KROHNE OPTISONIC-7300Ex User Manual

Supplementary instructions

Supplementary instructions

OPTISONIC 7300 / 8300

OPTISONIC 7300 / 8300

OPTISONIC 7300 / 8300OPTISONIC 7300 / 8300

Supplementary instructions Supplementary instructions

Ultrasonic gas flow meter

Addendum for hazardous areas. These additional instructions are an extension to the
OPTISONIC 7300 and OPTISONIC 8300 quick start and handbook

© KROHNE 05/2012 - 7312262200 - AD EX OPTISONIC 7300/8300 R02

CONTENTS

OPTISONIC 7300 / 8300

1 Introduction 4

1.1 Safety instructions from the manufacturer ..................................................................... 4

1.1.1 Copyright and data protection ................................................................................................ 4

1.1.2 Disclaimer ............................................................................................................................... 4

1.1.3 Information concerning the documentation........................................................................... 5

1.1.4 Warnings and symbols used................................................................................................... 6

1.2 Safety instructions for the operator................................................................................. 7

1.3 Approval............................................................................................................................ 8

1.4 OPTISONIC 7300 C/...-Ex .................................................................................................. 8

1.5 OPTISONIC 7000...-Ex.......................................................................................................8

1.6 OPTISONIC 8000...-Ex.......................................................................................................9

1.7 GFC 300 F/...-Ex................................................................................................................ 9

1.8 Ultrasonic gas transducers.............................................................................................. 9

1.9 Technical data................................................................................................................. 10

1.10 Marking codes .............................................................................................................. 10

1.11 Marking labels .............................................................................................................. 12

2 Temperature limits 16

2.1 General ........................................................................................................................... 16

2.2 GFC 300 F/...-Ex.............................................................................................................. 16

2.3 OPTISONIC 7300 C/...-Ex ................................................................................................ 16

2.4 OPTISONIC 7000...-Ex..................................................................................................... 17

2.5 OPTISONIC 8000...-Ex..................................................................................................... 17

3 Connection of separate systems 18

3.1 General ........................................................................................................................... 18

3.2 Cable marking ................................................................................................................ 18

3.2.1 Sensor ................................................................................................................................... 18

3.2.2 Converter............................................................................................................................... 20

3.3 Equipotential bonding..................................................................................................... 21

4 Electrical connections 22

4.1 General ........................................................................................................................... 22

4.2 Non-"Ex i" I/O connections............................................................................................. 25

4.3 "Ex i" I/O connections .....................................................................................................27

5 Maintenance 29

5.1 Maintenance ................................................................................................................... 29

5.2 Before and after opening................................................................................................ 29

5.3 Replacement of mains fuse............................................................................................ 30

5.4 Exchange of electronics unit .......................................................................................... 31

5.4.1 Field version.......................................................................................................................... 32

5.5 Service / repair information ........................................................................................... 34

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OPTISONIC 7300 / 8300

5.6 Form (for copying) to accompany a returned device ..................................................... 35

5.7 Disposal .......................................................................................................................... 35

CONTENTS

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1 INTRODUCTION

1.1 Safety instructions from the manufacturer

1.1.1 Copyright and data protection

The contents of this document have been created with great care. Nevertheless, we provide no
guarantee that the contents are correct, complete or up-to-date.

The contents and works in this document are subject to copyright. Contributions from third
parties are identified as such. Reproduction, processing, dissemination and any type of use
beyond what is permitted under copyright requires written authorisation from the respective
author and/or the manufacturer.

The manufacturer tries always to observe the copyrights of others, and to draw on works created
in-house or works in the public domain.

The collection of personal data (such as names, street addresses or e-mail addresses) in the
manufacturer's documents is always on a voluntary basis whenever possible. Whenever
feasible, it is always possible to make use of the offerings and services without providing any
personal data.

OPTISONIC 7300 / 8300

We draw your attention to the fact that data transmission over the Internet (e.g. when
communicating by e-mail) may involve gaps in security. It is not possible to protect such data
completely against access by third parties.

We hereby expressly prohibit the use of the contact data published as part of our duty to publish
an imprint for the purpose of sending us any advertising or informational materials that we have
not expressly requested.

1.1.2 Disclaimer

The manufacturer will not be liable for any damage of any kind by using its product, including,
but not limited to direct, indirect or incidental and consequential damages.

This disclaimer does not apply in case the manufacturer has acted on purpose or with gross
negligence. In the event any applicable law does not allow such limitations on implied warranties
or the exclusion of limitation of certain damages, you may, if such law applies to you, not be
subject to some or all of the above disclaimer, exclusions or limitations.

Any product purchased from the manufacturer is warranted in accordance with the relevant
product documentation and our Terms and Conditions of Sale.

The manufacturer reserves the right to alter the content of its documents, including this
disclaimer in any way, at any time, for any reason, without prior notification, and will not be liable
in any way for possible consequences of such changes.

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OPTISONIC 7300 / 8300

1.1.3 Information concerning the documentation

To prevent any injury to the user or damage to the device it is essential that you read the
information in this document and observe applicable national standards, safety requirements
and accident prevention regulations.

If this document is not in your native language and if you have any problems understanding the
text, we advise you to contact your local office for assistance. The manufacturer can not accept
responsibility for any damage or injury caused by misunderstanding of the information in this
document.

This document is provided to help you establish operating conditions, which will permit safe and
efficient use of this device. Special considerations and precautions are also described in the
document, which appear in the form of underneath icons.

INTRODUCTION 1

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1 INTRODUCTION

1.1.4 Warnings and symbols used

Safety warnings are indicated by the following symbols.

DANGER!

This information refers to the immediate danger when working with electricity.

DANGER!

This warning refers to the immediate danger of burns caused by heat or hot surfaces.

DANGER!

This warning refers to the immediate danger when using this device in a hazardous atmosphere.

DANGER!

These warnings must be observed without fail. Even partial disregard of this warning can lead to
serious health problems and even death. There is also the risk of seriously damaging the device
or parts of the operator's plant.

OPTISONIC 7300 / 8300

WARNING!

Disregarding this safety warning, even if only in part, poses the risk of serious health problems.
There is also the risk of damaging the device or parts of the operator's plant.

CAUTION!

Disregarding these instructions can result in damage to the device or to parts of the operator's
plant.

INFORMATION!

These instructions contain important information for the handling of the device.

LEGAL NOTICE!

This note contains information on statutory directives and standards.

• HANDLING

HANDLING

HANDLINGHANDLING

This symbol designates all instructions for actions to be carried out by the operator in the
specified sequence.

i RESULT

RESULT

RESULTRESULT
This symbol refers to all important consequences of the previous actions.

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1.2 Safety instructions for the operator

WARNING!

•

Do not change the device. Unauthorized changes may 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 (equivalent to HD 384 or 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 Part 1) must be strictly followed.

•

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

These additional instructions are an extension to the standard documentation and only apply to
the Explosion protected versions of the devices. All technical information as described in the
standard documentation is applicable, when not specifically excluded, completed or replaced by
the instructions in these additional instructions.

INTRODUCTION 1

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1 INTRODUCTION

1.3 Approval

The ultrasonic flowmeters are manufactured according to the European Directive 94/9/EC (ATEX
100a). These flowmeters are approved for installation and use in hazardous classified locations
of Zone 1 and 2 and are in accordance with the European Standards of the EN 60079 series. They
have approval number:

OPTISONIC 7300 / 8300

OPTISONIC 7300: PTB 10 ATEX 1052 X
OPTISONIC 8300: DEKRA 12 ATEX 0063 X

PTB 10 ATEX 1052 X and DEKRA 12 ATEX 0063 X

PTB 10 ATEX 1052 XPTB 10 ATEX 1052 X
DEKRA 12 ATEX 0063 X

DEKRA 12 ATEX 0063 XDEKRA 12 ATEX 0063 X

1.4 OPTISONIC 7300 C/...-Ex

The OPTISONIC 7300 C/...-Ex is the compact configuration of the GFC 300 ultrasonic flow
converter and the OPTISONIC 7000 ultrasonic gas flow sensor. The gas flow sensor contains
flameproof (Ex d) gas transducers made of titanium or flameproof (Ex d) transducers with a
partly encapsulated (Ex ma) synthetic front. The gas flow converter is provided with non-Ex or
intrinsically safe (Ex ia or Ex ib) signal outputs that are located in the terminal compartment,

which can either be configured as “Ex d” (flameproof enclosure) or “Ex e” (increased safety).

The marking code can be:

"Ex d" terminal compartment "Ex e" terminal compartment

II 2 G Ex d IIC T6...T3 II 2 G Ex de IIC T6...T3

II 2 G Ex d [ia] IIC T6...T3 (PTB)
II 2 (1) G Ex d [ia] IIC T6...T3 (DEKRA)

II 2 G Ex d [ib] IIC T6...T3 II 2 G Ex de [ib] IIC T6...T3

II 2 G Ex d ma IIC T6, T5 II 2 G Ex de ma IIC T6, T5

II 2 G Ex d ma [ia] T6, T5 (PTB)
II 2 (1) G Ex d ma [ia] T6, T5 (DEKRA)

II 2 G Ex d ma [ib] T6, T5 II 2 G Ex de ma [ib] T6, T5

DEKRA 12 ATEX 0063 X

DEKRA 12 ATEX 0063 XDEKRA 12 ATEX 0063 X

II 2 G Ex de [ia] IIC T6...T3 (PTB)
II 2 (1) G Ex de [ia] IIC T6...T3 (DEKRA)

II 2 G Ex de ma [ia] T6, T5 (PTB)
II 2 (1) G Ex de ma [ia] T6, T5 (DEKRA)

1.5 OPTISONIC 7000...-Ex

The OPTISONIC 7000...-Ex is the separate version of the ultrasonic flow sensor and has
flameproof (Ex d) gas transducers. It is available in two versions, the normal version up to a

process temperature of 180°C and the extended temperature (XT) version up to a 220°C process

temperature.

The marking code can be:

OPTISONIC 7000-Ex OPTISONIC 7000 XT-Ex

II 2 G Ex d IIC T6...T3 II 2 G Ex d IIC T6...T2

II 2 G Ex d ma IIC T6, T5

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OPTISONIC 7300 / 8300

1.6 OPTISONIC 8000...-Ex

The OPTISONIC 8000...-Ex high temperature (steam) flow sensor is for measuring (low and) high
temperature gases including steam. The thermal sensitive parts of the transducer are located at
a larger distance from the process medium inside the measuring tube. This meter is suitable for

process temperatures from -200°C up to +440°C.

The marking code is:

OPTISONIC 8000-Ex

II 2 G Ex d IIC T6...T1

1.7 GFC 300 F/...-Ex

The GFC 300 F/...-Ex is the separate version of the ultrasonic flow converter and has flameproof
protected connections to the flameproof gas transducers of the ultrasonic flow sensor. The
ultrasonic gas flow converter is either provided with non-explosion protected or intrinsically safe

in-/outputs (“Ex ia” or “Ex ib”). The connection terminals of these in-/outputs are located in the
terminal compartment, which is either configured as “Ex d” or “Ex e”.

INTRODUCTION 1

The marking code can be:

"Ex d" terminal compartment "Ex e" terminal compartment

II 2 G Ex d IIC T6 II 2 G Ex de IIC T6

II 2 G Ex d [ia] IIC T6 (PTB)
II 2 (1) G Ex d [ia] IIC T6 (DEKRA)

II 2 G Ex d [ib] IIC T6 II 2 G Ex de [ib] IIC T6

1.8 Ultrasonic gas transducers

The OPTISONIC 7000...-Ex gas flow sensor, can be equipped with the ultrasonic gas transducers
made of titanium (type G7.01 and G7.04) or with the gas transducers of type G5.nn and G6.nn
(body: stainless steel, front part: epoxy compound).

The gas transducers of type G7.01 and G7.04 have type of protection “flameproof enclosure”

(Ex d) in accordance with EN 60079-1. The electrical connections are established in specially
designed flameproof enclosures with a free volume well below 100 cm

Optionally the under KEMA 07 ATEX 0181 X approved gas transducers of type G5.nn and G6.nn

can be used. These gas transducers have types of protection “flameproof enclosure” (Ex d) in
accordance with EN 60079-1 and “encapsulation” (Ex ma) conform to EN 60079-18.

These transducers have marking code: II 1/2 G Ex d ma IIC T4...T6.

II 2 G Ex de [ia] IIC T6 (PTB)
II 2 (1) G Ex de [ia] IIC T6 (DEKRA)

3

.

The high temperature transducers (OPTISONIC 8000-Ex) are always flanged and have type of
protection flameproof enclosure (Ex d).

See Chapter 2 for details on the temperature classification table(s).

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1 INTRODUCTION

1.9 Technical data

Process medium Flammable and non-flammable gases

Protection category acc. to IEC 529 /
EN 60529

Ambient temperature range

Ambient temperature range

Ambient temperature rangeAmbient temperature range

Titanium transducers

Stainless steel HT / steam transducer OPTISONIC 8000-Ex: -40...+60°C

Synthetic transducers
(only available in OPTISONIC 7000-Ex)

Process medium temperature range

Process medium temperature range

Process medium temperature rangeProcess medium temperature range
Titanium transducers OPTISONIC 7300 C/...-Ex: -50...+180°C

Stainless steel HT / steam transducer OPTISONIC 8000-Ex: -200...+440°C

Synthetic transducers
(only available in OPTISONIC 7000-Ex)

OPTISONIC 7300 / 8300

IP 65 or better

OPTISONIC 7300 C/...-Ex: -40...+65°C
GFC 300 F/...-Ex: -40...+65°C

OPTISONIC 7000...-Ex (incl. XT-version) : -40...+70°C

2

2

Type G5.nn: -50...+70°C
Type G6.nn, Temp class T6: -50...+70°C
Type G6.nn, Temp class T5: -50...+85°C
Type G6.nn, Temp class T4: -50...+100°C

OPTISONIC 7000-Ex: -50...+180°C
OPTISONIC 7000 XT-Ex: -50...+220°C

Type G5.nn, Temp. class T6: -50...+70°C
Type G6.nn, Temp class T6: -50...+70°C
Type G6.nn, Temp class T5: -50...+85°C
Type G6.nn, Temp class T4: -50...+100°C

1

1

INFORMATION!

1

Maximum ambient temperature applies to aluminum converter housing. Stainless steel

version is limited to +55

2

The ATEX-certificate KEMA 07 ATEX 0181 X (Issue no. 3) describes the maximum ambient
temperatures of transducers type G5.nn and G6.nn, which should be read as process
temperature (this is the temperature of the medium that surrounds the transducers). The
ambient temperature is the (air) temperature at the location where the meter is installed.

1.10 Marking codes

Due to the various configuration options, the OPTISONIC 7300 gas flowmeter series can have
several (different) explosion safety measures implemented.

°

C.

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OPTISONIC 7300 / 8300

Marking code Converter housing Transducer I/O

OPTISONIC 7300 C-Ex

II 2 G Ex d IIC T6...T3 Ex d Titanium Non-Ex

II 2 G Ex de IIC T6...T3 Ex de Titanium Non-Ex

II 2 G Ex d ma IIC T6, T5 Ex d Synthetic Non-Ex

II 2 G Ex de ma IIC T6, T5 Ex de Synthetic Non-Ex

OPTISONIC 7300 C/i-Ex

II 2 G Ex d [ia] IIC T6...T3 (PTB)
II 2 (1) G Ex d [ia] IIC T6...T3 (DEKRA)

II 2 G Ex de [ia] IIC T6...T3 (PTB)
II 2 (1) G Ex de [ia] IIC T6...T3 (DEKRA)

II 2 G Ex d [ib] IIC T6...T3 Ex d Titanium Ex ib

II 2 G Ex de [ib] IIC T6...T3 Ex de Titanium Ex ib

II 2 G Ex d ma [ia] IIC T6, T5 (PTB)
II 2 (1) G Ex d ma [ia] IIC T6, T5 (DEKRA)

II 2 G Ex de ma [ia] IIC T6, T5 (PTB)
II 2 (1) G Ex de ma [ia] IIC T6, T5 (DEKRA)

II 2 G Ex d ma [ib] IIC T6, T5 Ex d Synthetic Ex ib

II 2 G Ex de ma [ib] IIC T6, T5 Ex de Synthetic Ex ib

INTRODUCTION 1

Ex d Titanium Ex ia

Ex de Titanium Ex ia

Ex d Synthetic Ex ia

Ex de Synthetic Ex ia

OPTISONIC 7000-Ex

II 2 G Ex d IIC T6...T3 n.a. Titanium n.a.

II 2 G Ex d ma IIC T6, T5 n.a. Synthetic n.a.

OPTISONIC 7000 XT-Ex

II 2 G Ex d IIC T6...T2 n.a. Titanium 1 n.a.

OPTISONIC 8000-Ex

II 2 G Ex d IIC T6...T1 n.a. HT / steam n.a.

GFC 300 F-Ex

II 2 G Ex d IIC T6 Ex d n.a. Non-Ex

II 2 G Ex de IIC T6 Ex de n.a. Non-Ex

GFC 300 F/i-Ex

II 2 G Ex d [ia] IIC T6 (PTB)
II 2 (1) G Ex d [ia] IIC T6 (DEKRA)

II 2 G Ex de [ia] IIC T6 (PTB)
II 2 (1) G Ex de [ia] IIC T6 (DEKRA)

II 2 G Ex d [ib] IIC T6 Ex d n.a. Ex ib

II 2 G Ex de [ib] IIC T6 Ex de n.a. Ex ib

1 Only available in separate version.

Ex d n.a. Ex ia

Ex de n.a. Ex ia

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1 INTRODUCTION

1.11 Marking labels

The marking labels shown here are configuration examples. Other marking codes are possible,
see previous section.

Example for the Ex measuring sensor nameplate

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Tag number.
4 PED data.
5 Calibration data.
6 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
7 Name and address of the manufacturer.

OPTISONIC 7300 / 8300

Example for the extended temperature (XT) version nameplate

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Tag number.
4 PED data.
5 Calibration data.
6 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
7 Name and address of the manufacturer.

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OPTISONIC 7300 / 8300

Example for the OPTISONIC 8000-Ex flow sensor nameplate

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Tag number.
4 PED data.
5 Calibration data.
6 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
7 Name and address of the manufacturer.

Example for the compact Ex version nameplate (PTB)

INTRODUCTION 1

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Intrinsical safe in-/output circuits information.
4 Warning messages.
5 Main supply data.
6 Calibration data.
7 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
8 Name and address of the manufacturer.

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1 INTRODUCTION

Example for the compact Ex version nameplate (DEKRA)

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Intrinsical safe in-/output circuits information.
4 Warning messages.
5 Main supply data.
6 Calibration data.
7 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
8 Name and address of the manufacturer.

OPTISONIC 7300 / 8300

Example for separate Ex signal converter nameplate

Figure 1-1: OPTISONIC 7300

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Intrinsical safe in-/output circuits information.
4 Warning messages.
5 Main supply data.
6 Calibration data.
7 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
8 Name and address of the manufacturer.

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OPTISONIC 7300 / 8300

Example for separate Ex signal converter nameplate

Figure 1-2: OPTISONIC 8300

1 Specific sign for explosion protection, Ex codes and number of EC type examination certificate.
2 Explosion safety notes.
3 Intrinsical safe in-/output circuits information.
4 Warning messages.
5 Main supply data.
6 Calibration data.
7 Type designation of the flowmeter and CE sign with number(s) of notified body / bodies.
8 Name and address of the manufacturer.

INTRODUCTION 1

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2 TEMPERATURE LIMITS

2.1 General

Due to the influence of the process medium (gas) temperature, ultrasonic flow sensors in
separate version with type designation OPTISONIC 7000...-Ex and ultrasonic compact gas flow
meters with type designation OPTISONIC 7300 C/...-Ex are not allocated to any fixed
temperature class.
The temperature limits apply under the following conditions:

• The instrument is installed and operated in accordance with the installation directions given

in the quickstart and / or handbook.

• The instrument is not heated up by any additional heat radiation (direct solar radiation, heat

from adjacent plant parts) so causing it to operate above the permissible ambient
temperature range.

• Insulation is not hindering free ventilation of the ultrasonic signal converter housing.

CAUTION!

The temperature data below only applies to the meters with ultrasonic gas transducers made of
titanium (types G7.01 and G7.04). For the partly encapsulated transducer types G5.nn and G6.nn,
refer to Technical data on page 10

OPTISONIC 7300 / 8300

.

2.2 GFC 300 F/...-Ex

The GFC 300 F/...-Ex signal converter has a temperature classification of T6 (85°C). The

permissible ambient temperature is dependent on the material that the electronics housing is
made of, namely:

• die-casted aluminum: -40...+65ºC

• die-casted stainless steel: -40...+55ºC

2.3 OPTISONIC 7300 C/...-Ex

The OPTISONIC 7300 C/...-Ex ultrasonic compact gas flow meter is provided with the same
electronics housing as the GFC 300 F/...-Ex and therefore has the same ambient temperature

range of -40...+65°C (aluminum housing) and -40...55°C (stainless steel). The temperature

classification table shows the relationship between the maximum process medium
temperatures at a certain maximum ambient temperature.

CAUTION!

The temperature data below only applies to the meters with ultrasonic gas transducers made of
titanium (types G7.01 and G7.04). For the partly encapsulated transducer types G5.nn and G6.nn,
refer to Technical data on page 10

Temperature class Maximum process temperature [ºC] at

.

16

T

= 40ºC Ta = 50ºC Ta = 65ºC (55ºC)

a

T6 80 80 80

T5 95 95 95

T4 130 130 125

T3 180 165 125

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OPTISONIC 7300 / 8300

2.4 OPTISONIC 7000...-Ex

The OPTISONIC 7000-Ex and OPTISONIC 7000 XT-Ex have an ambient temperature in the range

of -40...+70°C. The maximum process medium temperature is listed in the table below.

CAUTION!

The temperature data below only applies to the meters with ultrasonic gas transducers made of
titanium (types G7.01 and G7.04). For the partly encapsulated transducer types G5.nn and G6.nn,
refer to Technical data on page 10

Temperature class Maximum process temperature [ºC] at Ta = 70ºC

T6 80 80

T5 95 95

T4 130 130

T3 180 195

T2 n.a. 220

TEMPERATURE LIMITS 2

.

Standard design XT design

2.5 OPTISONIC 8000...-Ex

The OPTISONIC 8000...-Ex high temperature (steam) flow sensor has an ambient temperature in

the range of -40...+60°C. The maximum process medium temperature is listed in the table

below.

Temperature class Maximum process temperature [ºC] at Ta = 60ºC

T6 80

T5 95

T4 130

T3 195

T2 290

T1 440

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3 CONNECTION OF SEPARATE SYSTEMS

3.1 General

The electrical connection between the ultrasonic flow sensor and the signal converter is
established with one (single beam versions) or two (dual beam versions) MR 02 signal cable(s).
The ends of the coaxial cables are provided with SMB plugs. The signal cable is provided with the
system.

3.2 Cable marking

The coaxial transducer cables are marked at each end by yellow tubing with a black number of
subsequently 1.1 and 1.2 for a single-beam design and numbers 1.1, 1.2, 2.1 and 2.2 for a
double-beam design. The first number represents path, 1 (single-beam) or 2 (double-beam) and
the second the position of the transducer of that path (1 or 2). The marking of the SMB
receptacles in the connection box is identical to that of the transducers cables (1.1, 1.2, ...).

3.2.1 Sensor

OPTISONIC 7300 / 8300

Figure 3-1: Connect the cables on the sensor.

1 Sensor.
2 Open connection box.
3 Marking on cable.

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OPTISONIC 7300 / 8300

Figure 3-2: Clamp the cables on the shielding bush.

1 Cables.
2 Cable glands.
3 Grounding clamps.
4 Cable with metal shielding bush.

CONNECTION OF SEPARATE SYSTEMS 3

Figure 3-3: Connect the cables on the signal converter.

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3 CONNECTION OF SEPARATE SYSTEMS

3.2.2 Converter

1 Converter housing.
2 Open connection box.
3 Marking on cable.
4 Insert cables through cable glands.

OPTISONIC 7300 / 8300

20

Figure 3-4: Clamp the cables on the shielding bush.

1 Cables.
2 Cable glands.
3 Grounding clamps.
4 Cable with metal shielding bush.

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OPTISONIC 7300 / 8300

Figure 3-5: Connect the cables on the signal converter.

3.3 Equipotential bonding

CONNECTION OF SEPARATE SYSTEMS 3

The GFC 300 F/...-Ex ultrasonic signal converter must always
equipotential bonding system of the installation in the hazardous classified location. For this
purpose it must be connected to the external U-clamp screw terminal (size M5) on the wall­mounting device.

The separate bonding conductor must be at least 4 mm
is mechanically protected, see Clause 413 of HD 384.4.41 or IEC 364-4-41. Make sure that the
core of the bonding wire is properly mounted under the U-clamp of the external M5 terminal and
that the screw is tightly fixed.

The transducer circuits are galvanically isolated from earth and therefore an equipotential
bonding conductor between the ultrasonic flow sensor and the ultrasonic flow converter does
not have to be connected, but can be used if desirable.

Where screened signal cable is used, the screen should only be earthed at the flow sensor end.
In the special case of a screen being earthed at both ends of the system, a potential difference
between the sensor and converter is not permitted. Refer to EN 60079-14, Clause 12.2.2.3, for
further requirements of cable screens.

must always be incorporated within the

must alwaysmust always

2

(11 AWG) or 2.5 mm2 (14 AWG) in case it

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4 ELECTRICAL CONNECTIONS

4.1 General

The display cover seals the electronics compartment of the converter housing and provides type

of protection “flameproof enclosure” (Ex d) according to EN 60079-1. The terminal compartment

is either in type of protection "increased safety" (Ex e) or performed as "flameproof enclosure"
(Ex d). The threaded joints formed by the covers and housing are a tight fit due to the

requirements for type of protection “flameproof enclosure”. Screw the covers on and off with

care and never use excessive force !

Keep the screw-threads free of dirt and well-greased (e.g. with PTFE grease). The grease will
help to prevent the threads from locking due to corrosion.
To unscrew the covers, first release the interlocking devices (one at each cover). Therefore
unscrew the M4 head screw with internal hexagon socket set using a No. 3 Allen key until the
interlocking device can be turned. After the covers are screwed back onto the housing, make
sure that the interlocking devices are properly refitted.

WARNING!

Allow the electronics to de-energize before opening the electronics compartment of the flow
converter housing. Wait at least 35 minutes for T6 and 10 minutes for T5 before opening.

OPTISONIC 7300 / 8300

22

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OPTISONIC 7300 / 8300

Figure 4-1: Electrical connections of converter

1 Mains supply connections
2 I/O connections

Terminals Function, electrical data

ELECTRICAL CONNECTIONS 4

L, N

L+, L- 12...24 VDC, +30% / -10% (short periods -25%), 12W

A, A-, A+
B, B­C, C­D, D-

100...230 VAC, +10% / -15%, 22 VA, 50/60 Hz
Internal fuse protection IN ≤ 0.8 A

Um = 253 V

Connections for mains supply, always non-Ex i

Internal fuse protection IN ≤ 2.0 A
Um = 253 V

24 VACDC, 22 VA / 12W
24 VAC, +10% / -15%, 50/60 Hz
24 VDC, +30% / -25%
Internal fuse protection IN ≤ 2.0 A

= 253 V

U

m

Connections for mains supply, always non-Ex i

Connection to protective extra low voltage (PELV)
Connections for signal I/Os (PELV circuits), non-“Ex i” or “Ex i”,

are dependent on the specific version of the GFC 300
converter ordered. Consult the tables with CG36 numbers for
details.

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4 ELECTRICAL CONNECTIONS

The exact I/O-configuration for circuits A, B, C and D is order-specific and can be determined by
the CG36 number shown on the I/O sticker inside the terminal compartment. Therefore check
the data on the back of the GFC 300 electronics unit. The CG36 number contains 10 characters of
which the last three characters (XYZ) determine the configuration of the I/O circuits:

CG36 * * * X Y Z

Pos 1...4 5 6 7 8 9 10

OPTISONIC 7300 / 8300

determine I/O circuits

For schematic overviews of the CG36 numbers, refer to
and refer to
connection diagram of a specific GFC 300 signal converter can be found on the sticker inside the
terminal compartment.

For use in gaseous hazardous areas:

For use in gaseous hazardous areas: The chosen cable glands must have the appropriate type of

For use in gaseous hazardous areas:For use in gaseous hazardous areas:
protection for the terminal compartment that is increased safety (Ex e) or flameproof enclosure
(Ex d). They MUST be suitable for the conditions of use and correctly installed.

The flowmeter with the terminal compartment in type of protection increased safety “Ex e” is
factory supplied with two or three “Ex e” approved cable glands and one or no “Ex e” approved

blanking element (i.e. stopping plug).

"Ex i" I/O connections

on page 27. These overviews do not show all details. The exact

Non-"Ex i" I/O connections

on page 25

WARNING!

“

The flowmeter with the terminal compartment performed as flameproof enclosure

“

supplied with one

Ex d” approved stopping plug and two temporary plugs. The temporary plugs

Ex d” is

are only intended for sealing the housing against entry of dust, moisture or else during

“

transport, handling and storage. These temporary plugs must be replaced by suitable

Ex d”
approved cable glands, stopping plugs or conduit adapters with sealing devices before the
flowmeter is put into operation. Unused openings must be sealed by suitable certified plugs.

The wiring of instruments has to be in accordance with the requirements as specified in the
relevant national or international standard for electrical installations in hazardous areas, e.g.
EN 60079-14. Section 9 (wiring systems) of this standard applies to all types of protection.

Section 10 (additional requirements for type of protection “d” - flameproof enclosures), section
11 (additional requirements for type of protection “e” - increased safety) and section 12
(additional requirements for type of protection “i” - intrinsic safety) apply to respectively “Ex d”,
“Ex e” and “Ex i” performed connection (terminal) compartments.

24

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OPTISONIC 7300 / 8300

4.2 Non-"Ex i" I/O connections

The following non-intrinsically safe I/O (inputs/outputs) are available:

I/O PCB Input/output functions,

Basic I/O Current Output, active or passive, with HART

Modular I/O Current Output, active or passive, with HART

Modular carrier with 1 or 2 I/O modules Each module: 1 out of following 3 in-/output

Profibus DP I/O Profibus-DP, active

Fieldbus I/O Profibus-PA or Foundation Fieldbus

RS 485 Modbus Modbus with or without termination
The options separated by “/” are software selectable (can be changed by the user)

The options separated by “or” are hardware versions (must be ordered as such)
All outputs are passive unless otherwise indicated
HighC means High Current input/output, Namur means that the in-/outputs are according to the NAMUR
NE43 standard

ELECTRICAL CONNECTIONS 4

U

< 32 V DC, In < 100 mA, Um = 253 V

n

Status Output / Control Input
Status Output
Pulse / Status Output

Pulse / Status Output, active or passive, highC or
Namur

functions:
Current Output, active or passive
Pulse / Status Output, active or passive, highC or
Namur
Control Input, active or passive, highC or Namur

Overview of the possible combinations, defined by characters XYZ of the CG36 number

Characters
XYZ

100 Basic I/O CO

488 to 4LL
588 to 5LL
688 to 6LL
788 to 7LL
888 to 8LL
A88 to ALL
B88 to BLL
C88 to CLL

D88 Fieldbus I/O

D8A to DLL Fieldbus I/O

E88 Fieldbus I/O

E8A to ELL Fieldbus I/O

Name of I/O
circuits

Modular I/O
or
Modular
Carrier with 1
or 2 I/O
modules

Profibus PA

Profibus PA
with Module
Carrier with 1
or 2 I/O
modules

Foundation
Fieldbus

Profibus PA
with Module
Carrier with 1
or 2 I/O
modules

Terminals
A, A-, A+

CO(a) over A+

Many combinations possible

n.c. n.c. PA PA

Many combinations possible PA PA

n.c. n.c. FF FF

Many combinations possible FF FF

Terminals
B, B-

SO/CI SO PO/SO

Terminals
C, C-

Terminals
D, D-

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4 ELECTRICAL CONNECTIONS

Overview of the possible combinations, defined by characters XYZ of the CG36 number

OPTISONIC 7300 / 8300

Characters
XYZ

F00 to FL0 Profibus DP I/O n.c. DP(a) DP(a) DP(a)

F80 to FL0 Profibus DP I/O

G00 to GLL RS 485 Modbus Many combinations possible RS485 RS485

H00 to HLL Modbus with 1

Used abbreviations for in-/output functions: CO = Current Output, PO = Pulse Output, SO = Status Output,
CI = Control Input, PA = Profibus PA, FF = Foundation Fieldbus, DP = Profibus DP, RS485 = RS 485
Modbus, n.c. = not connected.
All in-/outputs are passive unless otherwise noted as active with extension (a).

Name of I/O
circuits

with 0 or 1 I/O
module

or 2 I/O
modules

Terminals
A, A-, A+

Many
combinations
possible

Terminals
B, B-

DP(a) DP(a) DP(a)

Terminals
C, C-

Terminals
D, D-

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OPTISONIC 7300 / 8300

4.3 "Ex i" I/O connections

The following intrinsically safe I/O connections are available:

I/O PCB I/O functions

ELECTRICAL CONNECTIONS 4

Ex i IO Current Output, passive + HART

communication
Pulse / Status Output, passive

Current Output, active + HART
communication

Ex i Option Current Output, passive

Pulse / Status Output / Control
Input, passive

Current Output, active Ex ia IIC or Ex ib IIC

Ex i Option 2 Current Input, passive

Pulse / Status Output / Control
Input, passive

Current Input, active Ex ia IIC or Ex ib IIC

Fieldbus I/O Profibus-PA

Foundation Fieldbus, passive

Ex ia IIC or Ex ib IIC
Ui = 30 V, Ii = 100 mA, Pi = 1.0 W

Ci = 10 nF, Li = negligibly low

Ex ia IIC or Ex ib IIC
Uo = 21 V, Io = 90 mA, Po = 0.5 W

Lineair characteristics

= 90 nF, Lo = 2.0 mH

C

o

Co = 110 nF, Lo = 0.5 mH

Ex ia IIC or Ex ib IIC
Ui = 30 V, Ii = 100 mA, Pi = 1.0 W

= 10 nF, Li = negligibly low

C

i

Uo = 21 V, Io = 90 mA, Po = 0.5 W
Lineair characteristics

Co = 90 nF, Lo = 2.0 mH

= 110 nF, Lo = 0.5 mH

C

o

Ex ia IIC or Ex ib IIC
Ui = 30 V, Ii = 100 mA, Pi = 1.0 W

Ci = 10 nF, Li = negligibly low

Uo = 24.1 V, Io = 99 mA, Po = 0.6 W
Lineair characteristics

= 75 nF, Lo = 0.5 mH

C

o

Ex ia IIC or Ex ib IIC / IIB
Ui = 24 V, Ii = 380 mA, Pi = 5.32 W

Ci = 5 nF, L
Suitable for connection to an

intrinsically safe fieldbus in
accordance with the FISCO­model

= 10 µH

i

The I/O circuits titled “Ex i IO” , "Ex i Option" and “Ex i Option 2” are always provided with type of
protection Intrinsic Safety (Ex ia). The I/O-circuits “Fieldbus I/O Profibus-PA” as well as “Fieldbus
I/O Foundation Fieldbus” can be provided with type of protection Intrinsic Safety.

Up to a maximum of 4 intrinsically safe (Ex ia) in-/outputs are possible. All intrinsically safe
circuits are galvanically isolated from earth and each other. To avoid summation of voltages and

current, the wiring of these “Ex ia”-circuits must be sufficiently separated, e.g. in accordance

with the requirements of standard EN 60079-14, clause 12.2.

The “Ex ia” in-/outputs may only be connected to other “Ex ia” or “Ex ib” approved devices (e.g.

intrinsically safe isolation amplifiers), even if such devices are installed in a non-hazardous
location!

Connection to non-“Ex i” devices cancels the “Ex ia” properties of the flowmeter.

Terminals L and N (or L+ and L-) for connection of the mains supply are not available with type of

protection “intrinsic safety”. To achieve the necessary separation distances according to EN
60079-11 between the non-”Ex i” and “Ex i” circuits, the mains terminals are provided with a
semi-circular protection cover with a “snap-in” lock. This cover MUST be closed before

establishing the power supply to the converter.

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4 ELECTRICAL CONNECTIONS

INFORMATION!

“

For converters with an
energized state for short periods of time, to access the intrinsically safe terminals for possible
checks. However, the semi-circular insulation cover over the non-intrinsically safe mains supply
terminals L and N (or L+ and L-) MUST be kept closed.

Overview of possible "Ex ia" in-/outputs, defined by characters XYZ of the CG 36 numbers

Ex e” terminal compartment, the compartment can be opened in an

OPTISONIC 7300 / 8300

Characters
XYZ

200 Exi-IO n.c. n.c. CO(a) PO/SO

300 n.c. n.c. CO PO/SO

210 Exi-IO with Exi-

220 CO PO/SO/CI CO(a) PO/SO

310 CO(a) PO/SO/CI CO PO/SO

320 CO PO/SO/CI CO PO/SO

230 Exi-IO with Exi-

330 Iina active PO/SO/CI CO PO/SO

240 Iinp passive PO/SO/CI CO(a) PO/SO

340 Iinp passive PO/SO/CI CO PO/SO

D00 Fieldbus I/O

D10 Fieldbus I/O

D20 CO PO/SO/CI PA PA

E00 Fieldbus I/O

E10 Fieldbus I/O

E20 CO PO/SO/CI FF FF

Used abbreviations for in-/output functions: CO = Current Output, PO = Pulse Output, SO = Status Output,
CI = Control Input, n.c. = not connected
All in-outputs are passive unless otherwise noted as active with extension (a).

Name of I/O
circuits

Option

Option 2

Profibus PA

Profibus PA
with Ex i Option

Foundation
Fieldbus

Foundation
Fieldbus with
Ex i Option

Terminals
A, A-, A+

CO(a) PO/SO/CI CO(a) PO/SO

Iina active PO/SO/CI CO(a) PO/SO

n.c. n.c. PA PA

CO(a) PO/SO/CI PA PA

n.c. n.c. FF FF

CO(a) PO/SO/CI FF FF

Terminals
B, B-

Terminals
C, C-

Terminals
D, D-

28

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OPTISONIC 7300 / 8300

5.1 Maintenance

The flowmeters are maintenance free with respect to the flowmetering properties. Within the
scope of periodic inspections required for electrical equipment installed in hazardous areas it is
recommended to check the flameproof converter housing and covers for signs of damage or
corrosion.

5.2 Before and after opening

WARNING!

the following instructions must always be carefully followed, if the housing of the signal
converter has to be opened respectively closed again.

Before opening:

• Make absolutely sure that there is no explosion hazard!

• Gas-free certificate!

• Make sure that all connecting cables are safely isolated from all external sources!

• Allow the electronics to de-energize before opening the electronics compartment of the

converter housing. Wait at least 35 minutes for T6 and 10 minutes for T5 before opening.

MAINTENANCE 5

When the instructions above are strictly followed, the display cover (includes glass window) of
the electronics compartment may be removed. First unscrew the head screw with internal
hexagon socket set (size M4) of the interlocking device by a No. 3 Allen key, until the cover can
rotate freely.

After opening:

• Before the cover is screwed back onto the housing, the screw-thread must be clean and well-

greased with an acid and resin-free grease, e.g. PTFE grease.

• Screw the cover as tight as possible onto the housing by hand, until it cannot be opened by

hand anymore. Fixate the screw of the interlocking device tight with the No. 3 Allen key.

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29

5 MAINTENANCE

5.3 Replacement of mains fuse

WARNING!

Before commencing the work, refer to Before and after opening on page 29

follows:

• Pull the display unit of the mounting frame and turn display unit carefully aside.

• Unscrew the two screws size M4 that hold the mounting frame with the electronics unit.

• Carefully pull the mounting frame with electronics unit out of the housing, until the small

printed circuit board with the six soldered coaxial cables can be pulled off of the sensor driver
PC-board. Now carefully remove the unit from the housing, while keeping the small printed
circuit board with coaxial cables down, close to the housing wall.

• The mains fuse is located in a fuse holder at the back-end of the electronics unit on the top

printed circuit board (power supply PCB). The specifications must be as follows:

Fuse type: 5 x 20 mm (H) according to IEC 60127-2/V

Fuse type: 5 x 20 mm (H) according to IEC 60127-2/V

Fuse type: 5 x 20 mm (H) according to IEC 60127-2/VFuse type: 5 x 20 mm (H) according to IEC 60127-2/V

Power supply

Power supply Electrical data

Power supplyPower supply

12...24 V DC 250 V / 2 A

24 V AC/DC 250 V / 2 A

100...230 V AC 250 V / 0,8 A

Electrical data

Electrical dataElectrical data

OPTISONIC 7300 / 8300

, then continue as

WARNING!

Before reassembling the unit, refer to Before and after opening on page 29

• Reassemble the unit in reverse order.

, then:

30

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OPTISONIC 7300 / 8300

5.4 Exchange of electronics unit

Before opening the converter housing:

Before opening the converter housing:

Before opening the converter housing:Before opening the converter housing:

DANGER!

All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!

WARNING!

Observe without fail the local occupational health and safety regulations. Any work done on the
electrical components of the measuring device may only be carried out by properly trained
specialists.

INFORMATION!

Make notes of important specific data, before exchanging the electronics.
Menu settings are stored on the circuit board (or backplane), that is fixed to the housing. After
exchange of electronics unit and power-up, the following start up screen appears:
Load all data?

Load all data?

Load all data?Load all data?

MAINTENANCE 5

• Select yes

i - if in the screen appears “load sensor data

compatible. You can proceed by selecting yes. Note that all settings need to be checked and
changed. Only the sensor calibration data are loaded.

- if in the screen appears “load no data
representative.

load sensor data”, the electronics units were not fully

load sensor dataload sensor data

load no data”, all data have been lost. Contact your local

load no dataload no data

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31

5 MAINTENANCE

5.4.1 Field version

DANGER!

All work on the electrical connections may only be carried out with the power disconnected. Take
note of the voltage data on the nameplate!

OPTISONIC 7300 / 8300

Figure 5-1: Unscrew the cover and remove the display

Figure 5-2: Pull off printed circuit board

Perform the following procedures:

• Unscrew the display cover of the electronics compartment by hand, by turning it counter

clockwise 1.

• Remove the display by using two screwdrivers 2.

• Unscrew the two M4 screws 3 at the electronics unit 4.

• Pull the two metal pullers 5 at the left and right of the display, using a screwdriver or similar

tool and partially pull out the electronics unit.

32

CAUTION!

Please pay attention that the same amount of force is applied on both pullers, otherwise the
connector at the backside can be damaged.

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OPTISONIC 7300 / 8300

Figure 5-3: Small printed circuit board and electronics unit

MAINTENANCE 5

DANGER!

Electrostatic discharge (ESD) can damage electronic parts. Make sure to discharge yourself by
wearing a wrist strap. If no wrist strap is available, ground yourself by touching a metal surface
that is grounded.

• Remove the printed circuit board 6 from the electronics unit 4.

• Check compatibility between the removed and new electronics unit 4, by checking the power

voltage.

• Slide the new electronics unit 4 partially back into the housing.

• Mount the small printed circuit board back onto the electronics unit 4.

• Push the metal pullers 5 back to their original position.

Don't use excessive force, otherwise the connector at the backside can be damaged!

• Screw the electronics unit back to the housing.

• Re-install the display and make sure not to kink the display's flat ribbon cable.

• Replace cover and tighten by hand.

• Connect power.

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33

5 MAINTENANCE

5.5 Service / repair information

This device has been carefully manufactured and tested. If installed and operated in accordance
with these operating instructions, it will rarely present any problems.

CAUTION!

Should you nevertheless need to return a device for inspection or repair, please pay strict
attention to the following points:

•

Due to statutory regulations on environmental protection and safeguarding the health and
safety of our personnel, the manufacturer may only handle, test and repair returned devices
that have been in contact with products without risk to personnel and environment.

•

This means that the manufacturer can only service this device if it is accompanied by the
following certificate (see next section) confirming that the device is safe to handle.

CAUTION!

If the device has been operated with toxic, caustic, flammable or water-endangering products,
you are kindly requested:

•

to check and ensure, if necessary by rinsing or neutralizing, that all cavities are free from
such dangerous substances,

•

to enclose a certificate with the device confirming that is safe to handle and stating the
product used.

OPTISONIC 7300 / 8300

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OPTISONIC 7300 / 8300

5.6 Form (for copying) to accompany a returned device

Company: Address:

Department: Name:

Tel. no.: Fax no.:

Manufacturer's order no. or serial no.:

The device has been operated with the following medium:

MAINTENANCE 5

This medium is: water-hazardous

toxic

caustic

flammable

We checked that all cavities in the device are free from such
substances.

We have flushed out and neutralized all cavities in the
device.

We hereby confirm that there is no risk to persons or the environment through any residual media
contained in the device when it is returned.

Date: Signature:

Stamp:

5.7 Disposal

CAUTION!

Disposal must be carried out in accordance with legislation applicable in your country.

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35

KROHNE product overview

• Electromagnetic flowmeters

• Variable area flowmeters

• Ultrasonic flowmeters

• Mass flowmeters

• Vortex flowmeters

• Flow controllers

• Level meters

• Temperature meters

• Pressure meters

• Analysis products

• Products and systems for the oil & gas industry

• Measuring systems for the marine industry

Head Office KROHNE Messtechnik GmbH
Ludwig-Krohne-Str. 5
47058 Duisburg (Germany)
Tel.:[phone]
Fax:[phone]
[e-mail]

© KROHNE 05/2012 - 7312262200 - AD EX OPTISONIC 7300/8300 R02 - Subject to change without notice.

The current list of all KROHNE contacts and addresses can be found at:
www.krohne.com