly followed, the display cover (with the glass window) can be removed.

7.1 Removal of the electronics unit

• Raise the latch of the interlocking device by loosening the hexagon socket head cap screw size 3, until the cover can rotate freely.

• Unscrew the cover with the special plastic wrench (black) that is supplied with the apparatus.

• Unscrew the two screws of the display unit and turn it carefully aside.

• Carefully disconnect the 12 pin connector (for field coil and electrode circuits connection) from

the electronic unit.

• Unscrew the two mounting screws of the electronics unit, which fixes the metal frame to the back of the signal converter housing. A crosshead screwdriver type 2 Pt. Phillips is most suitable.

• Carefully remove the electronics unit of the converter housing (see the Remark below).

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!

7.2 Insertion of the electronics unit

Reassemble in reverse order with the replacement of the IFC 040-EEx electronics unit:

• Insert the electronics unit in the converter housing

• Tighten the two mounting screws of the electronics unit.

• The metal 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.

Remark!

These two screw-connections also establish the safety-technical connection of the electronics unit to the signal converter housing and equipotential bonding system.

• Connect the 12-pin connector

• Mount the display-unit

• 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.

• Tighten the hexagon socket head cap screw of the interlocking device.

Refer to the standard Installation and Operating Instructions for detailed information about resetting and reprogramming the new electronics unit after replacement.

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