bdi-flx 2w-nis burst disc sensor system operator`s manual
Contents
1. 6613 Rev 100765 BC Ref 1 0 16484 Continental 0 Corporation 3160 WEST HEARTLAND DRIVE LIBERTY MISSOURI 64068 3385 PHONE 816 792 1500 FAX 816 792 2277 5447 BDI FLX 2W NIS 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 e E EEE Il SPECIFICATIONS ozine nine aE ET TEAN KEENE E A A AE A III HANDLING AND UNPACKING IV STORAGE V INSTALLATION renon EENEN A E te he he ENA 5 Miz DISCLAIMER OF WARRANTIES 4420 20 DISCLAIMER OF CONSEQUENTIAL 5 WARRANTY EXCLUSIONS 2011 2012 2014 Continental Disc Corporation 2 PRODUCT DESCRIPTION WARNING For full liquid applications The B2. 7 30 VDC including voltage fluctuation Operating Temperature 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 Output Configuration ON output 12 mA typical min 10 5 mA max 12 5 mA OFF max 850 min 75 Power up Time Delay 62 ms Polarity Protection Protected up to 60 V Transient Over voltage Protection Protected Output Cable 18 AWG shielded twisted pair STP PVC tray cable TC CMG under UL NEC Mechanical Specifications Housing Material ABS Housing Inflammability Class UL 94 V 0 Housing Dimensions 3 1 x 2 1 x 1 1 in 79 x 54 x 28 Mounting Panel Mount Cable Gland Material Nylon Cable OD 5 8mm Degree of Protection 67 Regulatory Information This product is designed and manufactured to comply with all applicable United cA 5 States and Canadian safety requirements and is UL 8 cUL recognized UL File no E350819 This product has been tested to the requirements of CAN CSA C22 2 61010 1 second edition including Amendment 1 or a later version of the same standard incorporating the same level of testing requirements 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 guidel
3. Section V are met The unit is connected to the control input channel in the correct polarity There is no ground loop through the cable signal transmission O W The BDI FLX sensor has been properly connected to the interface cable prior to powering the unit The power is on All wiring is connected properly per this instruction manual The connected terminal blocks or input channels are working properly mm The user receiving system PLC DCS etc is functioning properly There is no short or open circuit in the disc sensor interface cable or connectors J disc and sensor are in good condition Note If the 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 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 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
4. 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 replacement of defective parts furnished by Continental Disc Corporation which have been returned to Continental Disc Corporation s factory at purchaser s expense Itis 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 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 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 W
5. requirements for connecting the BDI FLX 2W NIS 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 BDI FLX 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 NIS System drops a certain amount of voltage in the ON state This voltage drop determines how many volts the load e g the 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 load will not turn ON Check the receiving system manufacturer s specifications for the input ON voltage threshold A resistor may be required to ensure the appropriate voltage drop across the load is obtained for an externally powered discrete input 3 The BDI FLX 2W NIS System leaks a small amount of current through the loop when it outputs a switching OFF signal This current value is minimum 0 075 mA at normal environmental condition and maximum 0 85 mA if under specified operating conditions The current flows through the load and produces a small voltage across the load If this voltage is greater t
6. ARRANTY 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
7. DI 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 Systems are designed to continuously monitor 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 Pre Amp Cable Sensor Cable M12 Connector Interface Sensing Element oupa 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
8. direct PLC or DCS discrete input BDI FLX 4W NIS for use as dry contact switch that can be used with 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 NIS The BDI FLX 2W NIS model is a 2 wire instrument that provides a digital switching signal over a single pair of wires This design is suitable for applications when the user wants the rupture disc signal to be sent directly to the digital input channel of a Programmable Logic Controller PLC or a Distributed Control System DCS It is powered from the PLC DCS discrete input or other suitable in series load to which it is connected and no separate power wiring is required 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 12 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 OFF condition SPECIFICATIONS Electrical Specifications Input Power
9. han 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 input OFF voltage threshold 4 The BDI FLX 2W NIS System output is designed as Normally Closed ON state when powered 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 a rupture disc 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 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 WARNING CAUTION This unit is not designed rated for hazardous environments Do not connect the BDI FLX 2W NIS output wires directly to a power supply without a suitable load or current limiting device in series with the unit Lead polarity must be observed when connecting the two wires to the PLC or DCS input channel Operating Requirements In normal operation the BDI FLX 2W NIS outp
10. ines 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 WARNING POTENTIAL ELECTROSTATIC CHARGING HAZARD Precautions should be taken to reduce the risk of electrostatic charge Prevent unintentional contact or cleaning 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 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
11. m supplied by the manufacturer Also check whether the input module uses a built in DC power supply Wiring Diagram INTERNALLY POWERED DISCRETE INPUT PLC or DCS Discrete Input White Sourcing Input BDI FLX 2W NIS SUPPLY EXTERNALLY POWERED DISCRETE INPUT DC POWER SUPPLY Black T 2W NIS to a sourcing input channel PLC or DCS Discrete Input Sinking Input White BDI FLX 2W NIS Black T DC POWER SUPPLY DC 1 White BDI FLX 2W NIS 8868 PLC or DCS Discrete Input 2W NIS to a sourcing input channel White PLC or DCS BDI FLX Discrete Input 2W NIS ew fe oe Black 2W NIS to a sinking input channel Note Installation Vi 1 Mount the BDI FLX Interface Cable Enclosure Bolt the BDI FLX interface cable enclosure to a panel rack using mounting holes Consider the distance and location for convenient sensor connection gt 2W NIS to a sinking input channel 2 Connect BDI FLX Sensor to the BDI FLX Interface Cable model 2W NIS Connect the BDI FLX sensor to the BDI FLX interface cable through the M12 connector After insertion faste
12. n the M12 screw ring to lock the connection 3 Connect Output Cable Terminate the output cable wires according to the wiring diagram The 2W NIS two wires are typically routed into the receiving system PLC or DCS discrete input channel Terminate all other correlated wires and ground properly before operation 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 and output load installed and properly connected the unit can be powered and ready for operation MAINTENANCE The shield drain wire of the 2W NIS output cable should be connected to ground at the PLC or DCS site and ground only at one point throughout the shield Shielded twisted pair cable should be used as extension cable when needed The shield of the shielded twisted pair cables should be connected at the terminal block and insulated from the metal case other conductors or ground SUPPLY Vil The BDI FLX interface cables have been designed to operate with little maintenance required Periodic checks 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 All specified conditions of the connected system listed in
13. uts an ON signal to the load PLC or DCS digital input channel through sourcing or sinking a current 12 mA typical and has a voltage drop across the 2W NIS that varies depending on voltage input In the event of a rupture disc burst or sensor wiring failure the 2W NIS outputs an OFF signal to the PLC or DCS input by drawing a small amount of current leakage current of maximum 0 85 mA with a voltage drop across the 2W NIS For proper application of voltage to PLC using the output current rating select load resistor to develop the correct voltage levels to the PLC inputs The following conditions must all be met for proper function of the device 1 The ON voltage of the load Vioaa in Volts and the power supply Vpw in Volts in series with the loop must satisfy Vioad lt Vpw 5 5V for example NOTE If the power supply voltage is in a range e g 24 VDC 420 uses the minimum value of the power voltage i e Vow 19 2 NOTE If the load impedance such as its internal resistance is given a constant it CAUTION reflects the total load voltage the Vioag can be calculated approximately as Vioag volts 12 ON state input signal current for the load lon must satisfy lon lt 10 5 mA OFF state input signal current for the load lore must satisfy lorr gt 0 85 mA For exact values always refer to specs of user PLC or DCS input module and its wiring diagra
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