- Continental Disc Corporation
Contents
1. GEP 6612 Rev F 100900 Ref I D 16128 DI Continental Disc Corporation 3160 WEST HEARTLAND DRIVE LIBERTY MISSOURI 64068 3385 PHONE 816 792 1500 FAX 816 792 2277 5447 BDI FLX 2W IS BURST DISC SENSOR SYSTEM OPERATOR S MANUAL IMPORTANT USER SHOULD READ CAREFULLY AND UNDERSTAND THIS MANUAL BEFORE INSTALLING OPERATING OR TESTING THIS UNIT TABLE OF CONTENTS l PRODUCT DESCRIPTION Il SPECIFICATIONS Il HANDLING AND UNPACKING IV STORAGE V INSTALLATION VI MAINTENANCE VII LIMITED WARRANTY VIII DISCLAIMER OF WARRANTIES IX DISCLAIMER OF CONSEQ X WARRANTY EXCLUSIONS Biz DAMAGES uses 02011 2012 2014 Continental Disc Corporation 2 PRODUCT DESCRIPTION WARNING For full liquid applications The BDI FLX Sensor requires dynamic movement to signal Slow reversal of the rupture disc such as with liquid thermal expansion will not cause the BDI FLX Sensor to indicate A small crack in a rupture disc score will not cause the BDI FLX Sensor to indicate Note that the BDI FLX Sensor is designed to indicate within a few milliseconds so full reversal and full opening of the rupture disc must occur within a few milliseconds If full liquid flow at set pressure or a gas head will not be present during rupture of disc contact CDC for evaluation The BDI FLX Burst Disc Sensor oystems are designed to continuously monitor2. 11 uF Li 0 Associate IS Barrier entity parameters must meet the following requirements P lt Co gt 1 11 2 cable SPECIAL CONDITIONS FOR SAFE USE When located in a Zone 0 hazardous area the user shall ensure that electrostatic charging of the interface enclosure cannot occur When located in Zone 1 or Zone 2 the interface enclosure represents an electrostatic hazard and the enclosure shall only be cleaned using a damp cloth Solvents shall not be used Operating Requirements 1 Max voltage drop across the barrier Varop with ON state current of 4 5 mA Varop lt Vpw 5 5V Vp is the in series power supply voltage 2 OFF state input signal current for the barrier loff lorr gt 0 85 mA 3 ON state input signal current for the barrier lon lon 2 5 mA NOTE The BDI FLX 2W IS Burst Disc Sensor System intrinsically safe entity parameters should not be mixed with equipment functionality operating parameters Those safety barriers that satisfy the entity parameter requirements do not guarantee proper functioning of the BDI FLX System Both requirements must be met for safe and proper operation oafety Barrier Selection Considerations The BDI FLX 2W IS Burst Disc Sensor System output is typically connected to the load through an intrinsically safe barrier or isolated repeater Proper selection of the barriers or isolators is essential The barrier input power and capacitance inductance cap
3. lost profits and damages for resulting harm to property other than the Continental Disc Corporation assemblies and their component parts Customer acknowledges and understands that the provisions of these additional terms and conditions including this paragraph concerning disclaimer of consequential damages and limitation or remedy apply fully to the purchase of the products X WARRANTY EXCLUSIONS This warranty does not apply in the event of misuse or abuse of the product or as a result of unauthorized alterations or repairs It is void if the serial number is altered defaced or removed
4. the status of rupture discs and output a switch signal to a system when such rupture discs have relieved an over pressure condition The system is comprised of two components the BDI FLX sensor and the BDI FLX interface cable The interface cable processes the sensor s signal and outputs a switch type signal BDI FLX sensor BDI FLX Interface Cable _ ee Pre Amp Sensor Cable Pm ae 5 M12 Connector Sensing Element Interface oup Module Cable The BDI FLX Burst Disc Sensor Systems contain numerous advances in rupture disc burst monitoring and alarm switching technology Designed to meet the needs of a variety of applications and diverse industries the BDI FLX product family includes three models e BDI FLX 2W IS for use in hazardous environments and intrinsically safe applications BDI FLX 2W NIS for direct PLC or discrete input e BDI FLX 4W NIS for use as dry contact switch that can be used a wide variety of power options and control alarm inputs This user manual provides detail specifications electrical system requirements wiring and operating instructions for model 2W IS The BDI FLX 2W IS model is a 2 wire intrinsically safe device for use with a safety barrier barrier not provided It provides a digital switching signal over a single pair of wires It is designed in compliance with ATEX and IECEx requirements for use in intrinsically safe applications as category 1 equi
5. to people property product and loss of all claims for damages STORAGE The BDI FLX interface cable is to remain packed in the box in which it is shipped until ready for installation This unit should be stored in a cool dry atmosphere with ambient temperatures within 40 C to 50 C 40 F to 122 F INSTALLATION WARNING These installation and servicing instructions are for use by qualified personnel only To avoid injury and electrical shock do not perform any servicing other than that contained in this manual The installation and wiring of this unit should be performed in accordance with the latest edition of the governing Electrical Code WARNING Disconnect power to the unit before wiring NOTE This section describes the procedures and requirements for connecting the BDI FLX 2W IS interface cable to the user s system For installation of the BDI FLX sensor please refer to Preparation and Installation of the BDI FLX Sensor and connection to the BDI FLX Interface Cable Assembly document provided with the BDI FLX sensor 1 The BDI FLX Burst Disc Sensor System is not equivalent to a traditional mechanical switch The user must read carefully the installation procedure for the selected model and verify that their system meets the required conditions for the specific unit 2 The BDI FLX 2W IS System drops a certain amount of voltage in operation typically about 5 5 V This voltage drop determines how many volts the load
6. acity must be within the BDI FLX System permitted range The isolated repeater or barrier must keep a proper activation current and provide the BDI FLX 2W IS oystem with enough voltage for a reliable operation The BDI FLX 2W IS System output is compatible with NAMUR IEC 60947 5 6 sensor current level Most NAMUR sensor applicable intrinsically safe switching amplifiers are suitable and can be found in various safety barrier manufacturers catalogs NOTE Certain shunt diode Zener barriers are designed for mechanical switch dry contact input applications These are not recommended for use with the BDI FLX 2W IS System since these barriers typically provide highly restrictive voltage for the hazardous field devices However some Zener barriers can be utilized if both the parameter entity and the 2W IS operating conditions are met If utilizing Zener barriers the user must verify the complete loop resistance including barrier end to end resistance and constant voltage drop For new installations the selection of an isolator is recommended Isolated barriers can typically drive higher load resistance than a Zener barrier Other advantages of isolators include isolation between input output and power Most isolators provide short circuit protection and regulated power to the field and no 1 5 earth required thus avoiding complex ground loop problems The following are recommended barriers that can be used with the BDI FLX 2W IS system IS Is
7. e g the safety barriers or control system digital input channel can obtain from the supply voltage If the supply voltage minus the voltage drop is not sufficient for load normal operation the device will not turn ON Check the receiving system manufacturer s specifications for the input ON voltage threshold 3 The BDI FLX 2W IS System leaks a small amount of current through the loop when they output a switching OFF signal This current value is typically 0 075 mA at normal environmental condition and will not be over 0 85 mA under specified operating conditions The current flows through the load and produces a small voltage across the load If this voltage is greater than the value that will allow it to turn OFF the load will remain in the ON state although the sensor unit has switched OFF Check the manufacturer specifications for the control input OFF voltage threshold 4 The BDI FLX 2W IS System output is designed as Normally Closed ON state Each time the unit is powered up the output stays OFF for about 62 ms power up time delay then switches ON This warm up period allows the power line to stabilize User should examine their receiving system power up set time for logic adaptation 5 The BDI FLX Burst Disc Sensor System is designed for continuous monitoring of disc burst When powering up on initial installation or upon restoring power from a lost power condition the unit will reset itself automatically When the BDI FLX system
8. for assistance Do not repair or modify the product without consultation of Continental Disc Corporation Disassembly of the unit and or replacement of components may lead to improper function of the system and safety hazards VII LIMITED WARRANTY Products manufactured by Continental Disc Corporation have a warranty against defective workmanship and material for a period of one year after date of invoice In no event shall Continental Disc Corporation s liability for damages with respect to any of the products furnished under this Agreement exceed the charges previously paid by the customer to Continental Disc Corporation for such products Buyer s sole remedy for breach of this Agreement is repair or replacement of defective parts furnished by Continental Disc Corporation which have been returned to Continental Disc Corporation s factory at purchaser s expense It is expressly agreed between purchaser and Continental Disc Corporation that the remedy of repair and replacement is the exclusive and sole remedy of the purchaser Vill DISCLAIMER OF WARRANTIES Except as specifically provided in this Agreement there are no warranties expressed or implied including but not limited to any implied warranties of merchantability or fitness for a particular purpose IX DISCLAIMER OF CONSEQUENTIAL DAMAGES In no event shall Continental Disc Corporation be liable for consequential damages including but not limited to damages for loss of use damages for
9. ly safe applications 2 Connect BDI FLX Sensor to BDI FLX Interface Cable model 2W IS Connect the BDI FLX sensor pigtail to the BDI FLX interface cable through the M12 connector After insertion fasten the M12 screw ring to lock the connection 3 Connect Output Cable Terminate the output cable wires according to the wiring diagram The 2W IS two wires must be routed into the appropriate barrier terminals typically the discrete input channel Terminate all other correlated wires and ground properly before operation CAUTION To properly maintain the intrinsic safety of the system and to ensure immunity of the system to external interference appropriate shielded cable should be used Individual runs should use a shielded twisted pair STP cable such as Belden 1032A or equivalent Multiple runs from safety barrier to field junction box should use individual or overall shielded multiple twisted pairs cable such as Belden 9504 9328 or equivalent Remove a maximum 20 mm of insulation from wires prior to connecting 4 Final Check Check all wiring to ensure proper connections with no unwanted possible shorts grounds or open circuits 5 Energize Power to Unit With the disc sensor system safety barrier and output load installed and properly connected the unit can be powered and ready for operation VI MAINTENANCE The BDI FLX interface cables have been designed to operate with little maintenance required Periodic checks
10. olators MTL MTL551x Series MTL5018 Pepperl Fuchs KCD2 SR Ex1 LB R STAHL 9170 0 1x Series Weidmuller ACT20X HDI SDO Series Phoenix PI EX NAM Series Zener barriers MTL MTL774x Series Wiring Diagram Hazardous Area T Safe Area Isolated Barrier Control BDI FLX system 2W IS Power 2W IS connected through an isolated barrier Hazardous Area T Safe Area Zener Diode Barrier BDI FLX oe 2W IS Control Room p Equipment High Quality I S Grounding 2W S connected through a zener diode barrier Note The shield drain wire of the BDI FLX System output cable should be grounded at the barrier site and the shield throughout the cable must be connected to ground at a single point The shield of shielded cable from barrier to control room should be grounded at the control panel site and NOT connected to the barrier site The Zener diode barrier safety ground requires the ground path must have less than 1 Q of resistance from the barrier to the main earth ground electrode Installation 1 Mount the BDI FLX Interface Cable Enclosure Bolt the BDI FLX interface cable enclosure to a wall or rack using mounting bracket hardware Consider the distance and location for convenient sensor connection The enclosure can be installed in hazardous or non hazardous environment The interface cable must always be connected through a safety barrier located at the non hazardous area for all intrinsical
11. pment for Group II and Group Ill i e gas and dust areas when it is connected to a compatible intrinsically safe isolated repeater or barrier The interface cable contains a built in microprocessor that processes the sensor signal and produces a logic output offering plant operators a reliable rupture disc status signal The unit outputs a continuous current signal 4 5 mA typical as disc in normal operation and requires maximum 0 85 mA leakage current flowing through the load which is in series connected to the module when switching OFF The interface cable incorporates a failsafe design should there be a disc burst or an interruption of the sensor signal or power line the output of the interface module is always switched automatically to the safe OFF condition SPECIFICATIONS Electrical Specifications Power Supply Operating Temperature Field sensor operating current Output configuration Power up Time Delay Polarity Protection Transient Over voltage Protection Output Cable Approvals Marking Code Mechanical Specifications Housing Material Housing Inflammability Class Housing Dimensions Mounting Cable Gland Material Output Cable OD Degree of Protection 6 12 VDC BDI FLX Interface Cable 40 C to 70 C 40 F to 158 F BDI FLX Sensor 40 C to 204 C 40 F to 400 F 15 uA ON 4 5 mA typical min 2 5 mA max 4 85 mA OFF max 850 pA min 75 pA 62 ms Protected up
12. should be made to ensure the units are clean and free from contaminating humid or hot atmospheres and are in good physical and electrical condition Should the system fail to function properly the user should check for the following items where applicable A You have the correct BDI FLX sensor model for your application All specified conditions of the connected system listed in Section V are met B C The unit is connected to the barrier or control input channel in the correct polarity D There is no ground loop through the cable signal transmission E The BDI FLX sensor pigtail cable has been properly connected to the interface cable prior to powering the unit F The power is on G All wiring is connected properly per this instruction manual H The connected barriers or input channels are working properly l The user receiving system PLC DCS etc is functioning properly J There is no short or open circuit in the disc sensor interface cable or connectors The disc and sensor are in good condition Note Ifthe sensor has tripped an OFF signal due to disc burst or signal interruption the system needs to be reset following instructions listed in Section V The BDI FLX interface modules are designed with industrial category components and every effort has been made to make the unit as easily serviceable as possible Should there be a problem before or during operation please contact Continental Disc Corporation Customer Service
13. to 60 V Protected 18 AWG shielded twisted pair STP PVC tray cable TC CMG under UL NEC CE ATEX IECEx UL cUL ATEX Directive 94 9 EC 0359 69 Ex ia IIC T4 Ga Ex ia T135 C Da IECEx IEC Ex Scheme Ex ia IIC T4 Ga Ex ia IIIC T135 C Da UL cULus Hazloc Refer to UL C US Intrinsic Safety Control Drawing GEP 6615 ABS UL 94 0 3 1 x 2 1 x 1 1 in 79 x 54 x28 mm Wall panel Nylon 5 8 mm IP67 HANDLING AND UNPACKING The personnel responsible for the assembly operation inspection and maintenance of the BDI FLX Burst Disc Sensor System must be appropriately qualified The BDI FLX Burst Disc Sensor System is a precision device Always follow these guidelines when handling and unpacking the product to prevent damage A Use care when unpacking handling the product B Inspect the package for damage or missing items upon delivery C Mark any damage or missing items and report it to Customer Service at Continental Disc Corporation IV WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD When installed in hazardous locations precautions must be taken to ensure electrostatic charging cannot occur Prevent unintentional contact or clean with a dry cloth Clean ONLY with a damp cloth Do NOT use any solvent CAUTION Always observe the applicable local standards regulations and safety requirements Failure to comply with required safety precautions may result in serious injury or damage
14. trips an OFF signal as a result of a disc burst the user should replace the rupture disc and BDI FLX sensor The user can reuse the interface cable Re powering the system without replacing the BDI FLX sensor could result in a false normal ON signal WARNING Installation of intrinsically safe equipment must be performed in accordance with the requirements of the government and other local authority having jurisdiction System components and installation methods must be approved by the appropriate recognized approval authority Prior to installation review the certification marking on the device label to confirm it is appropriately certified for your region suits your site classification and complies with your hazardous area safety philosophy When the BDI FLX 2W IS Burst Disc Sensor System is used in an explosive area it must be operated in conjunction with a safety barrier or isolator suitable for the hazardous area classification and substance group The BDI FLX 2W IS System entity parameters must match in accordance with the safety barrier or isolator entity parameters This is to insure safe operation within explosive environments CAUTION Lead polarity must be observed when connecting the two wires to the barrier input channel Required System Conditions Safety Entity Parameter Requirements 1 2W IS maximum intrinsically safe input parameters Ui 12 V li 60 mA Pi 180 mW 2 2W IS equivalent internal parameters Ci 2 1
Download Pdf Manuals
Related Search