[17] User`s Manual ver. 2.0.2
Contents
1. version with enclosure ss316 1D Ex ia T105 C Da FTZU 11 ATEX 0116X 2 3 Transmitter category and hazard areas The category 1 2G contained within the rating means that the transmitter may be installed within a type 1 or 2 hazard zone The APC 2000ALW Ex Safety APR 2000ALW Ex Safety process connections may connect to a 0 zone type see the diagram below for an example Zone 0 Zone 1 2 Safe area Pressure transmitter or differential pressure transmitter 3 Identifying marks Intrinsically safe transmitters must have a rating plate containing the information specified in paragraph 4 3 DTR APC APR ALW 20 ENG and also at least the following sign transmitters as below APC 2000ALW XX Ex Safety where XX marks process connector type CE mark and number of notified unit designation of explosion protection design certificate number values of parameters such as Ui li Ci Li Pi year of manufacture inscription Version SA separated supply for transmitters with the protection against overvoltage surge arrester where should be used galvanically separated powering to ground ver 2 0 2 DTR APC APR ALW 20 ENG Appendix Exi 4 User information Together with the ordered transmitters the user will receive Product Certificate Declaration of conformity Copy of certificate on request User s Manual numbe2. 2000ALW APC 3 383 10 1 553x10 1 734x10 2000ALW 1 h 1 h 1 h Ex 3383 FIT 1553 FIT 1734FIT 7 A 2 956x10 96 FIT n APR 3 383 10 1 553x10 1 734 10 0 962x107 2000ALW 1 h 1 h 1 h 1 h Ex 3383 FIT 1553 FIT 1734 FIT 96 FIT 2 956x10 h Periods between periodical tests for different products according to IEC 61508 6 p B 3 APC 2000ALW APR 2000ALW APC 2000ALW Ex APR 2000ALW Ex T Proof 1 year T Proof 2 years T Proof 5 years T Proof 10 years PFDe 5 35x10 T Proof 1 year PFDe 9 46x10 T Proof 2 years PFDg 2 18x10 T Proof 5 years PFDe 4 24 10 T Proof 10 years PFDe 5 35x10 T Proof 1 year PFDe 9 46x10 T Proof 2 years PFDg 2 18x10 T Proof 5 years PFDe 4 24 10 T Proof 10 years PFDe 5 46x10 T Proof 1 year PFDe 9 67x10 T Proof 2 years PFDg 2 23x10 T Proof 5 years PFDe 4 33x10 T Proof 10 years PFDe 5 46x10 PFDe 9 67x10 PFDg 2 23x10 SIL SIL2 HFT 0 Instrument type B Architecture 1001 D PFDs 4 33 10 39 2 0 2 DTR APC APR ALW 20 ENG The APC R 2000ALW Safety and APC R 2000ALW Ex Safety pressure transmitters meet the requirements of safety integrity level SIL2 with the hardware failure tolerance HFT 0 by implementing the 1001 architecture with dive
3. Square root characteristic cut of point setting Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following percent value across longer press button m After parameter confirmation transmitter will confirm the party of command by the DONE Type of the process variable displayed on LCD1 Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following option across longer press button After parameter confirmation transmitter will confirm the party of command by the DONE On LCD1 will displayed current value in current loop The percent value output signal will displayed on LCD1 23 ver 2 0 2 LCD2VARiable lt BACK PRESSURe USER UNIT NO UNIT LCD2 DP lt BACK XXXXXe XXXXeX XXXeXX XXeXXX l XXXXX FACTORY lt BACK ECALL DTR APC APR ALW 20 ENG Type of the process variable displayed on LCD2 Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following option across longer press button m After parameter confirmation transmitter will confirm the party of command by the DONE The pressure value will displayed on LCD2 The user s units will displayed on LCD2 The current unit or user s unit alternately
4. accuracy for 3 years for the nominal measuring range Error due to supply voltage changes max 0 002 FSO 1V Thermal error max 0 08 FSO 10 C max 0 1 FSO 10 C for ranges n 10 11 12 Thermal error for the whole thermal max 0 25 FSO compensation range max 0 4 FSO 10 C for ranges n 10 11 12 2 0 2 DTR APC APR ALW 20 ENG 4 2 3 PED versions Measurement ranges Transmitters APC 2000ALW Ex Safety in version compliant with Pressure Directive PED can be manufactured with measurement range width within 100kPa to 40MPa of overpressure and negative pressure 0 to 40 MPa of absolute pressure and limit overload can be 44MPa Allowed working temperature 40 100 C with connection S Mazut 40 150 C 4 2 4 Pressure Connectors M type connector with M20x1 5 thread see figure 5a available for PED version P type connector with M20x1 5 thread see figure 6a available for PED version G1 2 type connector with G1 2 thread see figure 8a available for PED version GP type connector with G1 2 thread available for PED version RM type connector with M20x1 5 thread and radiator RP type connector with M20x1 5 thread and radiator G1 4 type connector with G1 4 thread available for PED version 1 2 NPT type connector with 1 2 NPT tread available for PED version R1 2 type connector with R1 2 tread available for PED version 3 APR 2000ALW Ex Safety MEASUREMENT RANGES AND METROLOGICAL PARAMET
5. pipe or to a wall see Catalogue cards Fitting accessories Fig 7 Example of mounting of APR 2000ALW Ex Safety transmitter with type C connector 15 2 0 2 DTR APC APR ALW 20 ENG 18 132 18 1 I STVNIWHAL 071313 161 5 51 25 m U type handle made from 3 mm metal sheet for mounting the valve manifold 1 U 59 Fig 9 Example of mounting of APR 2000ALW Ex Safety transmitter with a valve manifold 16 2 0 2 DTR APC APR ALW 20 ENG 8 ELECTRICAL CONNECTIONS 8 1 GENERAL RECOMMENDATIONS 8 1 1 It is recommended that signal lines are executed in twisted wire and in the case of high electromagnetic interferences in shielded twisted wire Avoid routing signal cables along the interfering cables e g near large consumers of electric energy Appliances working with transmitters are to be resistant to electromagnetic interferences from power supply or signal transmission lines as per the requirements concerning electroma
6. with process variable will displayed on LCD2 The current unit or user s unit alternately with process variable will not displayed on LCD2 The process variable point position on LCD2 Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following option across longer press button te After parameter confirmation transmitter will confirm the party of command by the DONE Come back to factory setting Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm the command as bellow across longer press button After parameter confirmation transmitter will confirm the party of command by the DONE 24 DTR APC APR ALW 20 ENG The program enforcement of the transmitter restart lt BACK Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm the command as bellow across longer press button m After parameter confirmation transmitter will confirm the party of command by the DONE Local Menu error reports During executing in Local Menu some functions LCD2 announcement can be displayed on the screen The error displaying evidences about no realization of command of Local Menu The shortened description of errors announcements is showed below ERR_L07 ERR_L09 ERR_L10 ERR_L14 ERR_L16 WNG_L14 in_write_protected_mode Err
7. 13 6 4 MECHANICAL VIBRATION IMPACTS CORROSIVE MEDIA i T INSTALLATION AND MECHANICAL 5 4 04 0 7 1 APC 2000ALW SAFETY INSTALLATION AND CONNECTIONS TO PRESSURE SYSTEM 7 2 APR 2000ALW SAFETY INSTALLATION AND CONNECTIONS TO PRESSURE SYSTEM 8 ELECTRICAL CONNECTIONS BOO 4 8 1 GENERAL RECOMMENDATIONS 5 8 2 ELECTRICAL CONNECTIONS OF 8 2 2 u u u 8 3 LOCAL LCD DISPLAY 0 2 11 1 11 18 8 4 OVERVOLTAGE AND INTERFERENCE PROTECTIONS 19 8 5 19 9 SETTING AND REGULATION 19 9 1 BASIC RANGE AND PRESET RANGE 8 2 4 41 u u 19 9 2 CONFIGURATION AND 10 INSPECTIONS MAINTENANCE SPARE PARTS 10 1 PERIODIC 85 1 aaa aan aa aaa aaa aaa zaa aaa aaa aa aaa aaa aaa aaa a aaa aaa aan aan nawa 10 2 UNSCHEDULED 8 2 1 1111 a aaa aaa entes nens ains aa aaa tna aaa ains ains a aaa assa ains aaa 10 3 CLEANING THE DIAPHRAGM SEAL OVERLOADING DAMAG
8. 17 User s Manual ver 2 0 2 Revision no Date Description 1 0 27 November 2009 First edition Actualization to standard 2 0 1 30 November 2014 PN EN IEC 61508 2010 2 0 2 20 February 2015 Editorial corrections QPLISEN 5 DTR APC APR ALW 20 ENG APLISENS MANUFACTURE OF PRESSURE TRANSMITTERS AND CONTROL INSTRUMENTS USER S MANUAL SMART PRESSURE TRANSMITTER type APC 2000ALW Safety APC 2000ALW Ex Safety SMART DIFFERENTIAL PRESSURE TRANSMITTER type APR 2000ALW Safety APR 2000ALW Ex Safety ver 2 0 2 WARSAW FEBRUARY 2015 APLISENS S A 03 192 Warszawa ul Morelowa 7 tel 48 22 814 07 77 fax 48 22 814 07 78 www aplisens pl e mail aplisensQaplisens pl 2 0 2 DTR APC APR ALW 20 ENG Symbols used Symbol Warning to proceed strictly in accordance with the information contained in the documentation in order to ensure the safety and full functionality of the device Information particularly useful during installation and operation of the device Information particularly useful during installation and operation of a type Ex device Information on disposal of used equipment The manufacturer will not be liable for damage resulting from incorrect installation failure to maintain the device in a suitable technical condition or use of the device other than for its intended purpose Installation should be carried out by qualified staff having the required authorizations t
9. cover in a place free of vapours and reactive substances with temperature and humidity not exceed the limits specified in p 4 1 2 When storing transmitters with uncovered membrane or diaphragm seal connectors without package membranes are to be secured with guards protecting them against incidental damage Transmitters are to be transported in packages secured against displacement of transmitters in packages and displacement of packages in the means of transport Transmitters can be transported on land sea or in the air provided that means of transport eliminate direct effect of weather conditions Requirements concerning transport to PN EN 13876 2003 26 2 0 2 DTR APC APR ALW 20 ENG 12 GUARANTEE Manufacturer guarantees correct operation of transmitters for 60 months following the date of purchase as well as guarantee and post guarantee servicing In the case of special versions guarantee period is subject to agreement between the user and the manufacturer such agreed guarantee period cannot be shorter than 12 months 13 SCRAPPING UTILIZATION Worn or damaged pressure transmitters are to be scrapped to Directive WEEE 2002 96 EC on waste of electrical and electronic equipment or return to manufacturer for scrapping 14 ADDITIONAL INFORMATION Some applications of pressure transmitters require blocking and sealing of covers to prevent tampering with settings and adjustments For method of sealing transmitter serie
10. danger zone Transmitter electrical installation should be realised with engineering standard requirements It is not allowed to repair or otherwise interfere with the transmitter s electrical circuits in any way Damage and possible repair may be assessed only by the manufacturer or another authorized party Special conditions for safe use Version of transmitter with surge arrester marked on the plate Version SA does not meet the requirements of Section 10 3 of the EN 60079 11 2012 500Vrms This must be taken into account when installing the equipment see p 5 2 0 2 DTR APC APR ALW 20 ENG 1 USER INFORMATION Transmitters are delivered in single and or multiple packs Together with the ordered transmitters the user will receive a Product certificate which is also as the warranty card b Declaration of conformity on request C Copy of ATEX certificate on request d Users Manual numbered DTR APC APR ALW 20 ENG Items b c d are available at www aplisens pl 2 APPLICATIONS APC 2000ALW Ex Safety and APR 2000ALW Ex Safety MAIN FEATURES 2 1 The APC 2000ALW Ex Safety smart pressure transmitters are designed to measure gauge pressure vacuum pressure and absolute pressure of gases vapours and liquids including corrosive substances Differential pressure transmitters type APR 2000ALW Ex Safety are used to measure liquid levels in closed tanks with static pressure up to 25MPa or 32
11. for basic range After of transmitter at the facility transmitter zero can be displaced and require adjustment It applies in particular to small measurement ranges of pressure and position of the transmitter at the facility different than during calibration and also cases of filling impulse tubes with separating liquid and transmitters with remote diaphragm seals Setting adjustment of transmitter zero signal can be effected using buttons after unscrewing the cover of transmitter electronic assembly housing see Fig 3 using communicator or using computer Raport 2 software and modem Hart RS Clauses 9 2 3 9 2 4 9 2 5 9 1 BASIC RANGE AND PRESET RANGE DEFINITIONS 9 1 1 The maximum pressure or differential pressure range which can be processed by the transmitter is called basic range specification of basic ranges see Clause 4 2 1 4 3 1 The width of basic scope is the difference between the upper and the lower limit of basic range Transmitter memory holds the internal processing characteristics including basic range That is a reference characteristics for all settings that affect the output signal of the transmitter 9 1 2 Transmitter user uses the expression preset range of pressure Preset range is the range with current value 4mA assigned to the beginning and the value 20mA assigned to the end with inversion characteristics respectively 20mA and 4mA Preset range can coincide with basic range or only co
12. interferences 5 2 MECHANICAL CONSTRUCTION 5 2 1 Transmitter housing Housing of APC R 2000ALW Ex Safety transmitter is executed in high pressure aluminium cast or in stainless steel and comprise a body and two threaded lateral covers one of which is fitted with sight glass There are two openings for cable glands with thread M20x1 5 or 77 NPT in the housing redundant opening is to be stopped with a plug The housing is fitted with both internal and external earthing terminal Dimensions of transmitters are shown in Fig 2 18 132 18 133 M20x1 5 or 1 2NPT Cable gland Cable 6 012 FIELD TERMINALS 130 Lock preventing rotation of the casing Earthing terminal Fig 2 APC R 2000ALW Ex Safety pressure transmitter Dimensions 5 2 2 Electronics assembly with display The main electronics circuit board with display is placed in the polycarbonate housing The assembly is installed inside the bigger of two housing chambers Display can be adjusted for best viewing with 90 step Displayed is positioned by manufacturer as per the information included with order Default display position is vertical transmitter reading position pressure connection down without display backlight 11 2 0 2 DTR APC APR ALW 20 ENG 5 2 3 Sensor modules Pressure connectors of transmitters Examples Sensor
13. lt BACK H20 20 MM_H20 MM_HG PSI BAR MBAR GISQCM KGISQCM PA KPA TORR ATM M H20 MPA INH20 4 MMH20 4 _ lt BACK 0 S 2 S 5 S 10 S 30 S 60 S DTR APC APR ALW 20 ENG Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following characteristics across longer press button After parameter confirmation transmitter will confirm the party of command by the DONE Setting of the solid temporary suppression of the process variable Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following values time constant across longer press button After parameter confirmation transmitter will confirm the party of command by the DONE 22 ver 2 0 2 TRANSFEr_ SQRT _ LCD1VARiable lt BACK LINEAR SQRT SPECIAL SQUARE lt BACK 0 2 0 4 0 6 0 9 1 0 CURRENT l PERCENT DTR APC APR ALW 20 ENG Setting of the current output form Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu Confirm one of the following characteristics across longer press button After parameter confirmation transmitter will confirm the party of command by the DONE Linear Square root user s square
14. module is a transmitter assembly fitted with silicon measuring membrane The membrane is located in the space filled with silicon oil closed with a gland with glass isolated electrical leads on one side and with membrane isolating the medium on the other side Heads are fitted with stub pipes allowing connection of transmitter to pressure system Standard pressure connections and system outlets are shown in drawings The head of APR 2000ALW Ex Safety transmitter is fitted with two type P connectors or type process connector for mounting the valve manifold M20x1 5 225 1 011 24 5 1 G1 2 27 Fig 5 1 2 NPT type G1 2 type pressure connector with 61 2 thread 12 2 0 2 DTR APC APR ALW 20 ENG 6 PLACE OF INSTALLATION 6 1 GENERAL RECOMMENDATIONS 6 1 1 Pressure and differential pressure transmitters can be installed both indoors and outdoors When outdoors it is to be installed in the booth or under the roof 6 1 2 Location of transmitter in the facility is to ensure access for maintenance and protection against mechanical damages Method of mounting the transmitter and configuration of pressure feeding ducts so called impulse tubes are to meet following requirements impulse tubes are to be possibly short and with sufficient cross section routed without sharp kinks in order to prevent their blocking in the case of gaseous medium transmitters are to be installed abov
15. or converter RS Hart Miliamperomierz Fig 10a dinge Test To measure the current in the transmitter without disconnecting the signalling gt Ro RD 240 Q circuit connect a milliammeter to control terminals lt Test gt and lt Test gt a Si I Permitted fall in voltage on the milliammeter 200mV 2 signa A I 2 Signal Connecting the communicator 5 7 1 When resistance seen from transmitter to the line is gt 2400 then a Test transmitter communicate with the transmitter via connection to line Signal gt and Signal gt see Fig 10a Ro line resistance load 2 When lt 2400 communication shall not be established and Ro is to be increased to min 2400 as in Fig 10a Transmitter is fitted with additional communication resistor RD 2400 Fig 10b During normal operation terminals Signal gt and Test gt are to be together not to introduce additional resistance from line circuits RD resistor is used when we want to establish local communication with transmitter from its terminals when Ro lt 2400 Then terminals Signal gt and Test gt are to be apart Communicator or converter RS Hart Fig 10b Fig 10 Electrical system of transmitter connections with available variants for reception of analogue signal 4 20mA and Hart for purposes of configuration at the facility 17 2 0 2 DTR APC APR ALW 20 ENG 8 3 LOCAL LCD DISPLAY
16. socket with torque corresponding with type of seal used and measured pressure 7 1 3 Transmitter APC 2000ALW Ex Safety can be installed using universal AL holder allowing installation in any position on supporting structure or vertical or horizontal tube 235 265 Fig 6 COVER gt Oy 4 182 Fig 6 Mounting methods of APC 2000ALW Safety transmitter 14 2 0 2 DTR APC APR ALW 20 ENG 7 2 APR 2000ALW Ex Safety INSTALLATION AND CONNECTIONS TO PRESSURE SYSTEM 7 2 1 Transmitters APR 2000ALW Ex Safety can be mounted directly on rigid impulse tubes Differential pressure transmitters are mounted on three or five way valves Such connection of transmitter allows its easy cutting off of the system for washing of measuring membrane local calibration diagnostics etc Connections of transmitters with two stub pipes M20 x 1 5 type P connector are to be executed using straight couplers with type nuts to PN 82 M 42306 When flexible tubes are used in connection transmitters are to be additionally mounted on tube panel supporting structure Transmitters with type P stub pipes or other type can be mounted using mounting set 225 holder Fig 8 for tube 225 or to flat surface using angle sectio
17. was sent by the customer to the service centre since all tested transmitters are covered by 5 year warranty of their manufacturer In accordance with the IEC 61508 standard the reliability parameters have been specified at 70 of one sided lower confidence limit The purpose of the Proven in use analysis was establishing the ADU undetected dangerous failure rate coefficients 37 2 0 2 DTR APC APR ALW 20 ENG Reliability parameter values calculated using the FMEDA method for the APC R 2000ALW Safety transmitter version ASD 0 ASU 1 487248032x10 1 h ADD 1 698482536x10 1 h ADU 0 093924697 10 1 h Atotal 3 279655265 10 1 h DC 94 75985731 SFF 97 13614118 MTTF 304910 h MTTR 72h MTBF 304982 h Reliability parameter values calculated using the FMEDA method for the APC R 2000ALW Safety transmitter Ex version ASD 0 ASU 1 553211672 107 1 h ADD 1 734435474 107 1 h ADU 0 0960715x10 1 h Atotal 3 383718647x10 1 h DC 94 75164521 SFF 97 16077161 MTTF 295533 MTTR 72h MTBF 295605 h 38 2 0 2 DTR APC APR ALW 20 ENG Summary analysis Type of Transmitter 2000ALW 3 279 10 1 487x10 1 698x10 0 939x107 1 h 1 h 1 h 1 h 3279 FIT 1487 FIT 1698 FIT 94 FIT 3 279 10 1 487x10 1 698x10 0 941x107 1 h 1 h 1 h d h 3279 FIT 1487 FIT 1698 FIT 94 FIT APR
18. 0ALW Ex Safety and differential pressure transmitters series APR 2000ALW Ex Safety are attached with SIL 2 certificate for application in LDM HDM work safety systems to PN EN 61508 1 2010 PN EN 61508 2 2010 PN_EN 61508 3 2010 PN EN 61511 1 2007 PN EN 62061 2008 A1 issued by notified entity UDT CERT 02 353 Warszawa ul Szczesliwicka 34 Copy of SIL Certificate can be found at www aplisens pl 3 IDENTIFYING MARKS Each APC R 2000ALW Safety transmitter has a nameplate with at least the following information CE symbol name of manufacturer type of transmitter basic range admissible static pressure output signal supply voltage marking marks of admissions and certificates Marking for order purposes and versions as per up to date Information Sheets and the Catalogue 4 TECHNICAL DATA 4 1 APC R 2000ALW Ex Safety COMMON PARAMETERS 4 1 1 Electrical parameters Power supply 15 45V DC Usu 15V Load resistance Ro O 0 0225A ver 2 0 2 DTR APC APR ALW 20 ENG Minimum value of transmitter supply voltage can be calculated using below formula Umin 15 0 0225 x Ro V or see drawing below The area of safe operation uniform light coloured is above the area indicated with grid Umin V Umin f Ro 60 50 40 Umin 30 Umax 20 10 0 0 100 200 300 400 500
19. 2 0 2 DTR APC APR ALW 20 ENG 5 CONSTRUCTION 5 1 ELECTRONIC SYSTEM MEASUREMENT PRINCIPLE Electrical signal from Sensor module s proportional to the value of measured pressure and temperature is fed to the input of analogue digital transmitter and transformed into digital signal Digital signal is then transferred via optoelectronic galvanic isolation to the main circuit board Microchip controller of the main circuit board reads the values measured and based on such values calculates the accurate pressure value Digital value of measured pressure is then transformed into analogue signal 4 20 mA Furthermore the calculated value is displayed on integrated LCD screen The transmitter can be configured using local MENU buttons Implemented communication stack HART rev5 enables communication and configuration of transmitter using modem connected to PC computer and suitable software or using communicator Electrical connection of the transmitter is fitted with interference eliminator with overvoltage protections Transmitters APC R 2000ALW Ex Safety continuously monitor the operation of their hardware resources and correctness of calculations and in the event of any failures they report errors by setting of alarm current in current loop Furthermore error message is displayed on local LCD screen stating the error number Head electronics are galvanically isolated from measuring line Galvanic isolation reduces susceptibility of measurement to
20. 586 Yr 28584 813989 Hr 3 263107 Yr 46301 73 Hr 5 29 Yr 28584 81 Hr 3 26 Yr Reliability R 43800 Hr 90 5138 90 5 Lower Bound 0 3 85 0916 85 1 Expected Failure 3 035584 3 43800 B2 Life Reliable Life Lower Bound 0 3 8878 281758 Hr 1 013502 Yr 5481 091537 Hr 0625695 Yr 8878 28 Hr 1 01 Yr 5481 09 Hr 0 63 Yr Probability of Failure t 43800 9 4862 9 5 Failure Rate 2 276E 06 Hr 2 28E 06 Hr Lower Bound 0 3 3 686E 06 Hr 3 69E 06 Hr Results of the Proven in use analysis for APC 2000ALW Ex Safety Number of transmitters working until suspension 29 pcs Number of working hours until freezing 386 170 Number of working hours to failure 0 Number of failing transmitters 0 pc In selected time period no failures of APC 2000ALW Ex SAFETY transmitters were detected The mechanical design and the electronics of analysed transmitters are identical with differential pressure transmitters type APC 2000ALW SAFETY After performing the analysis it was found that with high probability the results for APC 2000ALW Ex SAFETY transmitters are comparable with the results for differential pressure transmitters type APC 2000ALW SAFETY 36 2 0 2 DTR APC APR ALW 20 ENG 15 6 The FMEDA method Failure Modes effects and Diagnostic Analysis The calculations of reliability parameters were made on the basis of electronic components used in the tested transmitters The reliabil
21. 600 700 800 900 1000 1100 1200 1300 1400 1500 RO Om Power supply of intrinsically safe versions Output signal only for workplace configuration purposes Resistance for communication Hart as per Appendix Exi 4 20mA 20 4mA Hart rev5 250 11000 min 2400 time of readiness to work after switching on the power supply 3s Output updating time Additional electronic damping 500ms 0 60s 4 1 2 Permitted environmental conditions Operating temperature range Medium temperature range for intrinsic safe versions Thermal compensation range Relative humidity In operation vibrations and impacts EMC Safety Integrity Level type of operation LDM HDM Basic alert levels Critical alert level 25 for APR 2000ALW Ex Safety preset by manufacturer 40 C 85 C for PED version in accordance with p 4 2 3 4 3 3 40 C 120 C for direct measurement over 120 C measurement with a transmission tube or diaphragm seal using in accordance with Appendix Exi 25 80 C 5 65 C for range n 14 for APC 40 80 C special version for APC 0 100 amplitude 1 6mm max acceleration 4g frequency up to 100Hz to PN EN 61326 industrial environments SIL 2 to PN EN 61508 low LO lt 3 7mA or high HI gt 21 5mA selected by HART command always low LO lt 3 7mA 8 2 0 2 DTR APC APR ALW 20 ENG 4 1 3 Construction materials Dia
22. CONFIGURATION Indicator options can be modified in local MENU of transmitter using buttons or communicator or modem Hart RS232 and PC software The indicator can be deactivated as necessary Deactivation function is available via communicator or PC computer Transmitter APC R 2000ALW Safety can be configured only outside of functional safety loop Transmitter operating in functional safety system is to feature output signal 4 20mA 20 4mA inversion system and preset modification blocked by software and by sealing For method of sealing transmitter covers see Fig 12 For local display of transmitter APC R 2000ALW Safety see Fig 11 A im x x k CS ni x q za a S 2 AEP yy lt Sy LS Wa EE NVA 7 rian i M 1 E Fig 11 LCD display screen of transmitter APC R 2000ALW Ex Safety 3 basic fields are represented in the display screen Bargraph the field of current output control degree With 096 output control the segments of bargraph rule are not blackened The segments shall blacken with increase in control level One segment is 1096 control With 10096 control all bargraph rule segments are blac
23. E 26 10 4 SPARE PARTS 26 11 PACKAGING STORAGE TRANSPORT 26 12 GUARANTEE 27 13 SCRAPPING UTILIZATION anna aaa ADNA WAS aaa aa ana Vs aiias assa assa asas aa aaa ana nawa 27 14 ADDITIONAL INFORMATION 27 15 INFORMATION RELATED TO FUNCTIONAL SAFETY 2 0 2 DTR APC APR ALW 20 ENG l APPENDIX Exi 1453 APC 2000ALW Ex Safety PRESSURE TRANSMITTER C APR 2000ALW Ex Safety DIFFERENTIAL PRESSURE TRANSMITTERS Ex VERSION 1 Introduction 1 1 This Appendix applies to transmitters of types APC 2000ALW Ex Safety and APR 2000ALW Ex Safety marked on the rating plate as shown in 3 1 2 The appendix contains supplementary information relating to the Ex versions of these transmitters During installation and use of Ex transmitters reference should be made to DTR APC APR ALW 10 ENG conjunction with Appendix Exi 2 Use of APC APR transmitters in danger zones 2 1 The transmitters are produced in accordance with the requirements of the following standards EN 60079 0 2012 EN 60079 26 2007 EN 60079 11 2012 EN 50303 2000 2 2 The transmitters may operate in areas where there is a risk of explosion in accordance with the rating of the explosion protection design II 1 26 Ex ia IIC 5 6 Ga Gb I M1 Ex ia I
24. ERS 4 3 1 Measurement ranges Ne Nominal KS range Minimum set range Rangeability PUP 1 0 16bar 0 1 6 1 6bar 160kPa 10 1 kPa 250 320bar __ 40barfor P type connector 4 0 0 25bar 0 25kPa 10mbar 1kPa 25 1 250 for version compliant 4 with the PED pressure directive 7 0 5 0 5bar 50 50kPa 0 1bar 10 10 1 Other nominal ranges to be agreed 4 3 2 Metrological parameters Accuracy 0 075 of the calibrated range Long term stability lt accuracy for 3 years for the nominal measuring range Error due to supply voltage changes 0 0029 FSO 1V Thermal error 0 08 FSO 10 C Thermal error for the whole thermal compensation range 0 3 FSO Zero shift error for static pressure 0 08 FSO 10bar 0 01 FSO 10bar for range n 4 0 03 FSO 10bar for range n 5 Cut off on radical characteristic curve up to10 of flow zeroing in static pressure conditions with zero differential pressure eliminate this error 4 3 3 PED versions Measurement ranges Measurement ranges of transmitters APR 2000ALW Ex Safety in variant compliant with PED are 100kPa 2 5MPa max static pressure 25MPa and max overload 27 5MPa They can be used within temperature range 25 C 70 C 4 3 4 Pressure Connectors C type connector to mount together with a valve manifold P type connector 10
25. HI option 9 error damage processor damage p Checksum error in Uncontrolled overwriting of the of the Alarm sianal selection EEPROM memory memory coefficients FLASH LO or HI 9 blocks memory damage processor damage p Error of the local quartz Resonator damage processor Alarm signal selection oscillator damage damage of LO or HI resonator option component connection Error of local NARA Damage of components or communication loop component connections Alarm signal selection with the Master LO or HI overnormative radioelectric option processor of the optical interference barrier Error of remote ane Damage of components or communication loop s component connections Alarm signal selection with the Slave LO or HI I overnormative radioelectric option processor of the optical interference barrier RER Damage of components or Communication error of component connections Alarm signal selection packages through the 2 LO or HI overnormative radioelectric option optical barrier 2 interference Error of the ADC Damage of components or component connections transmitter in the Alarm signal selection overnormative radioelectric LO or HI pressure measurement option interference Pressure overload channel Pressure sensor structure damage Error of the ADC Damage of components or component connections 2 transmitter in the sensor 5 Alarm
26. MPa for special versions and to measure differential pressure across constrictions such as filters and orifices 2 2 Transmitters APC R 2000ALW Ex Safety can be fitted with a series of diverse process connectors and also when application so requires they can be installed with direct or spaced demisters which allows using them with various measured media such as dense media or aggressive media at high and low temperatures 2 3 Transmitter series APC R 2000ALW Ex Safety generates output signal 4 20 20 4mA in inversion system in double duct arrangement 2 4 Transmitters can be configured following their installation at the workplace Due to application of smart electronics the following settings are available beginning and end of measurement range attenuation elemental processing characteristics low LO and high HI level of basic alert Transmitters can be configured using communicator KAPO3 APLISENS some other HART communicators or PC computer with HART RS232 converter and RAPORT 2 software 2 5 Transmitter series APC R 2000ALW Ex Safety in version compliant with Pressure Directive PED are qualified in category IV modules H1 H1D or B D and marked correspondingly on nameplates PED Certificate was issued by notified entity no 0062 Bureau Veritas 67 71 Bd du Chateau 92200 NEUILLY SUR SEINE France Copy of SIL Certificate can be found at www aplisens pl 2 6 Pressure transmitters series APC 200
27. e and load resistance are correct In case of connecting communicator to power supply line of transmitter the symptom of line damage could be the message No response or Check connections When the line is working check the transmitter 10 3 CLEANING THE DIAPHRAGM SEAL OVERLOADING DAMAGE 10 3 1 Sediment and dirt which have formed on the diaphragm in the course of operation must not be removed by mechanical means as this may damage both the diaphragm and the transmitter itself The only permitted method is the dissolving of sediment 10 3 2 Other causes of incorrect operation of transmitters are also damages to sensor membranes due to overloads caused by e g feeding excessive pressure freezing or solidification of medium pushing or scraping of membrane with hard object e g screwdriver Damage symptoms are usually absence of or incorrect response of transmitter to changes in pressure stable value of output current usually below 4mA or above 20mA rarely in the range 4 20mA 10 4 SPARE PARTS Parts of transmitter exposed to wear and tear or damage subject to replacement cover seal In case of versions ATEX PED SIL other parts can be replaced only by manufacturer or entity authorized by manufacturer 11 PACKAGING STORAGE TRANSPORT Transmitters are to be protected against damage during transport and packed in collective and or unitary packages The transmitters should be stored in multiple packs under
28. e measuring point so that the condensate could flow to the intake of measured pressure whereas in the case of liquid medium steam or when using protecting liquid downstream the the pressure intake it is recommended that impulse tubes are declined i e they are not to be installed horizontally or vertically unless the impulse tube is looped so called pig tail when we install differential pressure transmitter equal level or equal differential level of filler liquid is 1 to be maintained both impulse tubes as well as the same temperature of both impulse tubes position effect error corrected be zeroing and impulse tubes filled avoid fitting of metering orifice at high points of process system for liquids and at low points for gases configuration of impulse tubes and connection system of three and five way valves are to be selected considering measurement results and such needs as pressure zeroing of facility transmitters operation of impulse tubes during degasification drainage and washing 6 1 3 Potential system sources of measurement errors such as leaks blocking of too narrow tubes by sediments gas bubbles in tubes with liquids or liquid in gas tube differential density and or differential level in measuring tubes etc are to be eliminated 6 2 LOW AMBIENT TEMPERATURES When measuring the pressure of liquid with freezing point higher than ambient temperature A adequate anti freezing protection of measuring sys
29. ed value shall be visible on indicator 18 2 0 2 DTR APC APR ALW 20 ENG 8 4 OVERVOLTAGE AND INTERFERENCE PROTECTIONS Overvoltage and interference protections in transmitters is ensured by interference eliminators Overvoltage protection between the conductors of measuring line loop is effected by means of TVS diodes installed in all interference eliminators of transmitters Overvoltage protections between measurement line and earthing or housing which are not protected by TVS diodes connected between loop conductors is effected by means of surge arresters Intrinsically safe versions of transmitters are not fitted with surge arresters To enhance the level of protection against interference and overvoltage also external protections can be used such as UZ 2 system by APLISENS as well as shielded system wiring With long measurement lines it is advantageous to use one protection near the transmitter or inside the transmitter and the other at inputs to appliances working with transmitter Transmitters without magnetos withstand insulation test voltage 500V AC or 750V DC in the case of transmitters with magnetos insulation test voltage is limited to the value of magneto ignition voltage and it exceeds 100V 8 5 EARTHING Transmitters are fitted with internal and external earthing terminals 9 SETTING AND REGULATION Transmitters APC R 2000ALW Ex Safety are factory calibrated for the range as specified in the order or
30. equipment failures N in type B subsystems SFF HFT 0 HFT 1 HFT 2 lt 60 Not allowed SIL1 SIL2 60 96 lt 90 SIL1 SIL2 SIL3 90 99 SIL2 SIL3 SIL4 299 SIL3 SIL4 SIL4 A hardware fault tolerance of N means that N 1 faults could causa a loss of the safety function 15 4 Hardware safety integrity architectural constraints on type B safety related subsystems IEC 61508 2 7 4 4 2 2 Average probability of a dangerous Average probability of a failure for a safety dangerous failure on demand functionoperating in high demand Safety integrity level SIL PFDavg of the safety function mode of operation or continuous LDM mode of operation HDM 4 10 10 107 10 M 3 107 07 10 07 2 1107 07 10 07 1 107 107 0 10 15 5 Proven in use method for pressure and differential pressure transmitters Pressure and differential pressure transmitters manufactured in the period from 06 2009 to 31 08 2013 were selected Operating time of transmitters was counted since 01 2010 date of SIL certification for products APC R 2000ALW Safety up to 31 08 2014 All transmitters were custom made Operating time of transmitters to suspend S or failure F was counted since next month after manufacture It should be assumed with great probability that the majority of defective products was sent by the customer to the service centre since all tested transmitters are covered by 5
31. er Bound 0 3 7 973E 07 Hr 7 97 07 Results of the Proven in use analysis for APR 2000ALW Safety Number of transmitters working until suspension 145 pcs Number of working hours until freezing 3 008 330 Number of working hours to failure 61 320 Number of failing transmitters 6 pcs Analysis Summary Calculated Rounded MTTF 635578 003308 Hr 72 554567 Yr 635578 Hr 72 55Yr Lower Bound 0 3 347352 328966 Hr 39 652092 Yr 347352 33Hr 39 65 Yr B10 Life 56827 046790 Hr 6 487106 Yr 56827 05 Hr 6 49 Yr Lower Bound 0 3 43933 577252 Hr 5 015249 Yr 43933 58 Hr 5 02 Yr Reliability R 43800 Hr 92 0874 92 1 Lower Bound 0 3 90 0302 90 0 Expected Failure 11 948026 12 43800 B2 Life Reliable Life Lower Bound 0 3 9852 752310 Hr 1 124743 Yr 7253 985624 Hr 0 828081 Yr 9852 75 Hr 1 12 Yr 7253 99 Hr 0 83 Yr Probability of Failure t 43800 7 9126 7 9 35 ver 2 0 2 DTR APC APR ALW 20 ENG Results of the Proven in use analysis for APR 2000ALW Ex Safety Number of transmitters working until suspension 31 pcs Number of working hours until freezing 446 760 Number of working hours to failure 1 460 Number of failing transmitters 1 pc Analysis Summary Calculated Rounded MTTF Lower Bound 0 3 439460 Hr 50 166667 Yr 271304 803419 Hr 30 970868 Yr 439460 Hr 50 17 Yr 271304 80 Hr 30 97 Yr B10 Life Lower Bound 0 3 46301 732211 Hr 5 285
32. eration of the transmitter in the functional safety loop errors may occur which are caused by external factors or internal factors related to the measurement device The group of external factors include pressure overload electric surge voltage dips or losses strong overnormative radioelectric interference etc The internal factors include all types failures to the transmitter caused by wear of components or defects of installation These faults may be divided into the following categories Safe diagnosable failures SD Safe undiagnosable failures 50 Dangerous diagnosable failures DD Dangerous undiagnosable failures DU 30 2 0 2 DTR APC APR ALW 20 ENG The design of the transmitter allows for the detection of numerous DD type failures SU type failure do not have a direct impact on the measurement process and do not affect the safety functions SD type failure do not have a direct impact on the measurement process and do not affect the safety functions however they may be detected by the device and signalled DD type failure may have a direct impact on the measurement process however they are detected by the internal control systems which signal the fault status using the alarm signal DU type failure are not detected by the internal control systems therefore they have a direct impact on the measurement process and affect the safety functions The probability of the above mentioned faults is described using t
33. gnetic compatibility It is also advisable to use interference eliminators on the primary side of transformers power supply units supplying power to transmitters and appliances working with transmitters 8 1 2 Cable diameter is to match the cable gland used in the transmitter The cable is to be so routed and placed that mechanical stresses are avoided Cable gland and transmitter housing cover are to be carefully tightened Transmitter earthing is to be analysed Transmitter can be earthed via process connector or A via earthing terminals external or internal The section of signal cable leading to transmitter gland is to be formed as drip loop the lowest point of which is to be situated below cable inlet to the gland to prevent condensate ingress to the gland 8 2 ELECTRICAL CONNECTIONS OF TRANSMITTERS For execution of electrical connections of transmitters APC R 2000ALW Ex Safety see Fig 10 Resistor 240 Q is serially integrated permanently in the current circuit of transmitter and shorted with jumper on connection terminals between lt SIGNAL gt and lt TEST gt see Fig 10b To use the that resistor in Hart communication e g in the event of too low resistance in measurement loop the jumper is to be removed Power supply r 24 mA gt 2400 1i Communicator
34. hall cause existing the MENU of local modification of settings Otherwise we can move up and down the MENU tree selecting and accepting desired parameters In any case pressing and holding time of 1 J te buttons is to be no longer than 1s Longer holding of 1 button shall cause automatic moving up and down MENU tree with 1 s step Pressing of 1 causes moving up the MENU tree Pressing of causes moving down the MENU tree Pressing of causes accepting and execution of selection EXIT First announcement which will see after inclusion of Menu Local 1 If you will confirm this option you will go out from Local Menu and you will come back to continue of measuring PV ZERO lt BACK Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu PV ZERO Pressure zeroing If you will confirm this option transmitter will confirm the party of command by the DONE announcement or the proper number of error will notify 20 ver 2 0 2 SET LRV SET URV__ DTR APC APR ALW 20 ENG The Setting of the range of the set LRV beginning no change of span lt BACK Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu BY PRESsure Setting LRV across setting pressure If you will confirm this option transmitter will confirm the party of command by the DONE announcement or the proper number of error will no
35. he FMEDA method in accordance with the IEC61508 2010 standard applied during the design analysis process The results describing the probable frequency of the failures will be presented further the table DD type failures and their respective alarm signals Alarm signals signalised by lt 3 7 mA current are designated as LO Alarm signals signalised by 2 21 5 mA current are designated as HI The APC R 2000ALW Safety transmitters are equipped with a dual alarm system The first of those is called the primary signal and it operates with HI or LO alarms type HI or LO depends on the configuration selected by the user The configuration of alarms may be set using the Raport 2 software developed by APLISENS or other software using the DDL DTM libraries provided by APLISENS The second of the alarm systems called the reserve operates only with LO type signals If the operation of the primary alarm system is diagnosed as faulty if the program loop is interrupted by the processor or if a erroneous mathematical operation is performed the reserve alarm system takes over the signalling of critical faults In that case the electrical system is completely disconnected from the power supply therefore the lt 3 7 mA alarm signal is used Alarms of the primary alarm system may be deactivated after their cause subsides e g return to the conditions before the pressure overload subsiding the overnormative radioelectric interference A
36. hout display back lighting 0 0225A from a source with trapezial or rectangular characteristic supply Usup 16V Ro max O 0 0225A barrier resistance the real value of voltage from barrier 6 How to connect Ex transmitters APC 2000ALW Ex Safety APR 2000ALW Ex Safety The transmitter and other devices in the measuring loop should be connected in accordance with the intrinsic safety and explosion safety regulations and the conditions for use in dangerous areas Failure to observe the intrinsic safety regulations can cause explosion and the resulting hazard to people Hazardous area Safe area Ex Milliammeter Ro 2400 a Ex power supply see p 5 Aplisens KAP 03Ex Communicator To measure the current in the transmitter without Connecting transmitter to comunicator should be disconnecting the signalling circuit connect done accorded to Fig 10a and Fig 10b at page 17 a milliammeter to control sockets lt TEST gt lt TEST gt The communicator must hold an eligibility to use in hazardous area In hazardous areas connections Exemple KAP 03 Ex Aplisens production to the control terminals must be In absence of such approval for communicator the are permitted to be used in such areas zone becouse communicator cannot be connected to made using only instruments which transmitter must be configured and calibrated in safe the line entering to the
37. inst writing data to the transmitter via the HART protocol using a communicator or an appropriate program e g Raport 2 example screenshot from the Raport 2 software BE Raport 2 0 File Converter Settings Help write protection Specific parameters Change password e81 LCD Read protection against making local changes in the settings using the Local Menu in the transmitter control buttons made using the communicator or an appropriate program e g Raport 2 example screenshot from the Raport 2 software REZ Raport 2 0 File Converter Settings Help LCD parameters Specific parameters 7 operation Disabled 284 LCD Nienlaw Tnetallad Before start up it is required to perform full tests of functions related to safety as specified in the manual SIL SAFETY MANUAL Safety function tests for APC APR 2000 Safety transmitters rev 2 0 2 The maximum period between consecutive safety function tests Proof test interval is 1 year Any faulty equipment must be replaced immediately after the fault is detected The probability of failure specified in this manual is based on the Mean Time To Repair MTTR equal to 72 hours 33 2 0 2 DTR APC APR ALW 20 ENG 15 3 Hardware safety integrity architectural constraints on type B safety related subsystems IEC 61508 2 7 4 4 2 2 Safe failure fraction Type B hardware fault tolerance Toleration of
38. ity of elements was determined using the MIL HDBK 217F standard taking into consideration the operating conditions of each component For all electronic components the mean ambient temperature of 55 C was assumed Failure rate for semiconductor components was given for the 60 confidence level The purpose of this analysis was to determine the following parameters A total Failure rate per hour of a channel a subsystem ASD detected safe failure rate per hour of a channel in a subsystem ASU undetected safe failure rate per hour of a channel in a subsystem ADD detected dangerous failure rate per hour of a channel in a subsystem ADU undetected dangerous failure rate per hour of a channel in a subsystem DC diagnostic coverage SFF safe failure factor MTBF mean time between failures Until the full calculations of the reliability parameters the Proven in use method has been selected to estimate the measurement sensors failures intensity coefficient Pressure and differential pressure transmitters manufactured in the period from 03 2012 to 31 08 2013 were selected for the analysis The operating times of the transmitters were counted between 03 2012 and 30 09 2014 All transmitters were custom made Operating time of transmitters until suspension or failure was counted starting in the month following the manufacture It should be assumed with great probability that the majority of defective products
39. kened LCD1 the field where current or percentage of preset range control is displayed Depending on indicator configuration either the value of current in current line 4 20 mA being actual process variable or preset range control percentage can be displayed When the current value is displayed the value is preceded with symbol c LCD2 the field where digital value of pressure measured by transmitter pressure value rescaled to user units variable process unit or user unit MENU messages and other alerts and informations are displayed In the case of displaying digital value of pressure and rescaled pressure such value can be preceded by symbol Position of decimal comma can be set either in local MENU or remotely In case of display overfilling displayed value exceeding 99999 in the filed LCD2 COMMA message is displayed In case of pressure value exceeding permissible limits UNDER or OVER message shall be displayed depending on the direction of excess Pressure unit or user unit can be displayed alternately to digital value indicated in the cycle 10s digital value 1 s unit As necessary displaying of unit can be deactivated in local MENU using communicator or PC software Transmitter MPC5 allows rescaling of pressure values to user units To rescale enter the value corresponding to beginning and end of preset range and select the name of unit using communicator or PC software After activation of user mode rescal
40. larms of the reserve alarm system and the disconnection of the transmitter from the power line are a static condition In order to restore the operation of the transmitter after a critical alarm the power must be disconnected and connected again Apart from the alarm signal denoting DD failures diagnosed by the electronic system and processor software there are also dangerous diagnosable failures which may occur in the connection in series of components which participate in conducting electric current in the 4 20 mA current loop In such cases this is related to damage of a component or connection of open components which results in the transmitter not receiving power from the current line and the current flow is lt 3 7 mA which may occur in output circuits of the transmitter filters overvoltage protection units as parallel damage of the short circuit type and as a result the transmitter will receive shunted power supply without operating and at the same time will receive 2 21 5 mA The table below presents the exact causes of diagnosable dangerous alarms and their membership in the HI or LO group 31 ver 2 0 2 DTR APC APR ALW 20 ENG Signal Type of detected fault Probable cause type Comments RAM error Processor damage LO or HI signal selection FLASH memory Uncontrolled overwriting of the of the Alarm sianal Selection program checksum program memory FLASH memory LO or
41. medium is likely to cause the corrosion of membrane executed in stainless steel 1 4404 1 4435 316L a transmitter utilizing coated membrane or membrane executed in other material more resistant to given medium is to be used 6 4 3 In locations exposed to hazard of hitting with heavy object which in extreme situations is likely to cause breaking of the part of the system with transmitter and leakage of the medium suitable guards or A other protections are to be used both for safety reasons and to prevent sparking or of transmitter in such location avoided 13 2 0 2 DTR APC APR ALW 20 ENG 7 INSTALLATION AND MECHANICAL CONNECTIONS 7 1 APC 2000ALW Ex Safety INSTALLATION AND CONNECTIONS TO PRESSURE SYSTEM 7 1 1 Transmitters APC 2000ALW Ex Safety can be mounted directly on rigid impulse tubes Pressure transmitters are mounted on one way vented valves Such connection of transmitter allows its easy cutting off of the system for washing of measuring membrane local calibration diagnostics etc Transmitters can work in any position however cable inlets are best positioned horizontally or facing downwards In the event of fitting at the facility with medium at elevated temperature it is beneficial to install transmitters in some distance from the stream of hot air It is recommended that pressure connectors of transmitters are used with corresponding outlets see Fig 3 4 7 1 2 Transmitter is to be tightened in the
42. n 7 2 2 Transmitters APR 2000ALW Ex Safety with connector covers type connector can be mounted on three or five way valve units to tube 2 or to flat surface using C 2 holder Fig 7 7 2 3 When completing the fittings for mounting of transmitters information on connecting and reducing components sockets valves reducing clamps signal tubes offered by APLISENS can be useful Such information can be found in our catalogue Pressure can be fed to transmitters after making sure that transmitter with correctly selected measuring range to value of measured pressure is installed that seals are correctly selected and installed and that all threaded joints are adequately tightened Any attempt to undo bolts or stub pipes at pressurized transmitter is likely to cause leakage of A the medium and resulting hazard to personnel When disassembling transmitter it is to be cut off from process pressure or process pressure is to be reduced to atmospheric pressure Exercise extreme care and use all precautions in case of working with aggressive caustic explosive or other media which constitute a hazard to personnel If necessary wash disassembled part of the system 97 161 5 72 Fastener C2 for fitting differential pressure transmitters with C type connection to a 2
43. n 2 0 MPC5 SIS rev2 main board and software version 2 0 MPC5 SIS rev2 hex The hardware and software version may be found using the RAPORT 2 software in the Identification tab OX L4 E Device identification Identification Manufacturer Aplisens Device BC7B 2 Description Device ID 7100085 a Software revision 2 variables Hardware revision 20 Universal command revision 5 Common parameters Transmitter specific command rev 2 Or in the Transmitter parameters gt Version Information tab Specific parameters Master software revision 1 8 CPU hardware revision CPU software revision Slave software revision 1 10 29 2 0 2 DTR APC APR ALW 20 ENG 15 1 Description of safety requirements and boundary conditions signals related to safety and safety functions For APC R 2000ALW Safety transmitters the signal related to safety is the analogue 4 20 mA output signal All safety functions are related to just this output The APC R 2000ALW Safety transmitters have the capability to communicate using the HART protocol to provide configuration and diagnostic readouts however the HART communication may not be used in case of operation in a safety loop APC R 2000ALW Safety transmitters generate an process variable analogue signal in the range gt 3 8 3 9 mA lt 20 5 mA Depending on the settings this signal may be proportional or inversely proportio
44. nal to the measured pressure or pressure difference This current is detected by the logic controller connected to the current loop which monitors whether the supplied signal is within the pressure or differential pressure measurement range between the lower range value LRV and the upper range value URV Range 2 4 0 mA lt 20 0 mA with simple characteristics 4 20 mA Range gt 20 0 mA gt 4 0 mA with inverse characteristics 20 4 mA within the pressure or differential pressure measurement range below the lower range value LRV Range 23 9 mA lt 4 0 mA for Normal mode with simple characteristics 4 20 mA Range 23 8 mA lt 4 0 mA for Namur mode with simple characteristics 4 20 mA or Range 2 20 0 mA lt 20 5 mA for Normal mode with inverse characteristics 20 4 mA Range 2 20 0 mA lt 20 5 mA for Namur mode with inverse characteristics 20 4 mA within the pressure or differential pressure measurement range above the upper range value RV Range 2 20 0 mA lt 20 5 mA for Normal mode with simple characteristics 4 20 mA Range 2 20 0 mA lt 20 5 mA for Namur mode with simple characteristics 4 20 mA or Range 23 9 mA lt 4 0 mA for Normal mode with inverse characteristics 20 4 mA Range 23 8 mA lt 4 0 mA for Namur mode with inverse characteristics 20 4 mA or Range lt 3 7 mA for type L alarm signal Range gt 21 5 mA for type H alarm signal During the op
45. o install electrical and pressure measuring devices The installer is responsible for performing the installation in accordance with these instructions and with the electromagnetic compatibility and safety regulations and standards applicable to the type of installation The device should be configured appropriately for the purpose for which it is to be used Incorrect configuration may cause erroneous functioning leading to damage to the device or an accident In systems with pressure transmitters there exists in case of leakage a danger to staff on the side where the medium is under pressure All safety and protection requirements must be observed during installation operation and inspections If a device is not functioning correctly disconnect it and send it for repair to the manufacturer or to a firm authorized by the manufacturer In order to minimize the risk of malfunction and associated risks to staff the device is not to be installed or used in particularly unfavourable conditions where the following dangers occur possibility of mechanical impacts excessive shocks and vibration excessive temperature fluctuation exposure to direct sunlight Installation of intrinsic safety versions should be performed with particular care in accordance with the regulations and standards applicable to that type of installation Changes in the production of transmitters may precede a paper updating for the user The current user manual
46. or will ensue out when we try to change setting in Local Menu but transmitter is protected before recording To to make the change of setting with Local Menu using transmitter has to have the included service of Local Menu as well as switched off protection before record These parameters modification is possible by using KAP 03 communicator RAPORT program or software using library EDDL default setting Local Menu service switched on protection before record switched off applied_process_too_high Error will ensue out when given parameter pressure exceed admissible value Zeroing or the range setting verifying is necessary applied_process_too_low Error will ensue out when given parameter pressure will too low Zeroing or the range setting verifying is necessary span_too_small Error will ensue out when in result of setting range executing change the width of the range will be smaller than admissible acces_restricted Error will ensue out when the service of Local Menu is switched off and the user tries to call out the Menu Local service You should switch on the service of Local Menu with the KAP 03 communicator RAPORT program or software using library EDDL Warning ERR_L16 announcement can be displayed as well by zeroing attempt of the absolute transmitter WARNING new Lower Range Value Pushed Error will ensue out when the end of range set the URV change will cause the change of the range se
47. phragm seal Stainless steel 1 4404 1 4435 316L or Hastelloy C276 Sensing module Stainless steel 1 4404 316L Liquid filling the interior the sensing module Silicone oil chemically inactive liquid for measurement of oxygen uses Connectors for APC APR Stainless steel 1 4404 316L or Hastelloy C276 only for P GP CM30x2 C type vented covers and connectors APR Stainless steel 1 4404 316L Electronics casing High pressure cast of aluminium alloy lacquered with chemical resistant oxide enamel colour yellow RAL 1003 or stainless steel 1 4401 316 4 1 4 Enclosure ingress protection IP66 67according to PN EN 60529 2003 4 1 5 Response time on pressure stroke Maximum response time on pressure stroke 1 2 s 4 2 APC 2000ALW Ex Safety MEASUREMENT RANGES AND METROLOGICAL PARAMETERS 4 2 1 Measurement ranges Nominal measuring range Overpressure limit N FSO Minimum set range Rangeability without hysteresis 1 0 1000bar 0 100 10bar 1 100 1 1200bar 120 9 0 5 0 5bar 50 50 50mbar__ 5kPa 20 1 2bar 200kPa 10 0 0 25 0 25 25mbar 2 5 10 1 1bar 100kPa 0 70bar abs 0 7MPa abs 0 7bar abs 70kPa abs 100 1 140bar 14 Other nominal ranges to be agreed 4 2 2 Metrological parameters Accuracy max 0 075 of the calibrated range max 0 16 for range n 12 Long term stability lt
48. red DTR APC APR ALW 20 ENG with Appendix Exi User can find them at www aplisens pl 5 Permitted input parameters based on data from the FTZU 11 ATEX 0116X certificate and certification documentation Transmitters equipped in installed surge arresters should be supplied from a source galvanically isolated from ground Transmitters not equipped in surge arresters meets requirement for insulation 500V rms to ground and doesn t require separated powering The designation on the rating plate of the above powering options are given at point 3 The transmitters should be powered via the associated power feeding and measurement devices provided with the relevant intrinsic safe certificates The parameters of their outputs to the danger zone should not exceed the limit power supply parameters below specified 5 1 for power supply with a linear characteristic Ui 28V li20 1A Pi 0 7W 70 and 5 Ui 28V li20 1A Pi 0 4W 40 and T6 Power supply with a linear characteristic may be e g a typical barrier with parameters Uo 28 0 093 Rw 3000 Ii Rw Ip r gt o 10 cia 1 1 E AGI Uo c 1 1 Fig 1 Power supply from a source with linear characteristic 5 2 for power supply with a trapezial characteristic Ui 24V 1 0 05 Pi 0 6W 80 5 Example of power supply from a source with trape
49. rse software diagnostics in one channel continuous operation mode in the type B subsystem For the above mentioned products manufacturer recommends periodic testing interval 1 Year The document 19 SIL SAFETY MANUAL describes Perfect Proof Test for the APC APR 2000ALW Safety transmitters This test has ability to detect 100 of the possible Dangerous Undetected failures 40 ver 2 0 2 Prepared by Agnieszka Gwiazda Piotr Pawelec Jacek Kowalski Janusz Szewczyk Daniel Samczak Dariusz Knap October 2014 DTR APC APR ALW 20 ENG 41
50. s APC R 2000ALW Safety see Fig 12 Lock the cover tight by unbolting the screw Fig 12 Method of sealing the housings of transmitter series APC R 2000ALW Ex Safety 27 2 0 2 DTR APC APR ALW 20 ENG M20x1 5 or G1 2 Moving M20x1 5 nut or G1 2 Moving nut i i 1 i i X Impulse line Pmax 10 MPa Marerials P235T1 PN R35 SO 1 4301 304 S Ordering code Impulse line S or SO M20x1 5 61 2 e 2 M20x1 5 i Siphon tube 25 s 300 Connector to weld Marerials Marerials 235 1 35 50 13CrMo4 5 PN 15HM SO l 1 4301 304 S 1 4404 316L S Ordering code Ordering code Siphon tube S or SO RedSpaw S or SO M20x1 5 61 2 M20x1 5 61 2 Fig 13 Additional equipment for fitting of pressure transmitters Prepared J Wasowski 28 2 0 2 DTR APC APR ALW 20 ENG 15 INFORMATION RELATED TO FUNCTIONAL SAFETY Note Estimating the functional safety applies only to base device with main electronic components pressure sensor with the membrane and electronic equipment process connection mounted directly Additional process equipment such as the separator adapters separators valves etc are not included in the calculations Note The following estimation of functional safety applies only to hardware versio
51. s are available at www aplisens pl 2 0 2 DTR APC APR ALW 20 ENG Important Pressure transmitter series APC 2000ALW Safety and APR 2000ALW Safety for operation in functional safety loop are to be configured for output signal 4 20mA or 20 4mA operation in inversion system Signal HART or local buttons changing transmitter settings can be used for both diagnostics and configuration of products at the workplace but only with functional safety loop deactivated Following configuration of workplace Safety transmitters and activation of functional safety system with Safety transmitters only their output current signals are to be used For safety reasons any tampering with settings of Safety transmitters is to be prevented transmitters offer the possibility of blocking the change of local settings by software means and by sealing of housing covers 2 0 2 DTR APC APR ALW 20 ENG CONTENTS APPENDDCEXl z u III IIIa zz eee zywy a wwa di dia di 4 USER INFORMATION APPLICATIONS APC 2000ALW Ex Safety and APR 2000ALW Safety MAIN FEATURES IDENTIFYING nui c X TECHNICAL DATA ER UD APC R 2000ALW SAFETY COMMON PARAMETERS u ennt 4 1 1 Electrical 4 1 2 Permitted environmental conditions 4 1 3 Construction materials 4 1 4 Enclosure ingre
52. signal selection overnormative radioelectric LO or HI structure temperature option interference Pressure sensor measurement channel structure damage Exceeding the threshold values of Allowed temperature ambient temperature of transmitter Alarm signal selection R LO or HI limit exceeding error damage of the element or element option connections Error of mathematical Error of the processor s calculations in the arithmometer threshold condition Lo Critical alarm Always pressure measurement during mathematical calculations LO channel division by 0 Error of mathematical Error of the processor s calculations in the arithmometer threshold condition a Critical alarm Always sensor structure during mathematical calculations LO LO temperature division by 0 measurement channel Current loop error Damage of components or difference between the component connections G tieal atta Always assigned value and the overnormative radioelectric LO M SER readout exceeds 1 of the current range 160uA interference incorrect power supply parameters LO 32 ver 2 0 2 15 2 DTR APC APR ALW 20 ENG Restrictions on using the APC APR 2000ALW Safety transmitters in functional safety systems The transmitter is configured for operation in a functional safety loop after the required settings related to its identification metrology and alarm modes are made must have the following locks set protection aga
53. ss protection 4 1 5 Response time on pressure 4 2 APC 2000ALW SAFETY MEASUREMENT RANGES AND METROLOGICAL PARAMETERS 4 2 1 Measurement ranges seed eta en dade erue dian eL ona eB naa aaa an 4 2 2 Metrological parameters 4 2 3 PED versions Measurement ranges 4 2 4 Pressure 4 3 APR 2000ALW Ex SAFETY MEASUREMENT RANGES AND METROLOGICAL PARAMETERS 4 3 1 Measurement ranges een diee eee elici eee HP ed e eei a edi ei 4 3 2 Metrological parameters 4 3 3 PED versions Measurement ranges 4 3 4 Pressure Connectors 5 CONSTRUCTION u u E 5 1 ELECTRONIC SYSTEM MEASUREMENT PRINCIPLE u u u u u 5 2 MECHANICAL 5 2 1 Transmitter housing 5 2 2 Electronics assembly with display 5 2 3 Sensor modules Pressure connectors of transmitters Examples 6 PLACE OF INSTALLATION 4 424 2 6 1 GENERAL RECOMMENDATIONS M 6 2 LOW AMBIENT 4 0 6 3 HIGH MEDIUM TEMPERATURE cesses nennen enne nnn u u u
54. t beginning LRV 9 2 6 Remote configuration Remote configuration is possible with KAP XX communicator or PC software Measuring circuit should be in accordance with the fig 10 25 2 0 2 DTR APC APR ALW 20 ENG 10 INSPECTIONS MAINTENANCE SPARE PARTS 10 1 PERIODIC INSPECTIONS Periodic inspections are to be performed in accordance with standards mandatory to user During inspection the condition of pressure connectors absence of clearances and leaks and electrical connectors integrity of connections and the condition of seal at the gland and the condition of isolating membranes bloom corrosion is to be checked Processing characteristics is to be verified by performing operations typical for CALIBRATION procedure and possibly CONFIGURATION procedure 10 2 UNSCHEDULED INSPECTIONS When at the place of installation transmitter is exposed to risk of mechanical damage pressure overload hydraulic pulses overvoltage sediments and crystallization of medium undercutting of membrane or incorrect operation of transmitter is observed inspections are to be performed as necessary Check the condition of the membrane clean it check protection diodes absence of shorting check processing li characteristics 1 In case of observing the absence or incorrect value of signal in transmission line check the line the condition of connections at terminal strips connectors etc Check if values of power supply voltag
55. tem is to be provided This applies in particular to transmitters installed outdoors Such protection can be in the form of filing impulse tubes with e g the mixture of ethyleneglycol and water or with other liquid with freezing point lower than ambient temperature Also available methods of thermal insulation can be applied It is to be remembered however than thermal insulation protection of transmitter and impulse tubes works only short term During long periods of low temperature both transmitter and impulse tubes are to be heated 6 3 HIGH MEDIUM TEMPERATURE In the case of pressure transmitter APC R 2000ALW Ex Safety the maximum temperature of medium is 120 C Sensor module of transmitter is protected against temperatures higher than 120 C by way of sufficiently long impulse tubes which disperse heat and reduce the temperature of transmitter Sensor module 6 4 MECHANICAL VIBRATION IMPACTS CORROSIVE MEDIA 6 4 1 Pressure transmitters APC R 2000ALW Ex Safety are resistant to vibrations at the place of installation up to 4g and within frequency range up to 100Hz Stronger vibrations are to be isolated by means of flexible impulse tubes or choosing other location for installation and using remote diaphragm seals 6 4 2 Parts which contact the medium are to be executed in materials corresponding with chemical T corrosive properties of the medium In particular the membrane material is to be thoroughly selected and when the
56. their indications to output pressure controlled by reference instrument 9 2 4 Configuration and calibration of transmitter are effected using type KAPO3 communicator by APLISENS some HART communicators or PC computer with HART RS232 converter and RAPORT 2 software by APLISENS Configuration software RAPORT 2 is delivered with INTERVAL LINEARISATION software which allows entering of 21 point non linear utility characteristics to the transmitter Functions of type KAP communicator are described in its Operating Manual and data related to HART RS232 converter are included in information sheet HART RS232 CONVERTER 9 2 5 Local configuration of transmitters using buttons When the option of local configuration is active operator shall be able to modify settings using buttons below the display Buttons can be accessed after undoing the side cover To enter modification of local presets mode press and hold any of the three buttons for ca 4s Absence of transmitter response to holding of button means that local configuration option is blocked In such case setting override using communicator or computer is possible preceded with making available using the same tools the option of local configuration see command HART 132 133 Buttons are marked with symbols M El Pressing and holding any of the three buttons for 4 seconds shall cause displaying of EXIT message Accepting of the message by pressing and holding for 1 s of ts button s
57. tify BY VALUe Setting the LRV across inscribing of value After confirmation will display current LRV value before the passage in mode of edition 1 1 Choose and confirm sign introduced parameter 00000 Introduce in sequence digit after digit 5 digital number with point or without point After confirmation the last 5 digit of the parameter transmitter will confirm the party of command by the DONE announcement or the proper number of error will notify The parameter will be written down in units UNIT The setting of the end of the set URV range lt BACK Return to Local Menu If you will confirm this option you will come back to main tree of Local Menu BY PRESsure Setting URV across setting pressure If you will confirm this option transmitter will confirm the party of command by the DONE announcement or the proper number of error will notify BY VALUe Setting the URV across inscribing of value After confirmation will display current URV value before the passage in mode of edition Choose and confirm sign introduced parameter 00000 Introduce in sequence digit after digit 5 digital number with point or without point After confirmation the last 5 digit of the parameter transmitter will confirm the party of command by the DONE announcement or the proper number of error will notify The parameter will be written down in units UNIT 21 ver 2 0 2 UNIT
58. ver its fragment The width of preset range is the difference between the end and the beginning of preset range Transmitter can be preset to any range within pressure values corresponding to basic range allowing for limitations as in Tables in Clause 4 2 1 and 4 3 1 9 2 CONFIGURATION AND CALIBRATION 9 2 1 Transmitter properties permit adjustment and modification of presets metrological parameters and identification parameters Adjustable metrological parameters of transmitter include a pressure units displayed with value of measured pressure b the end of preset range c the beginning of preset range time constant e characteristics linear or elemental Information parameters which cannot be modified or parameters preset by manufacturer include f basic alert level LO low or HI high 9 the upper limit of basic range h the lower limit of basic range i minimum width of preset range 19 2 0 2 DTR APC APR ALW 20 ENG 9 2 2 Other identification parameters not affecting the output signal include device address device type code factory identification code factory device code number of preambles 3 20 UCS TSD program version electronics version flags serial number label tag description tag date tag message record number sensing module number The process of setting the parameters listed in 9 2 1 and 9 2 2 is called Configuration 9 2 3 Transmitters can also be calibrated by referring
59. year warranty of their manufacturer In accordance with the IEC 61508 standard the reliability parameters have been specified at 70 of one sided lower confidence limit The purpose of this analysis was to determine the following parameters MTTF B10 Life Reliability Expected Failure B2 Life Probability of Failure Failure Rate The reliability parameters were calculated using ReliaSoft software Weibull 9 Results of the Proven in use analysis for APC 2000ALW Safety Number of transmitters working until freezing 94 pcs Number of working hours until freezing 2 007 500 Number of working hours to failure 24 090 Number of failing transmitters 1 pc 34 ver 2 0 2 DTR APC APR ALW 20 ENG Analysis Summary Calculated Rounded MTTF 2 031590E 06 Hr 231 916667 Yr 2 03E 06 Hr 231 92 Yr Lower Bound 0 3 832868 023521 Hr 95 076258 Yr 832868 02 Hr 95 08 Yr B10 Life 214049 370005 Hr 24 434860 Yr 214049 37 Hr 24 43 Yr Lower Bound 0 3 87751 404433 Hr 10 017284 87751 40 Hr 10 02 Yr Reliability R 43800 Hr 97 8671 97 9 Lower Bound 0 3 94 8770 94 9 Expected Failure 2 026255 2 T 43800 Hr B2 Life Reliable Life Lower Bound 0 3 41043 618159 Hr 4 685345 Yr 16826 188913 Hr 1 920798 Yr 41043 62 Hr 4 69 Yr 16826 19 Hr 1 92 Yr Probability of Failure t 43800 Hr 2 1329 2 1 Failure Rate 4 9223E 07 Hr 4 92E 07 Hr Low
60. zial characteristic see Fig 2 li lo Rw IQ des Ui Uo 7 8 isa S L Fig 2 Power supply from a source with trapezial characteristic If Uo lt re then parameters Ua lo interrelated as follows Uo Uo Uo Rw Ten for Uo lt 1 2Ua g Rw 5 3 for power supply with rectangular characteristic Ui 24V li 0 025A Pi 0 6W 80 and T5 The supply of power from a source with a rectangular characteristic means that the voltage of the Ex power supply remains constant until current limitation activates The protection level of power supplies with a rectangular characteristic is normally ib The transmitter powered from such a supply is also a Ex device with protection level ib 2 0 2 DTR APC APR ALW 20 ENG Appendix Exi Example of practical provision of power supply use a stabilized power supply with Uo 24V with protection level ib and current limited to lo 25mA 5 4 Input inductance and capacity Ci 30nF Li 1 35mH Range of permissible ambient temperature Ta 40 C to 80 C category M1 and 1D 5 5 Temperature of measured medium can t cause increase temperature housing of transmitter above the ambient temperature Ta specified for a given category 5 6 Supply voltage min 16VDC 5 7 Load resistance from 28V linear supply Ro max Q Usup 16V 30007 0 02A for transmitter wit
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