K-System Isolated Barriers

PROCESS AUTOMATION SYSTEM DESCRIPTION K-System Isolated Barriers ISO9001

System Description K-System – Isolated Barriers With regard to the supply of products, the current issue of the following document is applicable: The General Terms of Delivery for Products and Services of the Electrical Industry, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the supplementary clause: "Expanded reservation of proprietorship"

System Description K-System – Isolated Barriers System Description K-System – Isolated Barriers Contents 1 Safety................................................................................... 4 1.1 Validity ..........................................................................................................4 1.2 Target Group / Personnel..............................................................................4 1.3 Reference to further documentation..............................................................4 1.4 Marking.........................................................................................................4 1.5 Intended Use ................................................................................................5 1.6 Improper Use ................................................................................................5 1.7 Mounting/Installation.....................................................................................5 1.8 Operation, Maintenance, Repair ...................................................................6 1.9 Delivery, Transport, Disposal........................................................................6 2 Product Specifications ...................................................... 7 2.1 Function........................................................................................................7 2.2 Housing Styles..............................................................................................8 2.3 Terminals ....................................................................................................10 2.4 Color Identification ......................................................................................15 2.5 Status Indicators with LEDs ........................................................................16 2.6 Label Carrier ...............................................................................................17 3 Installation ........................................................................ 18 3.1 DIN Mounting Rail.......................................................................................18 3.2 Power Rail ..................................................................................................18 3.3 Mounting.....................................................................................................19 3.4 Connection .................................................................................................21 3.5 Device Configuration ..................................................................................26 4 Operation .......................................................................... 28 4.1 Fault Monitoring ..........................................................................................28 4.2 Fault Output ................................................................................................28 4.3 Current and Voltage Standard Signals........................................................32 5 Technical Specifications ................................................. 33 5.1 Technical Data............................................................................................33 5.2 Model Number Description .........................................................................36 5.3 Dimensions.................................................................................................38 3 2014-04

System Description K-System – Isolated Barriers System Description K-System – Isolated Barriers Safety 1 Safety 1.1 Validity The chapter “Safety” is valid as instruction manual. Specific processes and instructions in this document require special precautions to guarantee the safety of the operating personnel. 1.2 Target Group / Personnel Responsibility for planning, assembly, commissioning, operation, maintenance, and dismounting lies with the system operator. Mounting, installation, commissioning, operation, maintenance and disassembly of any devices may only be carried out by trained, qualified personnel. The instruction manual must be read and understood. 1.3 Reference to further documentation Laws, standards, or directives applicable to the intended use must be observed. In relation to hazardous areas, Directive 1999/92/EC must be observed. The corresponding data sheets, declarations of conformity, EC-type-examination certificates, certificates and Control Drawings if applicable (see data sheet) are an integral part of this document. You can find this information under www.pepperl-fuchs.com. Due to constant revisions, documentation is subject to permanent change. Please refer only to the most up-to-date version, which can be found under www.pepperl-fuchs.com. 1.4 Marking Device identification Pepperl+Fuchs GmbH Lilienthalstrasse 200, 68307 Mannheim, Germany Model number ATEX approval Group, category, type of protection, temperature classification Statement of conformity (where appropriate) Group, category, type of protection (where appropriate) The exact designation of the device can be found on the name plate on the device side. 4 2014-04

System Description K-System – Isolated Barriers Safety 1.5 Intended Use The devices are only approved for appropriate and intended use. Ignoring these instructions will void any warranty and absolve the manufacturer from any liability. The device must only be operated in the ambient temperature range and at the relative humidity (non-condensing) specified. The devices are used in C&I technology for the galvanic isolation of C&I signals such as 20 mA and 10 V standard signals or alternatively for adapting or standardizing signals. Devices that incorporate intrinsically safe circuit are used for operating intrinsically safe field devices in hazardous areas. 1.6 Improper Use Protection of the operating personnel and the overall system is not ensured if the product is not being used according to its intended purpose. The equipment is not suitable for isolating signals in high current applications unless this is noted separately in the corresponding datasheet. 1.7 Mounting/Installation Prior to mounting, installation, and commissioning of the device you should make yourself familiar with the device and carefully read the instruction manual. The device must not be installed at locations where corrosive vapors may be present. The devices fulfill a degree of protection IP 20 according to IEC/EN 60529. The devices are designed for use in pollution degree 2 and overvoltage category II as per IEC/EN 60664-1. If used in areas with higher pollution degree, the devices need to be protected accordingly. Only use power supplies that provide protection against direct contact (e. g. SELV or PELV) for the connection to power feed modules. Observe the tightening torque of the terminal screws. The installation instructions in accordance with IEC/EN 60079-14 must be observed. Intrinsically safe circuits of associated apparatus (installed in safe areas) can be led into hazardous areas, whereby special attention must be paid to maintain separation distances to all non-intrinsically safe circuits according to the requirements in IEC/EN 60079-14. 5 2014-04

System Description K-System – Isolated Barriers Safety All separation distances between two adjacent intrinsically safe circuits need to be observed in accordance with IEC/EN 60079-14. If "Ex i" protected circuits (intrinsically safe) were operated with non-intrinsically safe circuits, they must no longer be used as "Ex i" protected circuits. The respective peak values of the field device and the associated apparatus with regard to explosion protection should be considered when connecting intrinsically safe field devices with intrinsically safe circuits of associated apparatus (verification of intrinsic safety). Make sure to observe IEC/EN 60079-14 and IEC/EN 60079-25. If more channels of one device are connected in parallel, make sure the parallel connection is made directly at the terminals of the device. When verifying the intrinsic safety, the maximum values for the parallel connection must be considered. 1.8 Operation, Maintenance, Repair The devices must not be repaired, changed or manipulated. If there is a defect, the product must always be replaced with an original device. 1.9 Delivery, Transport, Disposal Check the packaging and contents for damage. Check if you have received every item and if the items received are the ones you ordered. Keep the original packaging. Always store and transport the device in the original packaging. Store the device in a clean and dry environment. The permitted ambient conditions (see data sheet) must be considered. Disposing of devices, packaging material, and possibly contained batteries must be in compliance with the applicable laws and guidelines of the respective country. 6 2014-04

System Description K-System – Isolated Barriers System Description K-System – Isolated Barriers Product Specifications 2 Product Specifications 2.1 Function Isolated barriers are used for protection of intrinsically safe circuits in hazardous areas. They have the necessary current and voltage limitation and additionally electrical isolation between field circuit and control. Sensor Control Actuator system Figure 2.1 Function – isolating, amplifying and transforming signals The K-System consists of wide range of isolated barriers suitable for mounting on 35 mm DIN mounting rail. K-System is easy to specify, integrate and expand. Our extensive line of intrinsic safe isolators for hazardous location applications contains over 150 different models, each containing industry leading features and benefits. Figure 2.2 K-System on Power Rail 7 2014-04

System Description K-System – Isolated Barriers Product Specifications 2.2 Housing Styles Depending on the functionality and application, K-System devices have three different housing widths:  KC devices with 12.5 mm width  KF devices with 20 mm width  KF devices with 40 mm width The three housing widths versions have the same system characteristics. All devices from the K-System can be combined on the Power Rail. KC Device Housing 1 2 3 4 KCD2-SR- Ex1.LB PWR OUT/CHK 1 2 S 3 4 I II 5 6 7 8 9 10 Figure 2.3 KC device housing (12.5 mm) Used for high signal integrity  Compact 12.5 mm housing  Maximum packing density with single loop integrity  Power loss only 0.8 W per device 8 2014-04

System Description K-System – Isolated Barriers Product Specifications KF Device Housing 1 2 3 4 5 6 KFD2-ER-Ex1.W.LB OUT CHK PWR sens. 7 8 9 10 11 12 13 14 15 Figure 2.4 KF device housing (20 mm) Used for high channel density  Compact 20 mm housing  Highest packing density on the market  Requires only 5 mm per channel 9 2014-04

System Description K-System – Isolated Barriers Product Specifications 1 2 3 4 5 6 KFD2-WAC2- Ex1.D PWR FLT 1 2 OUT ESC RS232 OK 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Figure 2.5 KF device housing (40 mm) Used for applications with high functionality  Digital devices monitor speed, direction of rotation, slip, flow rates and time.  Analog devices monitor transmitter signals, temperature signals and load cells.  Configured using PACTwareTM or keypad  AC/DC wide range supply available 2.3 Terminals 2.3.1 Removable Terminal Blocks The removable terminal blocks simplify connection and control cabinet construction significantly. These terminal blocks offer adequate space for the connection of leads with core cross-sections of up to 2.5 mm2 (14 AWG). The terminal blocks are coded with red coding pins so misconnection of terminal blocks are eliminated. Observe the tightening torque of the terminal screws. The tightening torque is 0.5 Nm to 0.6 Nm. The 20 mm and 40 mm wide KF devices are factory-equipped with screw terminals. The KC devices are available with screw terminals or spring terminals. The type code of the versions of the KC-devices with spring terminals has the extension ".SP". 10 2014-04

System Description K-System – Isolated Barriers Product Specifications As an alternative to the factory-equipped terminal blocks the devices can be used with other terminal blocks:  Terminal blocks with screw terminals  Terminal blocks with screw terminals and test sockets  Terminal blocks with spring terminals and test sockets These terminal blocks are available as accessories. The terminal blocks can be easily coded with KF-CP coding pins (available separately). 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 4 5 6 4 5 6 7 8 9 7 8 9 7 8 9 10 11 12 10 11 12 10 11 12 Figure 2.6 K-System removable terminal blocks 1 Terminal blocks with screw terminals 2 Terminal blocks with screw terminals and test sockets 3 Terminal blocks with spring terminals and test sockets 11 2014-04

System Description K-System – Isolated Barriers Product Specifications Protection against direct contact The removable terminal blocks have different heights:  Height 15 mm (1), (2), (3): These terminal blocks are used in applications that have rated voltages lower than 50 V AC. The insulation of the removable terminal blocks provides protection against direct contact. The insulation corresponds to a reinforced insulation according to EN 50178 for a rated insulation voltage of 50 V AC.  Height 15.5 mm (4), (5): These terminal blocks are used in applications that have rated voltages higher than 50 V AC. The insulation of the removable terminal blocks provides protection against direct contact. The insulation corresponds to a basic insulation according to EN 50178 for a rated insulation voltage of 300 V AC. The higher terminals are marked (X). 1 2 3 4 5 15.1 15.1 15.1 10.1 15.1 X Figure 2.7 Removable terminal blocks with different heights 1 Terminal block with screw terminals, height 15 mm 2 Terminal block with screw terminals and test sockets, height 15 mm 3 Terminal block with spring terminals and test sockets, height 15 mm 4 Terminal block with screw terminals and test sockets, height 15.5 mm 5 Terminal block with screw terminals, height 15.5 mm X Marking Note! For more information see the corresponding data sheets. 2.3.2 Terminal Designation Please reference appropriate device for precise terminal designation. 12 15 15.5 2014-04

System Description K-System – Isolated Barriers Product Specifications 1 2 3 4 1 2 3 4 5 6 7 8 9 10 5 6 7 8 9 10 Figure 2.8 KC device housing (12.5 mm) 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 7 8 9 10 11 12 13 14 15 Figure 2.9 KF device housing (20 mm) 13 2014-04

System Description K-System – Isolated Barriers Product Specifications 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Figure 2.10 KF device housing (40 mm) 14 2014-04

System Description K-System – Isolated Barriers Product Specifications 2.4 Color Identification The color identification of the devices has the following meaning:  Green (1) indicates devices with DC power supply.  Black (2) indicates devices with AC power supply.  Gray (3) indicates devices with AC/DC wide range supply of • 20 V DC to 90 V DC or • 48 V AC to 253 V AC  Blue (4) indicates devices that process signals from the hazardous area 4 1 2 3 1 2 3 1 2 3 4 5 6 4 5 6 4 5 6 KFU8-UFT- Ex2.D KFD2-ER-Ex1.W.LB KFA5-ER-Ex1.W.LB 1 2 PWR IN/ CHK 1 2 OUT OUT CHK PWR OUT CHK PWR 3 4 ESC sens. sens. RS232 OK 7 8 9 7 8 9 7 8 9 10 11 12 10 11 12 10 11 12 13 14 15 16 17 18 13 14 15 13 14 15 19 20 21 22 23 24 1 2 3 Figure 2.11 Color identification of devices 1 green 2 black 3 gray 4 blue 15 2014-04

System Description K-System – Isolated Barriers Product Specifications 2.5 Status Indicators with LEDs LEDs are often used on isolators to indicate different statuses (e. g. for power supply, device failure, status messages, binary switching states). Standard LED colors are assigned to the status display according to NAMUR NE44. LED Display function Display Meaning Green LED Power supply On Power supply OK Off Power failure or insufficient power supply – device faulty Red LED Device fault, On Internal fault signal, failure signal – fault/failure device failure display of causes detected inside the device, device needs replacing Line fault Flashing External fault signal, failure signal – fault/failure display of causes detected outside the device, inspection and elimination of fault required No fault Off No malfunction, device is operating properly Yellow LED Switching states of On Possible causes of the output: binary inputs and  The relay is energized. outputs  The NO contact (also a change-over contact) is actively closed.  The open collector is switched through.  The switching voltage generated inside the device is applied. Possible causes of the input:  An external contact is closed.  A NAMUR sensor is undamped (OK range according to closed-circuit current principle).  A switching signal is actively applied. Off Possible causes of the output:  The relay is de-energized.  The NO contact (also a change-over contact) is actively opened.  The open collector is not switched through.  The switching voltage generated inside the device is not applied. Possible causes of the input:  An external contact is opened.  A NAMUR sensor is damped (fault range according to closed-circuit current principle).  A switching signal is not applied. Table 2.1 Meaning of status indicators 16 2014-04

System Description K-System – Isolated Barriers Product Specifications 1 2 3 OUT CHK PWR Figure 2.12 Example status indicators 1 Yellow LED "OUT" Switching state of the output 2 Red LED "CHK" Lead breakage and short circuit status indicator 3 Green LED "PWR" Power supply status indicator 2.6 Label Carrier A label carrier for individually labeling the devices is provided in the factory. 1 2 2 3 Figure 2.13 Label carrier on the front 1 Label carrier on KC devices for 22 mm x 9 mm labels 2 Label carrier on KF devices for 22 mm x 16.5 mm labels 3 Label carrier on KF devices (old version) for 18 mm x 8 mm labels 17 2014-04

System Description K-System – Isolated Barriers System Description K-System – Isolated Barriers Installation 3 Installation 3.1 DIN Mounting Rail The devices are mounted on a 35 mm DIN mounting rail according to EN 60715. Figure 3.1 Example: DIN mounting rail UPR-MR (35 mm x 15 mm) 3.2 Power Rail To reduce wiring and installation costs, Power Rail is the optimum solution. The Power Rail is a DIN mounting rail with plastic insert, that delivers power to the devices (24 V DC) and transfers bus signals and a collective error message. The Power Rail is factory-equipped with cover and end caps. These parts cover empty and open segments of the Power Rail. Thus, the Power Rail is protected from contamination. Additionally the cover and end caps prevent that electrically conductive parts come in contact with the Power Rail. Power Rail is available in two versions:  Power Rail UPR-03 Version with three leads: • two conductors for power • one conductor for collective error messaging  Power Rail UPR-05 (only for KFD2-WAC2-(Ex)1.D) Version with five leads: • two conductors for power • one conductor for collective error messaging • two conductors for serial data exchange 18 2014-04

System Description K-System – Isolated Barriers Installation 1 2 4 3 Figure 3.2 Example: Power Rail UPR-03 1 Cover UPR-COVER 2 Insert UPR-INS-03 3 DIN mounting rail UPR-MR (35 mm x 15 mm) 4 End cap UPR-E 3.3 Mounting Mounting the Isolated Barrier Snap the device onto the DIN mounting rail in a vertical downward movement. See figure below. 19 2014-04

System Description K-System – Isolated Barriers Installation  CORRECT: Device snapped on vertically. INCORRECT: Device snapped on from the side. Can damage the contacts and cause the device to fail. Figure 3.3 Vertical and horizontal mounting Low heat dissipation allows vertical or horizontal mounting without spacing. Operation is guaranteed over the full temperature range of the system in any mounting direction and without restriction. 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 4 5 6 4 5 6 4 5 6 7 8 9 7 8 9 7 8 9 7 8 9 10 11 12 10 11 12 10 11 12 10 11 12 13 14 15 13 14 15 13 14 15 13 14 15 Vertical mounting Horizontal mounting Figure 3.4 20 1 2 3 1 2 3 1 2 3 1 2 3 4 5 6 4 5 6 4 5 6 4 5 6 7 8 9 7 8 9 7 8 9 7 8 9 10 11 12 10 11 12 10 11 12 10 11 12 13 14 15 13 14 15 13 14 15 13 14 15 2014-04