Systec IT8000-DC-W-Ex2/22, IT8000-AC-W-Ex2/22, IT8000-AC-E-Ex2/22, IT8000-DC-E-Ex2/22 Technical Manual
Technical Manual
IT8000-AC-W-Ex2/22
IT8000-DC-W-Ex2/22
IT8000-AC-E-Ex2/22
IT8000-DC-E-Ex2/22
Freely Programmable Weighing Terminal
For Installation In Ex Zone 2 / 22
II 3G Ex ic nA IIC T4 Gc
II 3D Ex ic tc IIIB T50°C Dc IP54
or II 3D Ex ic tc IIIC T50°C Dc IP65
August 2013
ST.2309.1327
Rev. 4
© SysTec Systemtechnik und Industrieautomation GmbH, Bergheim, Germany
2 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 3
Technical Manual IT8000-**-*-Ex2/22
Date: August 30, 2013
File: IT8000_EX222_THE.DOC
Operating System: RTP 7.1 or higher
4 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
Published By:
© SysTec Systemtechnik und Industrieautomation GmbH, Bergheim, Germany
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted
in any form or by any means, mechanical, photocopying, recording, or otherwise, without the prior written
permission of SysTec GmbH.
Terms and product names mentioned in this publication are trademarks, registered trademarks or
service marks of their respecti
ve owners. Use of a term should not be regarded as affecting the validity
of any trademark, registered trademark or service mark.
EPSON ESC/P® is a registered trademark of the SEIKO EPSON Corporation.
TOLEDO® is a registered trademark of Mettler-Toledo Inc.
Please Note:
While every precaution has been taken in the preparation of this manual, SysTec GmbH assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of
the information contained herein.
The publisher is grateful for any information and/or advice that may contribute to correct errors or omissions
in following editions.
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 5
Contents
1 Introduction ......................................................................................................................... 7
1.1 About This Manual....................................................................................................... 7
1.2 Safety Symbols Used In This Manual .............................................................................. 7
1.3 Safety Advice ............................................................................................................. 7
1.4 Declaration Of Conformity............................................................................................. 9
2 Marking............................................................................................................................. 10
3 System Description ............................................................................................................. 11
3.1 General .................................................................................................................... 11
3.2 Basic Units And Options ............................................................................................. 11
3.3 Housing.................................................................................................................... 12
3.4 Main Board CPU8000 ................................................................................................. 13
4 Intended Use ..................................................................................................................... 14
5 Assembly .......................................................................................................................... 15
6 Installation......................................................................................................................... 16
6.1 General .................................................................................................................... 16
6.2 Equipotential Bonding ................................................................................................. 16
6.3 Shielding .................................................................................................................. 16
6.4 Connection Of Cables................................................................................................. 17
7 Installation Of External Connections With Type Of Protection 'Ex-nA' ........................................ 18
7.1 Connection Of Power Supply To IT8000-AC-*-Ex2/22 .................................................... 18
7.2 Connection Of Power Supply To IT8000-DC-*-Ex2/22 .................................................... 19
7.3 Connection Of Analog Scale To ADM / ADC .................................................................. 22
7.4 Connection Of IDNet Scale Base To IDN........................................................................ 25
7.5 Connection Of Digital Scale Bases With RS485 Interface To DWM.................................... 27
7.6 Connection Of Serial Interfaces SIM ............................................................................. 30
7.7 Connection Of Parallel I/Os PIM ................................................................................... 34
7.8 Connection Of Fieldbus Module FBM ............................................................................ 37
7.9 Connection Of Profibus DP Module PCM ....................................................................... 38
7.10 Connection Of Ethernet Module ECM .......................................................................... 40
7.11 Connection Of 15-Bit Analog Output DAU15 ............................................................... 42
8 Commissioning................................................................................................................... 44
8.1 General .................................................................................................................... 44
9 Installation Examples........................................................................................................... 45
9.1 Installation Example IT8000-AC-*-Ex2/22 ..................................................................... 45
9.2 Installation Example IT8000-DC-*-Ex2/22 ..................................................................... 46
9.3 Installation Example IT8000-DC-*-Ex2/22 With Akku-Box................................................ 47
10 Service Mode ................................................................................................................... 48
10.1 General................................................................................................................... 48
10.2 Display And Keyboard .............................................................................................. 49
10.3 Operator Prompting .................................................................................................. 50
10.4 Overview ................................................................................................................ 51
10.5 Interface Configuration ............................................................................................. 52
10.6 Header Ident Data .................................................................................................... 56
10.7 Detail Ident Data ...................................................................................................... 57
10.8 Application Setup..................................................................................................... 58
10.9 RAM Data Backup.................................................................................................... 61
6 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
10.10 Hardware Test ....................................................................................................... 62
10.11 S5 Data Block ........................................................................................................ 68
11 Transport, Maintenance And Cleaning .................................................................................. 69
11.1 Transport ................................................................................................................69
11.2 Maintenance ............................................................................................................ 69
11.3 Replacement Of Fuse (Only IT8000-DC-*-Ex2/22)......................................................... 69
11.4 Cleaning.................................................................................................................. 70
11.5 Security Check.........................................................................................................70
11.6 Functional Test ........................................................................................................ 70
11.7 Repair.....................................................................................................................70
11.8 De-Installation..........................................................................................................70
11.9 Disposal ..................................................................................................................70
12 Trouble Shooting............................................................................................................... 71
13 Technical Data.................................................................................................................. 72
13.1 Basic Units .............................................................................................................. 72
13.2 Options................................................................................................................... 73
13.3 Ex-Relevant Electrical Data For Type Of Protection 'Ex-nA' ............................................. 74
14 Annex ............................................................................................................................. 77
14.1 ACK/NAK-Protocol.................................................................................................... 77
14.2 Exchange Of EPROMs ............................................................................................... 78
14.3 Replacing The Battery ............................................................................................... 81
14.4 Combination Of Options ............................................................................................ 83
15 Dimensions ...................................................................................................................... 84
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 7
1 Introduction
1.1 About This Manual
This manual contains information and Technical Data for the use, the installation and the operation of
the weighing terminal IT8000-AC-W-Ex2/22, IT8000-AC-E-Ex2/22, IT8000-DC-W-Ex2/22 and IT8000DC-E-Ex2/22.
Information applicable to all versions refers to 'IT8000-Ex2/22'. Specific information is marked with the
full designation of the respective version, e.g. IT8000-DC-W-Ex2/22.
The weighing terminal must only be operated by trained personnel.
In addition to this manual further information is provided in the following documentation:
ADM / DUAL-ADM / ADM8000-Exi Calibration Manual, Order-No.: ST.2309.0688
MultiRange Calibration Manual, Order-No.: ST.2309.0057
Revere SLC, Calibration Manual, Order-No.: ST.2309.0362
HBM C16i, Calibration Manual, Order-No.: ST.2309.0248
1.2 Safety Symbols Used In This Manual
Safety relevant information is shown with corresponding symbols as follows:
Ex
W A R N I N G
Failure to observe this precaution could result in serious injuries or fatal accidents due to
ignition of an explosive atmosphere. Please make absolutely sure that these precautions are
observed in order to ensure safe operation of the equipment.
W A R N I N G
Failure to observe this precaution could result in serious injuries or fatal accidents. Please make
absolutely sure that these precautions are observed in order to ensure safe operation of the
equipment.
CAUTION
Failure to observe this precaution could result in damage to or destruction of the equipment or
bodily harm! Please make absolutely sure that these precautions are observed in order to ensure
safe operation of the equipment.
Note: This indicates an advice for the designated use of the equipment and/or additional information to
avoid inappropriate handling.
1.3 Safety Advice
Ex
W A R N I N G
Before opening the housing make absolutely sure that all power sources to this instrument are
disconnected and that no potentially explosive atmosphere can be present at any time!
The de-energized state is reached by disconnecting the supply voltages to the instrument and
to all external devices connected to the interfaces of the weighing terminal.
Ex
W A R N I N G
Exercise utmost care when making checks, tests and adjustments that can actuate movable
parts such as feeding devices, gates, flaps, conveyors, etc. Make absolutely sure that nobody
is within reach of movable parts.
8 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
Ex
W A R N I N G
When this unit is included as a component part of a system, the resulting system design must
be reviewed by qualified personnel who are familiar with the construction and operation of all
individual components in the system and the potential hazards involved.
Ex
W A R N I N G
For installation, service and operation of the unit, the ATEX directive as well as all locally
applicable regulations for safety and the prevention of accidents must be observed!
Ex
W A R N I N G
Input voltage of the instrument must comply with local mains supply!
Ex
W A R N I N G
This module and its associated equipment must only be installed, adjusted and maintained by
qualified personnel authorized by SysTec GmbH!
Ex
W A R N I N G
Connection of peripheral devices to IT8000-Ex2/22 is made in compliance with Ex type of
protection 'Ex-nA'. The values of connected load must be observed. Connected peripheral
devices installed in hazardous area must have appropriate Ex protection.
Ex
W A R N I N G
When the instrument is permanently connected to the power supply, an easily accessible
separator must be included in the supply circuit! It must either be located in safe area or -if
installed in Ex area- have appropriate Ex protection for the place of installation.
Ex
W A R N I N G
The weighing terminal must not be installed in areas where electrostatic charging is possible
which may produce spark discharges, brush discharges or propagating brush discharges at the
front panel.
Comment: According to common knowledge, the use of the equipment and the cleaning with a
damp cloth do not produce such a high surface charge density. However, the front panel must
not be wiped with a dry cloth!
W A R N I N G
Risk of electrical shock! When operating electrical devices, parts of this devices are connected
to dangerously high voltages. Inappropriate use of such devices may lead to serious bodily
injuries or substantial damages to property.
W A R N I N G
The power supply unit of the weighing terminal provides SELV voltages in accordance with EN
60950. Make sure that any peripheral device connected to the weighing terminal containing its
own power supply also uses SELV voltages!
Ex
W A R N I N G
This weighing terminal must not be used in Ex-Zone 0, 1, 20 and 21.
It is the sole responsibility of the employer / operating company to classify the area of
installation (zone, group, temperature class). To that effect, the assistance of the Technical
Supervisory Service or any other technical authority may be utilized!
W A R N I N G
The device uses the short-circuit / overcurrent protection of the on-site mains supply.
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 9
1.4 Declaration Of Conformity
10 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
2 Marking
Systec Systemtechnik und Industrieautomation GmbH
Ludwig-Erhard-Straße 6
Manufacturer
50129 Bergheim-Glessen
IT8000-AC-W-Ex2/22
IT8000-AC-E-Ex2/22
IT8000-DC-W-Ex2/22
Designation
IT8000-DC-E-Ex2/22
Serial-No. Ex yy nnnn (yy=year of construction / nnnn=consecutive number)
Range of ambient temperature –10°C to +40°C
Ex classification
II 3G Ex ic nA IIC T4 Gc
II 3D Ex ic tc IIIB T50°C Dc IP54 or
II 3D Ex ic tc IIIC T50°C Dc IP65
CE marking
Type examination certificate TÜV 11 ATEX 7618 X
Service Only by qualified service personnel authorized by SysTec GmbH
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 11
3 System Description
3.1 General
IT8000Ex is a universal weighing terminal for use in a variety of applications such as data logging, data
capturing and set point control, suitable for installation in Ex zones 2 and 22.
It connects to weighing platforms with analog or digital force transducers. The analog version supports
the connection of up to two understructures with a total of up to 16 strain gauge loadcells with an
impedance of 350 each in any combination. By means of an external extension module it is possible
to connect up to 6 additional understructures.
Alternatively, understructures with digital force transducers can be connected.
With its modular concept, the IT8000-Ex2/22 features in its basic configuration three serial interfaces
as well as four parallel opto-isolated inputs and four opto-isolated outputs for external devices. For
more complex applications several interface extension modules are available, for a fourth serial
interface (FBM), Profibus DP (PCM) or Ethernet communication ECM).
The variable I/O design provides up to 64 digital inputs and 64 digital outputs, plus analog inputs /
outputs.
The IT8000-Ex2/22 is freely programmable, operation and program sequence can be easily adapted to
the specific application. Comprehensive standard software is available for standard applications such as
filling, batching, checkweighing, data logging, truck weighing, etc. The design of custom-specific
programs is possible with the RTG program generator which provides the tools for simple and efficient
programming.
3.2 Basic Units And Options
IT8000-Ex2/22 is available in 4 basic versions:
Type Housing Description Article-No.
IT8000-AC-W-Ex2/22 Wall-mount/
desk-top
Basc unit for wall-mount / desk-top installation
with 2.5m line cord with free ends
to connect to 110 - 240 VAC
X8SYS001
IT8000-AC-E-Ex2/22 Panel-mount Basic unit for panel-mount installation
with 2.5m line cord with free ends
to connect to 110 - 240 VAC
X8SYS011
IT8000-DC-W-Ex2/22 Wall-mount/
desk-top
Basc unit for wall-mount / desk-top installation
with screw terminals
to connect to 12 – 30 VDC
X8SYS005
X8SYS006*
IT8000-DC-E-Ex2/22 Panel-mount Basic unit for panel-mount installation
with screw terminals
to connect to 12 – 30 VDC
X8SYS015
X8SYS016*
* The versions X8SYS006 and X8SYS016 feature the main module CPU8000-NTP-Ex2/22 that
provides low-battery indication for battery operation.
12 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
The following modules are available as options:
Option Description Article-No.
ADM Plug-on weighing module for connection of analog loadcells 13OPT100
ADC Plug-on weighing module for connection of analog loadcells 17OPT100
IDN Plug-on module to connect one digital IDNet platform 17OPT101
DWM Plug-on module to connect one digital platform with RS485 interface 17OPT103
SIM-RS232 Plug-on module with serial RS232 interface 10OPT220
SIM-20mA Plug-on module with serial 20mA interface 10OPT221
SIM-RS485.4 Plug-on module with serial RS485 4-wire interface 10OPT222
SIM-RS485.2 Plug-on module with serial RS485 2-wire interface 10OPT225
SIM-RS485.Opto Plug-on module with opto-isolated serial RS485 interface 10OPT230
DAU15 Plug-on module with analog 0/2-10V or 0/4-20mA output 10OPT231
PIM Plug-on module with two digital inputs/outputs 10OPT300
FBM Plug-on module with socket for fourth serial interface 11OPT301
PCM Plug-on module with Profibus-DP interface 17OPT400
ECM Plug-on module with Ethernet interface
(11OPT304-5/10 incl. 5m/10m Ethernet-Kabel)
11OPT304
3V battery 3V lithium battery Varta CR ½ AA 96ZUB002
3.3 Housing
IT8000-Ex2/22 is incorporated in a stainless steel housing with cable glands to connect cables to
peripheral devices. It is available in two versions:
The housing for desk-top / wall-mount installation (IT8000-**-W-Ex2/22) is protected to IP65.
The housing for panel-mount installation (IT8000-**-E-Ex2/22) is inserted in a suitable cutout of a
switch cabinet and fixed from the rear with 8 mounting brackets. When installed accordingly, the front
of the terminal -in combination with the circumferential gasket between terminal and switch cabinet- is
protected to IP65. When installed in Ex zone 2 (as per II 3G Ex ic nA IIC T4 Gc) and Ex zone 22 with
non-conductive dust (as per II 3D Ex ic tc IIIB T50°C Dc IP54) the surrounding housing must be
protected to IP54 or better.
When installed in Ex zone 22 with conductive dust (as per II 3D Ex ic tc IIIC T50°C Dc IP65) the
surrounding housing must be protected to IP65 or better. The surrounding housing (e.g. switch cabinet)
must conform to the requirements of EN60079-0 section 26.4.
Ex
The housings must be included in the equipotential bonding of the installation.
See section 'Dimensions' for space requirements.
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 13
3.4 Main Board CPU8000
The main board contains the Central Processing Unit of the industrial weighing terminal IT8000Ex2/22. It includes the 32bit/16MHz microprocessor 68HC000, 1 MByte battery-backed data,
128 kByte application memory and a battery backed realtime clock..
It is available in three different versions:
Main board Description Used for
CPU8000-230V-Ex2/22 CPU8000 with 110-240 VAC PSU IT8000-AC-*-Ex2/22
Article-No. X8SYS0x1
CPU8000-24VDC-Ex2/22 CPU8000 with 12–30 VDC PSU IT8000-DC-*-Ex2/22
Article-No. X8SYS0x5
CPU8000-NTP-Ex2/22 CPU8000 with 12-30 VDC PSU
and low-bat detection
IT8000-DC-*-Ex2/22
Article-No. X8SYS0x6
Two sockets are provide to insert A/D converters (ADM or ADC) for the connection to understructures
with analog loadcells. Three serial interfaces can be individually configured by means of plug-on
modules (SIM) as RS232, RS485 or 20mA interfaces. Two additional slots can be fitted with plug-on
modules for parallel I/Os (PIM) which contain 2 inputs and two outputs each. For the connection to an
interface expansion board (FBM or PCM) appropriate connectors are available.
Also included on the main board is the wide range power supply, alternatively in AC or DC version.
For information on how to change memory components refer to section 'Changing of EPROMs' in the
annex of this manual.
Position of components on the CPU8000 main board
Socket 2 Connector X2 Socket 1 Terminal KL3/KL2/KL1 Terminal KL4/KL5 Connection AC or
for ADM2 (MFII Keyboard) for ADM1 (SIM3/SIM2/SIM1) (PIM2/PIM1) DC power supply
Lithium Connector X7 Connector X8-X11 Connector X1
battery (Display) (Interface expansion) Keyboard
14 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
4 Intended Use
In compliance with RL 94/9/EG (ATEX 95) appendix I, the weighing terminal IT8000-Ex2/22 is
an apparatus of group II category 3G, that following RL 99/92/EG (ATEX 137), can be used in
zone 2, as well as in gas groups IIA, IIB and IIC, which are at risk of explosion through
combustible substances of temperature classes T1 to T4. The following instructions on the
installation of the IT8000-**-E-Ex2/22 in a surrounding housing must be observed.
IT8000-Ex2/22 is also an apparatus of group II category 3D, that following RL 99/92/EG (ATEX
137) can be used in zone 22 (dust), the maximum surface temperature is 50°C. The following
instructions on the installation of the IT8000-**-E-Ex2/22 in a surrounding housing must be
observed.
Applicable only to IT8000-**-E-Ex2/22: The housing for panel-
mount installation is inserted in a
suitable cutout of a switch cabinet and fixed from the rear with 8 mounting brackets. If
installed accordingly, the front of the terminal -in combination with the circumferential gasket
between terminal and switch cabinet- is protected to IP65. When installed in Ex zone 2 (as per
II 3G Ex ic nA IIC T4 Gc) and Ex zone 22 with non-conductive dust (as per II 3D Ex ic tc IIIB
T50°C Dc IP54) the surrounding housing must be protected to IP54 or better. When installed in
Ex zone 22 with conductive dust (as per II 3D Ex ic tc IIIC T50°C Dc IP65) the surrounding
housing must be protected to IP65 or better. The surrounding housing (e.g. switch cabinet)
must conform to the requirements of EN60079-0 section 26.4.
The weighing terminal must not be installed in areas where electrostatic charging is possible
which may produce spark discharges, brush discharges or propagating brush discharges at the
front panel.
All external connections are designed for type of protection Ex 'nA'. The connection values
shown in chapter 'Installation of external connections with type of protection Ex-nA' must be
observed.
Ex
When installed in hazardous area, all peripheral devices connected to IT8000-Ex2/22 must have
appropriate Ex protection.
The metal housing of the IT8000-Ex2/22 terminal must be integrated at the PA stud into the
equipotential bonding system of the installation. Use serrated washers.
The permissible range of ambient temerature is –10°C to +40°C.
When installing IT8000-**-E-Ex2/22 in a switch cabinet (panel-mount version), this
temperature range also apllies to the inside the switch cabinet.
Furthermore, for use and installation all requirements as per EN 60079-14 must be observed.
Any other but the intended use of the equipment, modifications and extensions must not be
made without the explicit approval of the manufacturer and is deemed not to be intended. Part
of the intended use is observance of this Technical Manual and the adherence to inspection and
maintenance instructions and intervals. The manufacturer does not assume any liability
whatsoever for damages resulting from non-intended use. Any risk resulting from non-intended
use is solely borne by the user.
The weighing terminal and all connected components must be integrated into a common sytem
of equipotential bonding.
Protective covers or other parts covering the housing completely or in part must not be used.
Ex
The housing must be protected against permanent exposure to ultraviolet radiation.
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 15
5 Assembly
Ex
It must be made sure that installation of the weighing terminal is only carried out when all
power to the instrument is disconnected and no potentially explosive atmosphere is present.
The weighing terminal must not be installed in areas where electrostatic charging is possible
which may produce spark discharges, brush discharges or propagating brush discharges at the
front panel.
Installation must be made in compliance with the generally accepted rules of technology. In particular
for all work carried out on electrical installations the specific safety regulations must be observed.
The weighing terminal may be installed in Ex zone 2 or 22. The terminal must not be damaged. The
place of installation must be clean.
The IT8000-**-W-Ex2/22 (wall-mount / desk-top version) has mounting brackets for wall or table-top
installation. They must be fixed with suitable screws which are not part of the supply. All screws must
be tightened securely.
The IT8000-**-E-Ex2/22 (panel-mount version) has screw clamps to fix the terminal in the cutout of
the switch cabinet. To connect the bonding conductor, an M5 stud is provided at the rear or bottom of
the housing. Use serrated washers to prevent the nuts from becoming loose.
The permissible temperature range is –10°C to +40°C at a max. of 95% relative humidity (non
condensing). Direct exposure to ultraviolet radiation must be avoided.
For wall-mount installation the unit can be fixed at the wall first and then the cables can be installed
with the front lid open.
Before the device is put into operation, the housing must be closed and tightened securely with the
hexagonal srews provided. The screws must be tightened with a torque of 1.1Nm.
16 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
6 Installation
6.1 General
This apparatus must only be installed by qualified personnel who are familiar with all regulations
applicable to the different types of protection and the methods of installation, as well as the
general principles for the classification of zones. This level of competence must correspond to
the work that is to be carried out and appropriate training should be provided on a regular basis.
When the weighing terminal is to be installed in Ex zone 2 / 22 the regulations as per
EN 60079-14 must be adhered to.
The weighing terminal must not be installed in areas where electrostatic charging is possible
which may produce spark discharges, brush discharges or propagating brush discharges at the
front panel.
It must be made sure during installation of the weighing terminal that all power to the
instrument is disconnected and that no potentially explosive atmosphere can be present at any
time.
Installation must be carried out in compliance with applicable DIN/VDE regulations. Also, all
country-specific regulations must be observed. Connection of supply volatage must be made in
compliance with VDE 0100 and VDE 0160.
Ex
When the instrument is permanently connected to the power supply, an easily accessible
separator must be included in the supply circuit! It must either be located in safe area or -if
installed in Ex area- have appropriate Ex protection for the place of installation.
All cables are led into the housing through Ex cable glands. Strip cable jacket only as long as
required for the wires to reach the screw terminals. Use wire end ferrules with plastic collar on
stranded cable and avoid protruding wires. When assembling the cable glands make sure that
shield of cable is connected inside the cable gland. Observe instructions in section 'Connection
of cables'.
Ex
Before the device is put into operation, make sure that the housing is closed and tightened
securely with all hexagonal srews provided. The screws must be tightened with a torque of
1.1Nm.
6.2 Equipotential Bonding
Ex
In compliance with EN 60079-14 the apparatus must be integrated into the equipotential
bonding system of the installation. The bonding conductor must have a cross section of min.
4mm². To connect the bonding conductor, an M5 stud with serrated washer is provided at the
rear or bottom of the housing.
6.3 Shielding
Ex
Use only shielded connection cables. The shield must be connected at both sides in the cable
glands. It is mandatory to additionally install equipotential bonding as per EN60079-14
paragraph 12.2.2.3 exception b). The bonding conductor must have a cross section of min.
4mm².
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 17
6.4 Connection Of Cables
All cables are led into the housing through cable glands.
Cable jacket Shield Compression nut Plastic insert Bushing Counter nut
Cable connection via cable glands:
1. Slide compression nut over cable jacket;
2. Slide plastic insert (retainer) over cable jacket until inner end is aligned with cut end of jacket;
3. Unravel shield, bend over retainer and push into retaining comb. Cut wires of shield to length of
comb, avoid protruding wires;
4. Insert retainer with cable into bushing;
5. Screw compression nut onto bushing and use wrench to tighten securely.
Permissible diameter of cables and torque for cable glands:
Wrench size of
counter nut
Permissible
diameter of cable
Torque to tighten
counter nut
17 mm 4 – 8 mm 6 Nm
20 mm 5 – 10 mm 5 Nm
22 mm 6 – 12 mm 8 Nm
Contact SysTec service for different cable diameters.
Ex
Use crimped wire end ferrules with plastic collar on stranded cable and avoid protruding wires.
Ex
All connecting cables must be firmly installed to avoid tension load at the cable glands and to
comply with the requirements of EN60079-14 paragraph 9.3.1.
18 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
7 Installation Of External Connections With Type Of
Protection 'Ex-nA'
7.1 Connection Of Power Supply To IT8000-AC-*-Ex2/22
IT8000-AC-*-Ex2/22 (article-No. X8SYS0x1) is supplied with a line cord with free ends to connect the
supply voltage.The power supply unit is soldered to the main board CPU8000-230V-Ex2/22. The line
cord is connected to screw terminal KL6 of the CPU8000-230V-Ex2/22.
The power supply has a fused input (2A T). The fuse cannot be replaced.
Terminal KL6
110-240 VAC
PE L1 N
Ex
The connection of the supply voltage at the free cable end of the weighing terminal
IT8000-AC-*-Ex2/22 is designed for type of protection Ex-nA. The listed nominal connection
values must be adhered to.
For the connection of the line cord in hazardous area a suitable method must be chosen in
compliance with EN60079-0 (e.g. Ex-e, Ex-d). A suitable protection against overload and short
circuit in compliance with VDE regulations must be provided.
Nominal voltage UN
110 - 240VAC –15%/+10%
Nominal current IN
300 mA
Frequency range
47 - 63 Hz
Type of protection
Ex-nA
Color code free end of cable
brown L
blue N
green/yellow PE
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 19
7.2 Connection Of Power Supply To IT8000-DC-*-Ex2/22
The weighing terminal IT8000-DC-*-Ex2/22 is intended for power supply with 12 – 30 VDC. The
connecting terminal KL6 is located on the main board CPU8000-24VDC (for article-No. X8SYS0x5)
and on the CPU8000-NTP-Ex2/22 (for article-No. X8SYS0x6).
A diode is provided as protection against reverse polarity. The power supply of the CPU8000-24VDCEx2/22 has a fused input (2A T). For replacing the fuse see chapter 'Replacing the fuse'.
Terminal KL6
12-30 VDC
PE L1 N
Ex
The connection of the supply voltage to the weighing terminal IT8000-DC-*-Ex2/22 is
designed for type of protection Ex-nA. The listed nominal connection values must be adhered
to.
For the connection of the supply cable in hazardous area a suitable method must be chosen in
compliance with EN60079-0 (e.g. Ex-e, Ex-d). A suitable protection against overload and short
circuit in compliance with VDE regulations must be provided.
Nominal voltage UN: 12 – 30 VDC +10% / –15%
Nominal current IN: 1.5 – 0.5 A
Cross section (rigid wires): 0.75 – 1.5 mm
2
Cross section (flexible wires with insolated wire end ferrule): 0.75 – 1.5 mm
2
Length of stripped insolation: 6 mm
Fastening torque screw terminal: 0.5 – 06 Nm
Ex type of protection: Ex-nA
Terminal assignment CPU8000 terminal KL6
+ V Supply voltage (+)
0 V Supply voltage (—)
20 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
7.2.1 Connecting Cable With Ex Plug For Battery Operation
The weighing terminal IT8000-DC-*-Ex2/22 (article-No. X8SYS0x6) with CPU8000-NTP-Ex2/22 is
suitable for connection to an external rechargeable battery box. To this effect the instrument is
supplied with an assembled connecting cable with ex plug. The following notes must absolutely be
observed:
Absolutely adhere to operating instructions 'Ex-connector mini Clix Reihe 8591'.
Components must have identical coding to avoid damages to connector/socket.
The supply cable to the plug-and-socket connection must be firmly installed and sufficienty
protected against mechanical damage. Cables must comply with the thermic and mechanical
requirements of the location of installation.
When connectors are not connected correctly, protection against risk of explosion is no longer
warranted. Strictly follow the instructions!
After separating, immediately cover components of the plug-and-socket connection conducting
voltage with protective cap!
Ex
For the supply of the weighing terminal the following rechargeable batteries can be used:
1) AkkuBox Ex; 12VDC for use in Ex zone 2 and 22; article-No. E3AKK001
2) Equivalent 12V rechargeable batteries may be used. When a rechargeable battery is used
in hazardous area a suitable type of protection must be provided. Compliance with the
requirements of EN 60079-14 is mandatory.
Observe the operating instructions for the rechargeable battery.
7.2.2 Coding And Pin Assignment Ex Connectors
No. of
pins
Coding Female connector / socket
e.g. AkkuBox Ex
Male connector
IT8000-DC-*-Ex2/22
(article-No. X8SYS0x6)
2 + PE 12 h
Assignment
Pin Voltage
1 12VDC
2 not used
3 GND
PE Shield
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 21
7.2.3 Instructions For Connecting And Separating Coupler
Before plugging in check connectors for any damages.
Align male/female connectors along groove (1).
Push components together up to stop position (2).
Twist right approx. 30° up to stop (3).
Push connectors together completely (4).
Fasten coupling ring tightly (5). This procedure provides for mechanical connection, electrical
contact and IP protection.
Disconnect in reverse order.
22 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
7.3 Connection Of Analog Scale To ADM / ADC
The ADM or ADC provides connection for one weighing platform with strain gauge loadcell(s). A
second weighing platform can be connected using a second ADM or ADC board. The modules are
plugged into sockets ADC1 / ADC2 on the CPU8000 main board.
ADM2 ADM1 Jumper W1
Ex
The connection is designed compliant to type of protection 'Ex-nA'. If the loadcell is to be
installed in hazardous area, compliance with the applicable Ex regulations is mandatory. The
following connection values must be observed:
ADM/ADC
Terminal KL1
Signal Description Nominal value
1 +Excitation Output 5 V / 240 mA
2 – Excitation Output 5 V / 240 mA
3 +Sense Input 5 V / 1 mA
4 – Sense Input 5 V / 1 mA
5 +Signal Input 5 V / 1 mA
6 – Signal Input 5 V / 1 mA
Cross section rigid wire: 0.25 – 1.5 mm
2
Cross section flexible wire
with insolated wire end ferrule:
0.25 – 1.5 mm
2
Length of stripped insolation: 6 mm
Fastening torque screw terminal: 0.5 – 0.6 Nm
Ex type of protection: Ex-nA
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 23
Connection of weighing platforms and loadcells is to be made as specified below:
Max. 16 strain gauge loadcells 350 each
Overall impedance 21.5 ...4500
W&M approved resolution of 6000d at a max. preload of 80%, internal resolution 524,000d
Smallest permissible input signal for approved applications: 0.33 µV / e
Update rate 50 updates / second
Loadcell excitation: 5 V ±5%, gated power supply (ADM), DC (ADC)
Connection in 4- or 6-wire mode.
Principal schematics of 6-wire and 4-wire strain gauge loadcell:
6-wire loadcell
4-wire loadcell
Connection of 6-wire loadcell to ADM or ADC:
Terminal Assignment
1 +Excitation
2 – Excitation
3 +Sense
4 – Sense
5 +Signal
6 – Signal
Connection of 4-wire loadcell to ADM or ADC:
To connect loadcells without sense lines (4-wire connection), two jump leads must be connected at
terminal row KL1 between terminal 1 and 3, and between terminal 2 and 4.
Terminal Assignment
1 +Excitation
2 – Excitation
3
4
5 +Signal
6 – Signal
24 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
7.3.1 Connection Cables For Analog Weighing Platforms
For the installation of connection cables for analog weighing platforms please follow the recommendations listed below:
Only use suitable loadcell cable, (e.g. SysTec order-No. 10KAB214 (3 x 2 x 0,75mm², shielded)
Nominal voltage of cable ±250V.
Unsuitable loadcell cable may affect accuracy.
The shield of the loadcell cable must be connected all around the cable in the cable gland of the
weighing terminal (see also chapter 'Installation' / 'Connection Of Cables'). Loadcells, platforms
junction boxes and the weighing terminal must be integrated into the equipotential bonding of
the sytem. Depending on the situation on site this may require the installation of a separate earth
lead of appropriate diameter (e.g. 16mm²) in parallel to the loadcell cable. If the junction box is
installed in hazardous area it must be designed with appropriate type of protection.
To extend the loadcell cable only use metal junction boxes and connect shield of cable on both
sides inside cable gland.
Distance between loadcell cables and power lines min. 0.5m. Loadcell cables to be installed in
grounded metal conduits, metal hoses or metal cable trays.
Maximum length of connection cable between weighing platform and weighing terminal: 200m.
If tension load is applied to loadcells instead of compression load, connection for +Signal
and –Signal must be transposed.
7.3.2 Sealing Of Calibration Parameters
By means of the jumper W1 the calibration parameters stored in EEPROM can be protected against
unauthorized modifications:
ADM in IT8000-Ex2/22 Calibration parameters
protected
Calibration parameters
accessible
ADC im IT8000-Ex2/22 Calibration parameters
protected
Calibration parameters
accessible
If required for W&M approved and stamped systems, the position of the jumper W1 can be sealed with
thread and lead seal:
For a description of the calibration mode refer to the 'Calibration Manual IT8000 ADM and ADC'.
Technical Manual IT8000-**-*-Ex2/22 Rev. 4 25
7.4 Connection Of IDNet Scale Base To IDN
The IDN module (IDNet interface module) permits the connection of one Mettler-Toledo understructure
with IDNet interface. It supports IDNet understructures which operate on 12VDC power supply (e.g.
PikBrick). Understructures which require an additional 32VDC supply cannot be connected.
Only one IDN interface (for 1 understructure) may be installed, which is either inserted in socket ADC1
(if the only scale is an understructure with IDNet interface) or ADC2 (for a mixed setup with digital and
analog scale base). In this case (one ADM/ADC and one IDN) the ADM board must always be installed
in the first socket ADC1, the IDN is then installed in socket ADC2.
In a mixed setup, one analog scale base with up to 8 x 350 loadcells can be connected to the
ADM/ADC interface.
The FBM or ECM module must not be used when an IDN board is in place, because the internal
communication with the IDN module is made via COM4, i.e. this interface is not available for the
fieldbus or Ethernet interface or an additional SIM module.
The IDN module provides a maximum of 12VDC / 150mA as supply for the IDNet scale base.
Ex
W A R N I N G
When an IDN module is installed the the auxiliary voltage (10VDC on CPU8000, terminal KL4)
must not be used.
IDN interface module
IDN
Ex
The connection is designed compliant to type of protection 'Ex-nA'. If the force transducer is to
be installaed in hazardous area, compliance with the applicable Ex regulations is mandatory.
The following connection values must be observed:
26 Technical Manual IT8000-**-*-Ex2/22 Rev. 4
IDN
Terminal KL1
Signal Description Nominal value
1 TxD— — Transmit line 20 mA CL 12 V / 20 mA
2 TxD+ + Transmit line 20 mA CL 12 V / 20 mA
3 RxD— — Receive line 20 mA CL 12 V / 20 mA
4 RxD+ + Receive line 20 mA CL 12 V / 20 mA
5 0 V 0 (12 V) Supply voltage 0 (12 V) / 150 mA
6 +12 V (150mA) +12V Supply voltage 12 V / 150 mA
For a description of the calibration mode refer to the
MultiRange Calibration Manual, Order-No.: ST.2309.0057
Cross section rigid wire: 0.25 – 1.5 mm
2
Cross section flexible wire with insolated wire end ferrule: 0.25 – 1.5 mm
2
Length of stripped insolation: 6 mm
Fastening torque screw terminal: 0.5 – 0.6 Nm
Ex type of protection: Ex-nA
7.4.1 Connection Cables For IDNet Scale Bases
Unsuitable cable may cause loss of data. For the installation of connection cables for IDNet scale bases
please note
Only use suitable connecting cable (data cable), e.g. 6 x 0.25 mm² shielded, SysTec order-No.
10KAB216, or data cable supplied by the manufacturer of the scale base.
Nominal Voltage of cable 250V.
Connect shield of cable at both sides, at cable gland of weighing terminal and at understructure
and/or extension cable. If a difference between potentials is experienced, an appropriate potential
equalization must be installed.
Distance between loadcell cables and power lines: 0.5m. Loadcell cables to be installed in
grounded metal conduits, metal hoses or metal cable trays.
Maximum length of connection cable between weighing platform and weighing terminal: 15m.
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