Mantracourt ALA5 Manual de usuario

ALA5 2-Wire 4-20mA ATEX

Load Cell Amplifier

ICA5ATEX Strain Gauge or Load Cell Analogue Amplifier Mounted Inside

an In-Line Stainless Steel Enclosure (ILEATEX)

User Manual

MICRON METERS

www.micronmeters.com

[email protected]

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Contents

Chapter 1 The ALA5..................................................................................................................... 2

Chapter 2: Installing the ALA5 ........................................................................................................ 2

Pre Installation............................................................................................................................ 2

Connections:............................................................................................................................... 3

Standard cable: ........................................................................................................................... 3

Table 1 ..................................................................................................................................... 3

Cable colour code: ....................................................................................................................... 4

Alternative Cable types.................................................................................................................. 4

Figure 2.1 Connection Details for the ALA5 .......................................................................................... 4

Output Connections ...................................................................................................................... 5

Output Shunt Resistance Formula ..................................................................................................... 5

Chapter 3: Calibration .................................................................................................................. 5

Chapter 4: Changing the Gain and Offset Ranges................................................................................. 6

Figure 4.1 .................................................................................................................................. 6

Calculating the Gain Resistor (R2) ..................................................................................................... 7

Offset Resistor (R1) ...................................................................................................................... 7

Chapter 5: OEM Customers ............................................................................................................ 7

The ICA5ATEX Connections.............................................................................................................. 8

ILEATEX Enclosure ........................................................................................................................ 8

Chapter 6: Specifications .............................................................................................................. 9

Table 6.1 ICA5ATEX –4-20mA 2 wire Specifications................................................................................ 9

Table 6.2 ILEATEX Enclosure Specifications.......................................................................................... 9

Environmental Approvals ............................................................................................................... 10

Appendix A: Special Conditions of Safe Use ......................................................................................10

ATEX Marking: ............................................................................................................................ 11

EU DECLARATION OF CONFORMITY .................................................................................................12

EU ATTESTATION OF CONFORMITY .................................................................................................13

EU ATTESTATION OF CONFORMITY .................................................................................................14

ALA5 Certificate: ........................................................................................................................ 15

ICA5ATEX Certificate: .................................................................................................................19

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Chapter 1 The ALA5

The ALA5 is an ATEX certified (intrinsic safety) 2-wire 4-20mA amplifier providing a wide range of signal conditioning

for Strain Gauges, Load Cells, Pressure and Torque Transducers.

Combining the ICA5ATEX miniature loadcell amplifier with the stainless steel ILEATEX enclosure produces a

compact, robust and certified in-line amplifier suitable for use in zones 0, 1, and 2 in hazardous locations.

The ICA5ATEX is designed for a 1k bridge, however, 350R can be used at the expense of noise and drift

performance.

Please note: the ICA5ATEX amplifier’s output is uni-polar output i.e. zero strain input = 4mA and full range input =

20mA output.

Sensitivity adjustment, between 0.5 mV/V and 55 mV/V is achieved by a combination of the SPAN (gain) resistor R2

(see fig 4.1) and associated fine adjustment by potentiometer. Chapter 4 gives details of how to calculate a new

value for R2 to suit loadcell outputs other than the factory set 2.5mV/V.

Similarly transducer ZERO can be compensated for in the module. This adjustment is to compensate for slight errors

in the strain gauge and not to offset tare. The value of R1 (see fig 4.1) can be modified to increase the trim range of

the zero point (see chapter 4).

Chapter 2: Installing the ALA5

Pre Installation

Carefully remove the ALA5 unit from its shipment box. Check that the unit is complete and undamaged.

The ALA5 can be installed in any industrial environment providing the following limits and ATEX conditions of use

are met.

Please refer to Appendix A –‘Special conditions of safe use’

Operating Temperature

-40ºC to +85ºC

Humidity

95% non condensing

Storage temperature

-40ºC to +85ºC

II 1 G Ex ia IIC T4

Tamb = -40°C to +85°C

CE0891 TRaC10ATEX11247X

Ui= 28V, Ii = 100mA, Pi = 0.7W

Co = 33nF, Lo = 3mH

For an explanation of the ATEX conditions of use see Appendix A

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Figure 2.1 Dimensions

Connections:

The ALA5 is supplied pre-wired with 2-core screened cable for the supply/signal and 4-core screened cable for the

loadcell connections.

If installing into a hazardous zone, the ALA5 must be connected via an approved ATEX Barrier with the following

parameters:

Uo = 28V, Io = 100mA, Po = 0.7W, Barrier Impedance 300Ω.

These are maximum values, actual barrier parameters will vary. However, the barrier impedance is not permitted to

change.

Please refer to Appendix A –‘Special conditions of safe use’

Two examples of suitable barriers are:

MTL7706+ (passive Zener diode type with active current limit) manufactured by MTL Instruments

KFD2-STC4-EX1/2 (3-way isolated type) manufactured by Pepperl and Fuchs

Standard cable:

IMPORTANT NOTE: The cables factory-fitted to the ALA5 (see table 1) limit the operating temperature range to

-25°C to +70°C.

Table 1

Country

Supplier

Part No

Description

Farnell

1218651

Loadcell cable 1m: Belden 8132

Twin twisted pair cable (28 AWG)

100% overall foil shield + 65% tinned copper braided outer shield

O.D. 5.6mm

Capacitance: core to core 33 pF/m & core to shield 61 pF/m

Worst case capacitance: 224pF/m –see note 1

Temperature range: -30°C to +80°C

Farnell

3855636

(per metre)

798-551

(100m reel)

Output cable 5m: Van Damme 268006C

Single twisted pair cable (24 AWG) + 95% tinned copper braided

shield

O.D. 4.85mm

Capacitance: core to core 100 pF/m & core to shield 165 pF/m

Worst case capacitance: 197pF/m –see note 1

Temperature range: -25°C to +70°C

Note 1: The maximum capacitance, Cc, can be taken as the capacitance between all cores connected together and

the screen (Annex C of the installations standard EN60079-14). A safety margin of +10% has been added.

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

The ground connection conductor should have sufficient cross-sectional area to ensure a low impedance path to

attenuate RF interference.

Cable colour code:

Power/signal

Red

Supply +

Green

Com

Loadcell

Orange/White

+Exc

White/Orange

-Exc

Blue/White

+In

White/Blue

-In

Alternative Cable types

The type of cable used should be suitable for use in the hazardous area with particular regard to the certified -40°C

to +85°C temperature range of the ALA5.

The cable should comprise twin twisted pairs of cables –four-core for the loadcell and a single pair for the

power/signal.

Each cable should have an overall braid to ensure a good EMC seal with the glands on the ALA5.

Figure 2.1 Connection Details for the ALA5

The barrier limits the amount of electrical energy that can be transferred into the hazardous area thereby

preventing the ignition of a flammable atmosphere in the event of a fault condition occurring.

A simple passive barrier is shown above but this can be replaced by an isolated barrier to avoid ground loops that

may affect measurement accuracy and stability. These devices provide three-way isolation between power, input

and output.

The ALA5 is supplied with a 1m input cable and a 5m output cable. If the cables are too short for a particular

installation, they can be replaced with longer lengths or joined provided that an ATEX approved junction box is used

and the conditions set out below are satisfied. Excessively long leads, particularly the load cell cable may cause

noise and stability problems.

IMPORTANT NOTE: In order to remain ATEX compliant, the total amount of capacitance that can be connected

to the ALA5 enclosure (Co) must not exceed 33nF (0.033uF). This value must include the total cable

capacitance and the Ci value of the barrier supplying the unit. If the installation includes any ATEX junction

boxes their Ci values must also be included.

As an example, the maximum length for the output cable specified in table 1 will be:

(33nF –224pF)/197pF = 166.4m (multiply the pF/m figure given in table 1 by the length in metres to obtain the

total capacitance of each cable)

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Please refer to Appendix A –‘Special conditions of safe use’

For special cable types e.g. high temperature, armoured etc. please contact Mantracourt Electronics.

Output Connections

The ICA5ATEX analogue output is 4 to 20mA. The power and signal are combined in a single pair cable, simplifying

installation.

N.B. Neither connection to the output load is electrically common to the load cell.

The following formula gives the suitable range of shunt resistance for low supply voltage operation.

Output Shunt Resistance Formula

The shunt resistance must be less than: ((V supply -9) / 20mA) –Rwiring

e.g. assuming 10 Ohms wiring resistance and 24V supply:

Max shunt resistance = ((24 - 9) / 0.02) –10 = 740 Ohms

Chapter 3: Calibration

In order to calibrate the ALA5 the cover of the enclosure must be removed as follows:

Mechanical tools required: 1.5mm hex key, 14mm AF spanner and flat-blade screwdriver, maximum width 1.5mm.

1. Remove the two grub screws using a

1.5mm hex key

2. Loosen the gland furthest away from the

grub screw holes using a 14mm AF

spanner.

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

3. Gently ease the base out of the cover

ensuring that the cable slides through

the loosened gland to avoid any strain on

the internal connections.

4. The ICA5ATEX amplifier will now be

exposed allowing access to the two

trimming potentiometers.

Calibration:

1. Apply the low calibration conditions (weight, force or mV/V). Set the output to 4mA using the Zero

potentiometer.

2. Apply the known high calibration conditions (ideally between 75% and full scale) and adjust the Span

potentiometer to give the required output current for the known input.

i.e. 16mA for 4-20mA final calibration with 75% input or 20mA if 100% input.

When re-assembling the ALA5 it is imperative that the ‘O’ is fitted correctly and the cable gland re-tightened to

maintain a gas-tight seal.

Chapter 4: Changing the Gain and Offset Ranges

The ICA5ATEX amplifier is supplied un-calibrated but optimized for a sensitivity of 2.5mV/V with a 1k bridge.

To accommodate other sensitivities the gain resistor, ‘R2’ (see below) can be changed to a value derived from the

following formula.

Figure 4.1

N.B. a high quality resistor (e.g. 1% 25-50 ppm metal film) should be used for best performance. It may be necessary

to use an E96 value for optimum trim range: -

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Calculating the Gain Resistor (R2)















10

)/( 2.1069

2VexcVmV

k Ohms

Where

VmV /

is the sensitivity of the load cell (in mV/V), Vexc is the excitation voltage (in volts).

The following table gives calculated values of Vexc for various standard load cell impedances:

Load Cell Impedance

Excitation voltage (Vexc)

350

0.53

700

0.87

1000

1.08

1400

1.29

2000

1.51

5000

1.97

e.g. For a 2.5mV/V 1000 Ohm load cell : R2 = 386k Ohms –use 390k (nearest preferred value)

Use the following formulae to calculate the excitation voltage for cell impedances not given in the table:















6exp10762.4)/1( 1

Rcell

Ohms

















1300

5.2

Rx Rx

Vexc

Volts

e.g. for a 500 Ohm load cell:

Rx = 498.8 Ohms

Excitation Voltage, Vexc = 0.693V

Offset Resistor (R1)

The value of R1 can be changed to offset the zero point, if outside the normal trimming range (±2% FS).

Its value will also depend on the impedance of the load cell. The factory-fitted value, 180k is optimised for a 1000

Ohm cell.

If a 350 Ohm cell is used, R1 should be reduced to 30k to achieve a trim range of ±2% FS

Chapter 5: OEM Customers

IMPORTANT: OEM customers must hold a notified body Quality Assurance Notification (QAN)

if the ICA5ATEX is to be installed into a Mantracourt ATEX approved ‘generic’ enclosure.

If installed into a non-ATEX approved enclosure, the whole assembly must be submitted for

ATEX certification by an appropriate body.

Please refer to Appendix A –‘Special conditions of safe use’

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

The ICA5ATEX amplifier is designed to fit into a pocket in a certified loadcell. Use the 2.1mm hole to secure the unit

and to provide a good ground connection.

The mounting hole will accept an M2 screw or American equivalent #0-80.

Important Note: DO NOT USE #2 screw size.

Take care when soldering cables to the pads. Use a temperature controlled soldering iron set to a maximum 330 ºC,

for no longer than 2 seconds per pad. Excessive heat or increased soldering time may result in damage to the PCB.

See fig 2.1 for recommended screen connections.

The ICA5ATEX Connections:

The power supply should be between 9 and 28V and must be connected through an ATEX approved barrier if

installing into a hazardous area.

ILEATEX Enclosure

Package Contents

EMC ‘O’ ring

enclosure body

enclosure Cover

2 x EMC cable glands PG7/20 TPI 14mm AF

2 x grub screws

1 x M2 spring washer

1 x M2 cylindrical spacer

M2 x 12mm cap screw

Ensure that the ‘O’ ring is fitted to the body.

Please refer to Appendix A –‘Special conditions of safe use’

Body

Cover

Mantracourt Electronics Limited ALA5, ILEAtex and ICA5Atex User Manual

Chapter 6: Specifications

Table 6.1 ICA5ATEX –4-20mA 2 wire Specifications

Environmental

Parameter

Minimum

Typical

Maximum

Units

Notes

Supply voltage Range

9.0

Volts

Operating Temperature

Range

-40

Deg C

Storage Temperature

Range

-40

Deg C

Reverse polarity

Protection

-30

Volts

Measurement

Parameter

Minimum

Typical

Maximum

Units

Notes

Bridge Excitation

1.05

1.11

1.16

Volts

Note 1

Bridge Impedance

350

1000

5000

Ohms

Bridge Sensitivity

0.5

2.5

mV/V

Note 2

Output load

300

Ohms

Note 3

Bandwidth

1000

‘Zero’ adjustment

±2

%FR

Note 4

‘Span’ adjustment

±8

%FR

Linearity

0.02

%FR

Temperature stability

‘Zero’ Temperature

Stability

0.001

0.005

+/-%FR/Deg C

At 2.5mV/V

‘Span’ Temperature

Stability

0.007

0.014

+/-%FR/Deg C

At 2.5mV/V

FR=Full Range (16mA)

Note 1: 1000 Ohm load cell –Typically 0.53V for 350 Ohm cell

Note 2: Set by calibration resistor

Note 3: Limited by the 300Ω barrier impedance

Note 4: 1000 Ohms load cell –change R1 to suit other load cell impedances.

Note: Recommended bridge impedance is 1,000 Ohms

Note: The voltage between either of the power supply connections and the load cell shield should not exceed 50V.

Any leakage will be greater than 10M Ohms.

Table 6.2 ILEATEX Enclosure Specifications

Parameter

Minimum

Cover material

Stainless steel type 304

Body material

Stainless steel type 316 or 17-4

Threaded entries

PG7 / 20 TPI

Cable entries

PG7 EMC glands

(e.g. Jacob 50.007/EMV 14mm AF)

Environmental rating

IP67

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