WIKA RTD User manual

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Operating instructions
Betriebsanleitung
Examples/Beispiele
Resistance thermometers and thermocouples
Intrinsically safe designs (Ex-i)
Widerstandsthermometer und Thermoelemente
Eigensichere Ausführungen (Ex-i)
TÜV 10 ATEX 555793 X
IECEx TUN10.0002 X

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2 WIKA operating instructions RTD and TC, intrinsically safe designs
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© 2010 WIKA Alexander Wiegand SE & Co. KG
All rights reserved. / Alle Rechte vorbehalten.
WIKA® is a registered trademark in various countries.
WIKA® ist eine geschützte Marke in verschiedenen Ländern.
Prior to starting any work, read the operating instructions!
Keep for later use!
Vor Beginn aller Arbeiten Betriebsanleitung lesen!
Zum späteren Gebrauch aufbewahren!
Operating instructions models RTD and TC, Ex-i Page 3 - 46
Betriebsanleitung Typen RTD und TC, Ex-i Seite 47 - 86

1. General information 4
2. Safety 5
3. Specications 10
4. Design and function 13
5. Transport, packaging and storage 14
6. Commissioning, operation 15
7. Information on mounting and operation in hazardous areas
(Europe) 21
8. Electrical connection values 30
9. Calculation examples for self-heating at the probe/
thermowell tip 32
10. Maintenance and cleaning 36
11. Faults 36
12.
Dismounting, return and disposal 37
Appendix 1: EC type examination certicate 39
Appendix 2: IECEx certicate 43
Appendix 3: EC declaration of conformity 46
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Contents
Contents
Declarations of conformity can be found online at www.wika.com.

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1. General information
■
The instrument described in the operating instructions has been designed and manufactured
using state-of-the-art technology. All components are subject to stringent quality and
environmental criteria during production. Our management systems are certied to ISO 9001
and ISO 14001.
■
These operating instructions contain important information on handling the instrument.
Working safely requires that all safety instructions and work instructions are observed.
■
Observe the relevant local accident prevention regulations and general safety regulations for
the instrument‘s range of use.
■
The operating instructions are part of the instrument and must be kept in the immediate vicinity
of the instrument and readily accessible to skilled personnel at any time.
■
Skilled personnel must have carefully read and understood the operating instructions, prior to
beginning any work.
■
The manufacturer‘s liability is void in the case of any damage caused by using the product
contrary to its intended use, non-compliance with these operating instructions, assignment of
insuciently qualied skilled personnel or unauthorised modications to the instrument.
■
The general terms and conditions, contained in the sales documentation, shall apply.
■
Subject to technical modications.
■
Further information:
- Internet address: www.wika.de / www.wika.com
- Application consultant: Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Explanation of symbols
WARNING!
... indicates a potentially dangerous situation that can result in serious injury or death,
if not avoided.
CAUTION!
... indicates a potentially dangerous situation, which can result in light injuries or
damage to equipment or the environment, if not avoided.
Information
… points out useful tips, recommendations and information for ecient and trouble-
free operation.
1. General information

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WARNING!
... indicates a potentially dangerous situation in a potentially explosive atmosphere,
resulting in serious injury or death, if not avoided.
WARNING!
... indicates a potentially dangerous situation, caused by hot surfaces or liquids, that
can result in burns if not avoided.
Abbreviations
RTD "Resistance Temperature Detector" = Resistance thermometers
TC "Thermocouple"
2. Safety
WARNING!
Before installation, commissioning and operation, ensure that the appropriate thermo-
meter has been selected in terms of measuring range, design and specic measuring
conditions.
Choose the thermowell with regard to the maximum pressure and temperature (e.g.
rating chart in DIN 43772).
Non-observance can result in serious injury and/or damage to equipment.
Further important safety instructions can be found in the individual chapters of these
operating instructions.
2.1 Intended use
These resistance thermometers and thermocouples are used for temperature measurement in
industrial applications, in hazardous areas.
Resistance thermometers are used for measuring temperatures from -200 ... +600 °C. For
thermocouples, the possible measuring ranges range from -200 ... +1200 °C. Thermometers
of this design can be installed directly in the process as well as in thermowells. The thermowell
designs can be selected as desired, but the operating process data (temperature, pressure,
density and ow rate) must be taken into account.
1. General information / 2. Safety

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The system operator is responsible for selecting the thermometer or thermowell, and for the
selection of their materials, so as to guarantee their safe operation within the system or machine.
When preparing a quote, WIKA can only give recommendations which are based on our
experience in similar applications.
The thermometer has been designed and built solely for the intended use described here and
may only be used accordingly.
The technical specications contained in these operating instructions must be observed.
Improper handling or operation of the instrument outside of its technical specications requires
the instrument to be shut down immediately and inspected by an authorised WIKA service
engineer.
If the instrument is transported from a cold into a warm environment, the formation of
condensation may result in the instrument malfunctioning. Before putting it back into operation,
wait for the instrument temperature and the room temperature to equalise.
The manufacturer shall not be liable for claims of any type based on operation contrary to the
intended use.
2.2 Personnel qualication
WARNING!
Risk of injury should qualication be insucient!
Improper handling can result in considerable injury and damage to equipment.
■
The activities described in these operating instructions may only be carried out by
skilled personnel who have the qualications described below.
■
Keep unqualied personnel away from hazardous areas.
Skilled personnel
Skilled personnel are understood to be personnel who, based on their technical training,
knowledge of measurement and control technology and on their experience and knowledge of
country-specic regulations, current standards and directives, are capable of carrying out the
work described and independently recognising potential hazards.
Special operating conditions require further appropriate knowledge, e.g. of aggressive media.
2.3 Additional safety instructions for instruments with ATEX and IECEx approvals
WARNING!
Non-observance of these instructions and their contents may result in the loss of
explosion protection.
2. Safety

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WARNING!
Follow the requirements of the 94/9/EC (ATEX) and IECEx directives.
Follow the respective national regulations concerning Ex-usage
(e.g. EN/IEC 60079-10 and EN/IEC 60079-14).
2.4 Special hazards
WARNING!
Observe the information given in the applicable type examination certicate and the
relevant country-specic regulations for installation and use in potentially explosive
atmospheres (e.g. EN/IEC 60079-14, NEC, CEC). Non-observance can result in
serious injury and/or damage to equipment.
For additional important safety instructions for instruments with ATEX/IECEx appro-
val, see chapter "2.3 Additional safety instructions for instruments with ATEX and
IECEx approvals".
WARNING!
For hazardous media such as oxygen, acetylene, ammable or toxic gases or liquids,
and refrigeration plants, compressors, etc., in addition to all standard regulations, the
appropriate existing codes or regulations must also be followed.
WARNING!
Protection from electrostatic discharge (ESD) required. The proper use of grounded
work surfaces and personal wrist straps is required when working with exposed
circuitry (printed circuit boards), in order to prevent static discharge from damaging
sensitive electronic components.
To ensure safe working on the instrument, the operating company must ensure
■
that suitable rst-aid equipment is available and aid is provided whenever required.
■
that the operating personnel are regularly instructed in all topics regarding work
safety, rst aid and environmental protection and know the operating instructions
and, in particular, the safety instructions contained therein.
WARNING!
Residual media in dismounted instruments can result in a risk to persons, the environ-
ment and equipment. Take sucient precautionary measures.
Do not use this instrument in safety or Emergency Stop devices. Incorrect use of the
instrument can result in injury.
Should a failure occur, aggressive media with extremely high temperature and under
high pressure or vacuum may be present at the instrument.
2. Safety

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2.5 Labelling / safety marks
2.5.1 Product labels for resistance thermometers
Model
Sensor in accordance with
standard
■
F Thin-lm resistor
■
W Wire-wound resistor
Approval number
Year of manufacture
For an explanation of
symbols, see page 10
Transmitter model
(only for design with transmitter)
Year of manufacture
For an explanation of
symbols, see page 10 Approval number
Model
2. Safety
■
Product label for TR10-A measuring insert
■
Additional data for Ex instruments

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2. Safety
2.5.2 Product labels for thermocouples
Model
Approval number
Year of manufacture
For an explanation of
symbols, see page 10
Transmitter model
(only for design with transmitter)
Year of manufacture
For an explanation of
symbols, see page 10 Approval number
Model
■
Product label for measuring insert TC10-A
■
Additional data for Ex instruments
"ungrounded"
Sensor in accordance with
standard
■
ungrounded
■
grounded
Legende:
■
ungrounded
welded insulated
■
grounded
welded to the sheath

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Explanation of symbols
Before mounting and commissioning the instrument, ensure you read the
operating instructions!
CE, Communauté Européenne
Instruments bearing this mark comply with the relevant European directives.
ATEX European Explosion Protection Directive
(Atmosphère = AT, explosible = EX)
Instruments bearing this mark comply with the requirements of the European
Directive 94/9/EC (ATEX) on explosion protection.
3. Specications
3.1 Resistance thermometer
Sensor connection method
■
2-wire The lead resistance is recorded as an error in the measurement.
■
3-wire With a cable length longer than approx. 30 m, measuring errors can occur.
■
4-wire The internal lead resistance of the connecting wires is negligible.
Limiting error of the sensor per DIN EN 60751
■
Class B
■
Class A
■
Class AA
The combination of a 2-wire connection with Class A / Class AA is not permissible, since the lead
resistance of the measuring insert negates the higher sensor accuracy.
Basic values and limiting errors
Basic values and limiting errors for the platinum measurement resistances are laid down in
DIN EN 60751.
The nominal value of Pt100 sensors is 100 Ω at 0 °C.
The temperature coecient α can be stated simply to be between 0 °C and 100 °C with:
α = 3.85 ∙ 10-3 °C-1
The relationship between temperature and electrical resistance is described by polynomialss,
which are also dened in DIN EN 60751. Moreover, this standard species the basic values in °C
steps in tabular form.
2. Safety / 3. Specications

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Class Temperature range Limiting error in °C
Wire-wound (W) Thin-lm (F)
B -196 … +600 °C -50 … +500 °C ± (0.30 + 0.0050 | t |) 1)
A -100 … +450 °C -30 … +300 °C ± (0.15 + 0.0020 | t |) 1)
AA -50 … +250 °C 0 … 150 °C ± (0.10 + 0.0017 | t |) 1)
1) | t | is the value of the temperature in °C irrespective of the sign.
Bold: standard version
Resistance values and limiting deviations at selected temperatures (Pt100)
Temperature
in °C (ITS 90)
Resistance value in Ω
Class B Class A Class AA
-196 19,69 ... 20,80 - -
-100 59,93 ... 60,58 60,11 ... 60,40 -
-50 80,09 ... 80,52 80,21 ... 80,41 80,23 ... 80,38
-30 88,04 ... 88,40 88,14 ... 88,30 88,16 ... 88,28
099,88 ... 100,12 99,94 ... 100,06 99,96 ... 100,04
20 107,64 ... 107,95 107,72 ... 107,87 107,74 ... 107,85
100 138,20 ... 138,81 138,37 ... 138,64 138,40 ... 138,61
150 156,93 ... 157,72 157,16 ... 157,49 157,91 ... 157,64
250 193,54 ... 194,66 193,86 ... 194,33 193,91 ... 194,29
300 211,41 ... 212,69 211,78 ... 212,32 -
450 263,31 ... 265,04 263,82 ... 264,53 -
500 280,04 ... 281,91 - -
600 312,65 ... 314,77 - -
This table represents the calibration process with predened temperatures. This means if a temperature
standard is available, the resistance value of the test piece must lie within the limits specied above.
For further information on accuracies and limits of use of resistance thermometers,
see data sheet IN 00.17 (download available at www.wika.de).
3.2 Thermocouples
Sensor type
Model Recommended max. operating temperature
K (NiCr-Ni) 1200 °C
J (Fe-CuNi) 800 °C
E (NiCr-CuNi) 800 °C
T (Cu-CuNi) 400 °C
N (NiCrSi-NiSi) 1200 °C
S (Pt10% Rh-Pt) 1600 °C
R (Pt13% Rh-Pt) 1600 °C
B (Pt30% Rh-Pt6%-Rh) 1700 °C
3. Specications

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Potential measuring uncertainties due to ageing eects
Thermocouples are subject to ageing and change their temperature/thermal voltage
characteristic. Type J thermocouples of (Fe-Cu-Ni) age slightly due to oxidation of the pure metal
leg. In types K and N thermocouples (NiCrSi-NiSi), high temperatures can result in substantial
changes to the thermal voltage due to chrome depletion in the NiCr leg, leading to a lower thermal
voltage.
This eect is accelerated if there is a shortage of oxygen, since a complete oxide layer, which
would protect it from further oxidation, cannot be formed on the surface of the thermocouple.
The chromium in the alloy is oxidised, but not the nickel, giving rise to "green rot" that eventually
destroys the thermocouple. When NiCr-Ni thermocouples that have been operating above 700 °C
are cooled quickly, this cooling causes certain states in the crystal structure (short-range order)
to freeze, which in Ttype K thermocouples can result in a change of the thermal voltage of up to
0.8 mV (K eect).
In Type N thermocouple (NiCrSi-NiSi), it has been possible to reduce the short-range-order
eect by alloying both legs with silicon. The eect is reversible and is largely eliminated again by
annealing above 700 °C, followed by slow cooling. Thin sheathed thermocouples are particularly
sensitive. Cooling in still air can even result in deviations of more than 1 K.
The application range of these thermometers is limited both by the permissible max. temperature
of the thermocouple and by the max. temperature of the thermowell material.
Listed thermocouples are available both as single or duplex thermocouples. The thermocouple
will be delivered with an insulated measuring point, unless explicitly specied otherwise.
Sensor limiting error
A cold junction temperature of 0 °C is taken as basis with the denition of the tolerance value
of thermocouples. When using a compensating cable or thermocouple cable, an additional
measuring error must be considered.
For limiting errors and further specications see current WIKA data sheet or order
documentation.
3. Specications

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4. Design and function
4.1 Description
These thermometers (resistance thermometers and thermocouples) detect temperatures in
processes.
Depending on their design, these thermometers are suitable for low, medium and high process
requirements in hazardous areas.
Insulated measuring point
The model TRxx or model TCxx thermometers consist of a welded tube, a mineral-insulated
sheathed cable or ceramic-insulated thermal wires (in which the temperature sensor is located,
embedded in a ceramic powder), a temperature-resistant sealing compound, cement compound
or a thermal transfer paste.
Alternatives:
The measuring insert or the cable probe can also be provided in a tubular form. In this case, the
sensor is located in a welded tube and embedded in a ceramic powder, heat-conducting paste or
in a sealing compound suitable for this purpose.
The measuring insert for high-temperature thermocouples can also be assembled from thermal
wires insulated with ceramic rods or ceramic beads. The ceramic tube is cemented into a metallic
support tube using a temperature-resistant cement.
Thermocouples, non-insulated (grounded)
For special applications, for example surface temperature measurements, the sensors are in
direct contact with the protective sleeve, or the measuring points of thermocouples are welded to
the bottom (see chapter "7.1.1 Special conditions of use (X conditions)").
Measuring point insulated (ungrounded) Measuring point not insulated (grounded)
Thermocouple Thermocouple Measuring point Measuring point
Sheath Sheath
AI203 powder
MI line
V-Pad
welded with
ller
V-Pad version
Measuring point not insulated
4. Design and function

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Vibration resistance
The thermometers have an impact- and vibration-resistant design. The vibration resistance of the
basic model corresponds to DIN EN 60751 (up to 3 g), while for special designs higher loads are
possible. The impact resistance of all versions complies with the requirements of EN 60751, with
the exception of high-temperature thermocouples assembled from ceramic-insulated thermal
wires.
Electrical connection
In terms of connection, the thermometer is equipped with a housing and a connector or bare wire
ends. The housing design will contain the terminals or a certified transmitter. Optionally, separately-
certified digital displays can be built into the housing.
4.2 Scope of delivery
Cross-check scope of delivery with delivery note.
5. Transport, packaging and storage
5.1 Transport
Check instrument for any damage that may have been caused by transport.
Obvious damage must be reported immediately.
5.2 Packaging
Do not remove packaging until just before mounting.
Keep the packaging as it will provide optimum protection during transport (e.g. change in
installation site, sending for repair).
5.3 Storage
Permissible conditions at the place of storage:
■
Storage temperature:
Instruments without built-in transmitter: -40 ... +85 °C
Instruments with built-in transmitter:
see operating instructions of the transmitter in question
■
Humidity: 35 ... 85 % relative humidity (no condensation)
Avoidance of exposure to the following factors:
■
Direct sunlight or proximity to hot objects
■
Mechanical vibration, mechanical shock (putting it down hard)
■
Soot, vapour, dust and corrosive gases
Store the instrument in its original packaging in a location that fulls the conditions listed above. If
the original packaging is not available, pack and store the instrument as described below:
1. Wrap the instrument in an antistatic plastic lm.
2. Place the instrument, along with shock-absorbent material, in the packaging.
3. If stored for a prolonged period of time (more than 30 days), place a bag, containing a
desiccant, inside the packaging.
4. Design and function / 5. Transport, packaging and storage

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WARNING!
Before storing the instrument (following operation), remove any residual media. This
is of particular importance if the medium is hazardous to health, e.g. caustic, toxic,
carcinogenic, radioactive, etc.
6. Commissioning, operation
WARNING!
When the thermometer is mounted, the temperature must not drop below the allowed
operating temperature (environment, medium) or exceed it, even when taking
convection and heat radiation into account!
WARNING!
Thermometers must be earthed if dangerous voltages could be expected at the
connection wires (caused, for example, by mechanical damage, electrostatic
discharge or induction)!
6.1 Electrical connection
CAUTION!
■
Damage to cables and wires, and to connection points, must be avoided
■
Provide nely stranded conductor ends with end splices (cable assembly)
■
Both the internal capacitance and inductance must be considered
For the electrical connections of thermometers (e.g. connection circuit diagrams, tolerance
values, etc.), please refer to the appropriate data sheets. If head transmitters or digital displays
have been built into the connection housing, these data sheets must also be given proper
consideration.
5. Transport, packaging and storage / 6. Commissioning, operation

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6.2 Electrical connection of resistance thermometers
6.2.1 Resistance thermometer with terminal block
3160629.06
red
1 x Pt100, 2-wire 1 x Pt100, 3-wire 1 x Pt100, 4-wire
white white
red
red
red
red
white
white
white white white
white
red
red red
red
red
2 x Pt100, 2-wire 2 x Pt100, 3-wire 2 x Pt100, 4-wire
red white
white red
red
white
black
yellow yellow yellow black
black
white
white
red
red
red
red
black
black
black
black
yellow yellow
yellow
red
white
black
yellow
white
6. Commissioning, operation

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6.2.2 Resistance thermometer with cable or connector
Without
connector
Lemosa connector
3366036.02
1 x Pt100
2-wire
1 x Pt100
3-wire
1 x Pt100
4-wire
2 x Pt100
2-wire
2 x Pt100
3-wire
red
red
red
red
red
red
red
red
white
white
white
white
Connector (male)
View from the front
Socket (female)
View from the front
white
white
black
black
black
yellow
yellow
3160629.06
6. Commissioning, operation

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6.3 Electrical connection of thermocouples
Cable colour coding of thermocouples
Sensor type Standard Positive Negative
KDIN EN 60584 green white
JDIN EN 60584 black white
EDIN EN 60584 violet white
TDIN EN 60584 brown white
NDIN EN 60584 pink white
6.3.1 Thermocouples with terminal block
Binder
Series 680
Binder
Series 680
Binder
Series 680
Binder
Series 680
Binder
Series 692
Binder screw/plug-in connector
3366142.02
Connector (male)
View of the connector contacts
Socket (female)
View of the socket contacts
3166822.03
Single thermocouple Dual thermocouple
The colour coding at the positive
connection to the devices always
decides the correlation of polarity
and connection terminal.
6. Commissioning, operation

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6.3.2 Thermocouples with cable or connector
Lemosa connector,
male at the cable Binder connector,
male at the cable
(screw/plug-in connection)
Single
thermocouple
For the marking of
the cable ends, see
table
Cable
Dual
thermocouple
Plus and minus are marked.
For dual thermocouples, two thermal
connectors are used.
Thermal connector
6.4 Multipoint thermocouples (as per 8.4 and 8.5)
They are usually equipped with a housing in which transmitters or terminal blocks are mounted.
The transmitters/digital displays are fastened mechanically (e.g. rail system in housing or holder
in connection head) and installed in accordance with EN/IEC 60079-11 and EN/IEC 60079-14.
Optionally, depending on design, the housings can be equipped with or without terminals (e.g.
terminal blocks, etc.) in accordance with EN/IEC 60079-11 and EN/IEC 60079-14.
When using several transmitters/digital displays, the housing volume increases as a function of
the "heat source", thus increasing the volume to be heated. This guarantees that the housing
surface temperature does not increase signicantly.
WARNING!
When using no terminals and line wiring, compliance with the installation regulations
in accordance with EN/IEC 60079-11 and EN/IEC 60079-14 must be guaranteed.
6.5 Cable glands
In thermometers equipped with connection heads, the cable glands must be fully sealed in order
to ensure that the necessary ingress protection is reached.
Requirements for meeting ingress protection
■
Only use cable glands within their indicated clamping range (cable diameter suitable for the
cable gland)
■
Do not use the lower clamping area with very soft cable types
■
Only use circular cross-section cables (if necessary, slightly oval in cross-section)
■
Do not twist the cable
6. Commissioning, operation

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■
Repeated opening/closing is possible; however only if necessary, as it might have a
detrimental eect on the protection class
■
For cable with a pronounced cold-ow behaviour the screw connection must be fully tightened
6.6 Parallel threads
If the thermometer connecting head, extension neck, thermowell or process connection are
connected with parallel threads (e.g. G ½, M20 x 1.5 ...), these threads must be secured using
seals which prevent liquids from penetrating into the thermometer.
As standard, WIKA uses copper prole seals for the connection between the neck tube and the
thermowell, and at paper seals for the connection of the connection head and the extension
neck or thermowell.
If the thermometer and the thermowell are already connected, the seals will already be mounted.
The plant operator must check whether the seals are suitable for the operating conditions and
must replace them, if necessary, with suitable seals.
For thermometers without a thermowell, and/or where these are delivered separately, the seals
are not included and must be ordered separately.
Tighten the threads by hand when carrying out the nal assembly on the plant. This will
correspond to the delivery status of the premounted components. The nal tightening torque
should be applied using a spanner (half rotation).
The seals must be replaced after dismantling!
The seals can be ordered from WIKA, indicating the WIKA order number and/or the
designation (see table).
WIKA
Order No. Designation Suitable for threads
11349981 per DIN 7603 Form C 14 x 18 x 2 -CuFA G ¼, M14 x 1.5
11349990 per DIN 7603 Form C 18 x 22 x 2 -CuFA M18 x 1.,5, G ⅜
11350008 per DIN 7603 Form C 21 x 26 x 2 -CuFA G ½, M20 x 1.5
11350016 per DIN 7603 Form C 27 x 32 x 2.5 -CuFA G ¾, M27 x 2
11367416 per DIN 7603 Form C 20 x 24 x 2 -CuFA M20 x 1.5
1248278 per DIN 7603 D21.2 x D25.9 x 1.5 -Al G ½, M20 x 1.5
3153134 per
DIN 7603 Form C D14.2 x D17.9 x 2 -StFA G ¼, M14 x 1.5
3361485 per
DIN 7603 Form C D33.3 x D38.9 x 2.5 -StFA G 1
Legend:
CuFA = Copper, max. 45HBa ; lled with asbestos-free sealing material
Al = Aluminium Al99 ; F11, 32 to 45 HBb
StFA = Soft iron, 80 to 95 HBa; lled with asbestos-free sealing material
6. Commissioning, operation