Rotronic HygroFlex5-EX User manual

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
1 of 23
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
2 of 23
Contents
1General Information.............................................................................................................................3
1.1 About This Manual............................................................................................................................3
1.2 Document Versions...........................................................................................................................3
1.3 Supporting Documents .....................................................................................................................3
2Overview...............................................................................................................................................4
2.1 Mechanical Configurations and Dimensions.....................................................................................5
2.2 Display and Keypad Option ..............................................................................................................6
3General Description.............................................................................................................................7
3.1 Commissioning .................................................................................................................................7
3.2 Calculated Parameters .....................................................................................................................7
3.3 Analog Output Signals......................................................................................................................7
3.4 Service Connector ............................................................................................................................7
3.5 Probes ..............................................................................................................................................8
3.6 Function Overview............................................................................................................................9
4Mechanical Mounting / Dismounting ...............................................................................................10
4.1 Zone Plan .......................................................................................................................................10
4.2 General Guidelines.........................................................................................................................11
4.3 Housing...........................................................................................................................................11
4.4 Mounting of the HygroFlex5-EX (Duct Mounting)............................................................................11
4.5 Mounting of the HygroFlex5-EX (Wall Mounting)............................................................................12
5Electrical Installation.........................................................................................................................12
5.1 General Guidelines for Wiring.........................................................................................................12
5.2 ATEX Guidelines for Wiring ............................................................................................................13
5.3 Wiring..............................................................................................................................................13
6Operation............................................................................................................................................14
6.1 Starting the Device..........................................................................................................................14
6.2 Internal Menu (Optional Keypad and Display).................................................................................15
6.3 Displayed Parameters (Optional Keypad and Display)...................................................................15
7Maintenance.......................................................................................................................................16
7.1 Service Cable..................................................................................................................................16
7.2 Location of the Service Connector (Mini-USB) ...............................................................................16
7.3 Periodic Check (Calibration) of the Probe.......................................................................................16
7.4 Cleaning and Replacement of the Dust Filter .................................................................................16
7.5 Checking Output Signal Transmission............................................................................................16
7.6 Repair.............................................................................................................................................16
8Firmware Updates..............................................................................................................................17
9Technical Data ...................................................................................................................................17
9.1 Specifications..................................................................................................................................17
10 Accessories .......................................................................................................................................19
10.1 Configuration and Communication Software...................................................................................19
10.2 Service Cable..................................................................................................................................19
10.3 Replacement Filter..........................................................................................................................19
11 ATEX Data ..........................................................................................................................................20
11.1 Ignition Protection Category, Type..................................................................................................20
11.2 ATEX-Relevant Standards..............................................................................................................21
11.3 Nominal Data..................................................................................................................................21
11.4 Product Identification Label.............................................................................................................22

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
3 of 23
1 General Information
This document is available in other languages on the website www.rotronic.com.
This manual applies to all devices in the HygroFlex5-EX series with firmware version 3.0 and later. Changes
to the last digit of the version number reflect minor firmware changes that do no affect the manner in which
the device works.
1.1 About This Manual
This instruction manual provides information on installation, operation and maintenance of the HygroFlex5-EX
humidity and temperature transmitter.
1.2 Document Versions
Document Version
Date
Notes
V1_01
February 2014
Original release
V1_02
June 2014
Various additions
V1_05
July 2014
Additions by electrosuisse (certification body)
V1_06
July 2014
Linguistic amendments
V1_07
January 2015
Stylistic improvements
V1_08
June 2015
Probe: Extension of Tamb to +85°C.
New temperature class: T4 or 110°C
V1_09
July 2015
Material identification
V1_10
October 2015
Graphic Adaption
V1_11
April 2017
Electro schematic, analog outputs description
Corrections chapter : 5.2 ; 5.3 ;11
V1_12
April 2018
Add new pictures on page 10.
1.3 Supporting Documents
Document File Name
Contents
E-M-HW4v3-DIR
List of HW4 manuals
E-M-HW4v3-Main
HW4 software version 3.4: General instructions and functions common to all
devices
E-M-CalBasics
Principles of temperature and humidity calibration
Instructions on use for ROTRONIC humidity standards
E-T-HumiDefs
Humidity definitions
DV04-14.0803.02
Critical chemicals
Note: All document file names have an extension corresponding to the document release number (example:
E-M-HW4v3-Main_15). This extension is not shown in the above table.

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
4 of 23
2 Overview
The HygroFlex5-EX series of humidity & temperature transmitters is designed for fixed installation in applications
where high measurement accuracy is required. The transmitters can be used with all ROTRONIC ATEX probes in
the AirChip 3000 series. Standard probes may not be used.
The HygroFlex5-EX has two analog current outputs for relative humidity, temperature or a derived parameter, e.g.
dew point, enthalpy, mixing ratio, etc. The HygroFlex5-EX transmitter has an internal digital service interface.
Digital communication with a PC allows simultaneous monitoring of three parameters: relative humidity,
temperature and calculated value. The HygroFlex5-EX can measure within the ranges of 0 to 100 %RH
and 100 to 200C (-148 to 392F). The working temperature range of the electronics is limited to -40 ... 60°C
(-10 ... 60°C with optional LCD).
The probes are equipped with proven, durable sensors.
User-configurable adjustments
Calculation of humidity parameters such as dew point or frost point
Interchangeable probes for humidity and temperature calibration and adjustment outside Ex zones
Simulator mode
Simple updating of the firmware for both the HygroFlex5-EX transmitter as well as the Hygroclip-2 probe keeps
the devices in the HygroFlex5-EX series up to date with improved functionality.
Note:
The housings for all types with display are designed for horizontal mounting.

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
5 of 23
2.1 Mechanical Configurations and Dimensions
Wall Version
HF520-EX-Wxxxxxxx
Duct Version
HF520-EX-Dxxxxxxx
Probe tube: Ø15 x 130 mm

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
6 of 23
Wall Version Combinable With Probe
HC2-SM-EX
HC2-IM102-EX (cable probe 2 m, probe length 125 mm)
HC2-IM105-EX (cable probe 5 m, probe length 125 mm)
HC2-IM110-EX (cable probe 10 m, probe length 125 mm)
HC2-IM302-EX (cable probe 2 m, probe length 285 mm)
HC2-IM305-EX (cable probe 5 m, probe length 285 mm)
HC2-IM310-EX (cable probe 10 m, probe length 285 mm)
HC2-IE102-EX (screw-in probe with 1/2'' G thread, cable length 2 m)
HC2-IE105-EX (screw-in probe with 1/2'' G thread, cable length 5 m)
HC2-IE110-EX (screw-in probe with 1/2'' G thread, cable length 10 m)
HC2-IE302-EX (screw-in probe with 1/2'' NPT thread, cable length 2 m)
HC2-IE305-EX (screw-in probe with 1/2'' NPT thread, cable length 5 m)
HC2-IE310-EX (screw-in probe with 1/2'' NPT thread, cable length 10 m)
Duct Version Combinable
With Probe:
HC2-SM-EX
2.2 Display and Keypad Option
The optional LCD does not have a backlight.
The first line of the display shows the relative humidity and the second line the temperature (or a calculated value,
e.g. dew point, frost point, ...).
The display can be configured to show a trend indicator at the start of every line:
▲: Increasing value
▼: Decreasing value
In the event of an alarm the display shows the symbol [ ! ] to the right of the value.

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
7 of 23
3 General Description
3.1 Commissioning
HygroFlex5-EX (two-wire current loop, loop-powered): 10 ... 28 VDC depending on the loads connected to the
outputs. The minimum supply voltage can be calculated as follows:
V min = 10 V + (0.02 A x load*) *Load resistance in ohms.
The minimum supply voltage for the maximum load of 500 is 10 V + (0.02 A x 500 ) = 20 VDC. If both output
circuits are closed, the maximum current consumption is 40 mA.
The device must be properly closed when in operation in order to achieve explosion protection.
3.2 Calculated Parameters
The HygroFlex5-EX reads out the data of the connected probe.
The user can configure the HygroFlex5-EX with the ROTRONIC HW4 software to calculate one of the following
parameters:
oDew point (Dp) above and below freezing point
oFrost point (Fp) below freezing point and dew point above freezing point
oWet-bulb temperature (Tw)
oEnthalpy (H)
oVapor concentration (Dv)
oSpecific humidity (Q)
oMixing ratio by weight (R)
oVapor concentration at saturation (Dvs)
oVapor partial pressure (E)
oVapor saturation pressure (Ew)
Note: Some of the above-mentioned parameters depend on the value of the atmospheric air pressure.
The user can define a fixed atmospheric air pressure value with the ROTRONIC HW4 software.
3.3 Analog Output Signals
Using the ROTRONIC HW4 software, each of the two analog output signals can be assigned to one of the
following parameters:
Measured relative humidity (%RH)
Measured temperature (°C/°F)
Calculated parameter (see 3.2)
The scale of each analog output can be set within the numerical limits of -999.99 and 9999.99.
The analog output signals are generated by 16-bit D/A converters.
3.4 Service Connector
The service connector (UART interface with mini-USB port) allows connection of the HygroFlex5-EX
to a PC running the ROTRONIC HW4 software. A service cable is needed for this. See chapter 7 “Maintenance”
for the location of the service connector and the type of service cable.
The service connector is used for configuration and for updating the firmware of the HygroFlex5-EX.

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
8 of 23
3.5 Probes
The HygroFlex5-EX may only be operated with the following ATEX probe models:
HC2-SM-EX (standard probe)
HC2-IM102-EX (cable probe 2 m, probe length 125 mm)
HC2-IM105-EX (cable probe 5 m, probe length 125 mm)
HC2-IM110-EX (cable probe 10 m, probe length 125 mm)
HC2-IM302-EX (cable probe 2 m, probe length 285 mm)
HC2-IM305-EX (cable probe 5 m, probe length 285 mm)
HC2-IM310-EX (cable probe 10 m, probe length 285 mm)
HC2-IE102-EX (screw-in probe with 1/2'' G thread,
cable length 2 m)
HC2-IE105-EX (screw-in probe with 1/2'' G thread,
cable length 5 m)
HC2-IE110-EX (screw-in probe with 1/2'' G thread,
cable length 10 m)
HC2-IE302-EX (screw-in probe with 1/2'' NPT thread,
cable length 2 m)
HC2-IE305-EX (screw-in probe with 1/2'' NPT thread,
cable length 5 m)
HC2-IE310-EX (screw-in probe with 1/2'' NPT thread,
cable length 10 m)
HC2-LDP102-EX (low-dew point probe -60…20, screw-in
probe with 1/2'' G thread, cable length 2 m)
HC2-LDP-105-EX (low-dew point probe -60…20, screw-
in probe with 1/2'' G thread, cable length 5 m)
HC2-LDP-110-EX (low-dew point probe -60…20, screw-
in probe with 1/2'' G thread, cable length 10 m)

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
9 of 23
3.6 Function Overview
Outputs
Functions
Description
►Humidity and temperature
measurement
The connected probe is read out digitally and its measured values
shown and outputted at the analog outputs.
Measurement Loop Validation
Functions
Description
►Operation in simulator mode
Generation of fixed values for humidity, temperature and the
calculated parameter. Can be configured, enabled or disabled.
Safety
Functions
Description
►Write protection
Protection against unauthorized digital access. Can be configured,
enabled or disabled.
► Menu access from keypad
Used to prevent accidental or unauthorized changes to the system
settings by disabling the MENU key. Can be enabled or disabled
PROCESS PROTECTION / PROTECTION OF OTHER DEVICES
Functions
Description
►Limit humidity to 100 %RH
This function prevents the humidity signal from exceeding 100
%RH when condensation forms on the sensor. Can be enabled or
disabled
►Out-of-limit value alarm
Used to define the normal range for humidity, temperature and the
calculated parameter, dependent on the application.
Out-of-limit values trigger a digital alarm. Can be configured,
enabled or disabled.
►Fixed value on alarm
Used to define a fixed output value for temperature or humidity in
the event of a defective sensor or quality alarm. Can be
configured, enabled or disabled.

D-M-HF520-EX-V1_12
Rotronic AG
Bassersdorf, Switzerland
HygroFlex5-EX
Humidity & Temperature Transmitter
Instruction Manual
Page
10 of 23
4 Mechanical Mounting / Dismounting
4.1 Zone Plan
Applies to gas (Zone 0/1/2) and dust (20/21/22)
Wall Mounting
Duct Mounting
Use the accessory AC1301-MEX (mounting gland
for 15 mm ATEX probes) for zone separation.
Wall Mounting With Cable Probe
Wall Mounting With Screw-In Probe
Use the accessory AC1301-MEX (mounting gland
for 15 mm ATEX probes) for zone separation.
The screw-in probe itself sees to zone separation.