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Fieldbus Fieldbus Accessing all Areas 1 Fieldbus Scope of presentation Safe Area Applications Non-Arcing Systems Zone 2 Non-Incendive Systems Zone 2 FNICO Intrinsic Safety Systems FISCO 2 Zone 2,1,0 Fieldbus Generalised Fieldbus connection Non-hazardous area Hub T T Fieldbus Host 18-30 volt Power General fieldbus application in safe area 3 terminated at both ends of bus Fieldbus Generalised Fieldbus connection Non-hazardous area Hub T T Fieldbus Host 18-30 volt Power Need for hazardous area protection suitable certified interface applied Non-hazardous area Hazardous area T 4 T T T Fieldbus Host Fieldbus MTL5995 Power Supply For general purpose applications in 31.25 kbit/s fieldbus systems terminate at both ends of fieldbus switched internal terminator option Isolated power conditioning 19V, 350mA output Suitable for Safe Area & Hazardous Area applications Certified for installation in Zone 2 hazardous areas Needs suitable certified interface eg, MTL791, for intrinsically safe field connection 5 ATEX II 3 G EEx n A IIC T4 Fieldbus Redundant Fieldbus Power System Backplane connects to : bus terminator input power supplies host system fieldbus trunk alarm circuitry Load sharing by redundant supplies Up to 8 units may be daisy-chained with common alarm carrier jumper supplied version without segment terminator available 6 Fieldbus Redundant Fieldbus Power System Fieldbus Host Power Conditioning high impedance to fieldbus network Redundant DC Power Inputs Power Isolation to fieldbus 250 V ac galvanic isolation Redundant Output Power 25 Volt, 350mA output per module LED indicates bus is powered Hot-swappable modules & / or input supply can be replaced without affecting fieldbus operation T System Alarm Supply ‘A’ Supply ‘B’ 18-30 volt Power Alarm Circuitry input power or unit failure galvanic isolation from other functions Certification FM Class 1 Div2 ATEX II 3 G EEx nA IIC T4 7 Zone 2 Mounting Fieldbus Fieldbus Redundant Fieldbus Power System Common connections within addressing limitations Fieldbus Host System Alarm Fieldbus Host T T Fieldbus Fieldbus Supply ‘A’ Supply ‘B’ 18-30 volt Power 8 Fieldbus Redundant Fieldbus Power System Note : the fieldbus connection is certified as non-arcing EEx nA IIC T4 It is NOT a FISCO / FNICO field connection an added interface would be necessary to achieve this end 9 Fieldbus MTL5053 Isolator / Power Supply The MTL5053 extends 31.25kbit/s fieldbus networks into hazardous areas Provides power to the highway & for communication to field devices Separate power may be required for safe-area field devices Supply voltage 20 to 35Vdc Isolation : 250V ac between safe area fieldbus circuits hazardous area fieldbus circuits power supply Provides 18.4 volts at max 80 mA Safety description 22V, 102, 216mA Isolator transparent to fieldbus, hence 31.25kbit/s fieldbus termination at isolator is not a pre-requisite Switchable safe area terminator Hazardous area Safe area MTL5053 Ex II (1) GD [EEx ia] IIC 10 T T Fieldbus Some definitions Safe area Zone 2 Division 2 Safe Area system NA system NI system Non-Arcing Systems Non-Incendive Systems 12 Zone 1 Zone 0 Division 1 Fieldbus The principle of live working Limit the energy in the circuit Ethylene group Propane group Current Methane group Hydrogen group Power = volts x amps Resistive Curves 13 Voltage Fieldbus Safety Factor Unity : Zone 2 1.5 : Intrinsic Safety Fault-tolerant components not required for Zone 2 Hydrogen group Current 230 mA Apply a Safety Factor 14 Resistive Curves 24 Volts Voltage Fieldbus Types of circuit in Zone 2 NON-INCENDIVE CIRCUITS : NON-ARCING CIRCUITS : Energy-limited • Unity Safety Factor • Low energy circuits • Systems concept • Live-workable • High energy & mains circuits • No systems concept • Not live-workable User must NOT permit arcing 15 Fieldbus Complete hazardous area capability Safe area Unclassified location Safe Area system NA system NI system IS system Zone 0 system 16 Zone 2 Division 2 Zone 1 Zone 0 Division 1 Fieldbus Safe Area or Non Arcing Installation Installation in => IP54 Live working NOT permitted in a hazardous area Max output : 32 V 1.5 A ‘nA’ All trunks & spurs EEx nA IIC T4 Vmax 32 V Imax 1.5 A MTL5995 FPS-I ‘nA’ System Certification : Ex nA IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : FBT-1 17 Vmax 32 V FF-816 specification : 32 V 1.5 A Fieldbus Non Incendive / ‘Spurguard’ legs Installation in => IP54 Live working NOT permitted on ‘nA’ trunk ‘nA’ ‘nL’ Max output : 32 V 1.5 A Main trunks : EEx nAL IIC T4 Vmax 32 V Spurguard legs : Imax 1.5 A EEx nL IIC T4 MTL5995 Vmax 32 V ‘nA’ FPS-I Imax 60 mA ‘nL’ Live working safe on ‘NI’ spurs System Certification : Ex nA [nL] IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : 18 Vmax 32 V FF-816 specification : 32 V 1.5 A Fieldbus Non Incendive System Installation in => IP54 Live working permitted throughout ‘nL’ MTL9111 Max output : 14 V 233 mA ‘nL’ All trunks & spurs EEx nL IIC T4 Vmax 14 V Imax 233 mA ‘nL’ MTL9112 ‘nL’ System Certification : Ex nL IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : 19 Vmax 32 V option for IIB with appropriate safety parameters Fieldbus Non Incendive >> ‘Spurguard’ legs Installation in => IP54 Live working permitted throughout ‘nL’ ‘nL’ MTL9111 Max output : 14 V All trunks & spurs 233 mA EEx nL IIC T4 Vmax 14 V Spurguard legs Imax 233 mA EEx nL IIC T4 Vmax 14 V ‘nL’ Imax 60 mA MTL9112 ‘nL’ System Certification : Ex nL IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : 20 Vmax 32 V option for IIB with appropriate safety parameters Fieldbus Intrinsically Safe (Non-FISCO) Installation Installation in => IP54 Live working permitted throughout ‘IS’ ‘IS’ MTL5053 Available output : ‘IS’ 18.4 V into Zone 0 80 mA Safety parameters : 22 V 216 mA ‘IS’ System Certification : Ex ia IIC T4 Class 1, Div 1, Groups A,B,C,D, T4 Terminator : 21 FF-816 specification : Vmax 24 V 24 V Imax 250 mA 250 mA FISCO 22 Fieldbus Fieldbus Intrinsically Safe (FISCO) Installation Installation in => IP54 Live working permitted throughout ‘IS’ MTL9121 IS : IIC ‘IS’ 14.0 V 180 mA MTL9122 IS : IIB 14.8 V Megablock rating : 380 mA Vmax 14.8 V ‘IS’ Imax 380 mA ‘IS’ System Certification : Ex ib IIC T4 Class 1, Div 1, Groups A,B,C,D, T4 Use in appropriate gas group Terminator : Vmax 24 V 23 Imax 250 mA Limited to Zone 2 & 1 All devices to be approved for FISCO Fieldbus Network Calculations 24 Fieldbus Multiple power supply configuration Sufficient current capacity ? T T 25 Host T T Fieldbus Basic configuration Host L N E 9121 & 9122 T 24V supply Host trunk 2- 3+ 4- 5 S 6+ T T 7+ 8 S 9 - Safe Area Zone 1 / Div1 Hazardous Area 6 devices (120 mA) in IIC 13 devices (260 mA) in IIB if 20 mA consumption each device T 26 Fieldbus Power & data Host L N E T 24V supply 2- 3+ 4- 6+ T T 7+ 8 S 9 - Safe Area Zone 1 / Div1 Hazardous Area The Fieldbus The 24 volt power supply is converted to an intrinsically safe supply to feed the IS trunk 27 T signal, which is superimposed on the IS voltage, is fed via the interface device to & from the field devices Fieldbus Mains or 24-volt power supply 8913 8914 Power Units Zone2 / Div2 Host Power consumption 9121 : 190mA 9122 : 300mA Mains 5991 Power Unit 8914 : 10 A 5991 : 2 A T Mains 28 Safe Area T T T Fieldbus Design Parameters System design determined from : power supply output voltage power supply available current knowledge of current consumption of each field device survey shows a range of 10 to 28 mA 20 mA is assumed application of Ohm’s Law to the cable network assessment for adequate voltage at each field device Line resistance of 50 /km is assumed within the FISCO range of 15 to 150 /km Model Apparatus Number Class 9121-IS 9122-IS 29 IIC IIB Useable Output V mA 12 120 12.8 260 Parameter Value Loop resistance 15 ohm to 150 ohm / km Loop inductance 0.4 mH to 1 mH / km Capacitance 80 nF to 200 nF / km Spurs are in addition to permitted maximum cable length FISCO cable parameters Fieldbus Model 9121-IS : IIC 5 connected field devices at end of trunk Eg : I = 100 mA 600 metres 30 = 3 volts 30m spur = 1.5 carrying 20 mA volt drop = 30 mV 31 Hydrogen Gas Group Typical IIC calculation 600 metre IS trunk Useable Output V mA 12 120 12 volts 600 metre IS trunk 3 volts 100 mA If current drawn < 20 mA then instrument population can be increased 9 volts NODE T each instrument draws 20 mA Fieldbus Typical IIC calculation I = 80 mA 12.5 = 1.0 volt I = 40 mA 12.5 = 0.50 volts 32 Model 9121-IS : IIC 5 distributed field devices I = 100 mA 12.5 = 1.25 volts 750 metre IS trunk Hydrogen Gas Group 12 volts Useable Output V mA 12 120 each instrument draws 20 mA 250 metres 10.75 V 250 metres 9.75 V 250 metres 9.25 V T Fieldbus Typical IIB calculation 12 connected field devices at end of trunk I = 240 mA = 3.8 volts drop 316 thru 316 metres of 15.8 316 metre max IS trunk 33 Ethylene Gas Group Model 9122-IS : IIB 12.8 volts Useable Output V mA 12.8 260 metres 3.8 volts 240 mA Trunk length will increase if device population is reduced 9 volts NODE T 12 instruments each drawing 20 mA Fieldbus Power Supply as a IIB Repeater Safe Area Zone 2 / Div 2 Zone 1 / Div 1 316 metres 24 volts Power & Ex protection only Power, Repeater & Ex protection 1.8 kms 12 instruments 316 metres Power drawn in either direction Cable protection required 34 24 volts A similar scenario exists for a IIC repeater Fieldbus Power Supply as a Repeater Safe Area Zone 2 / Div 2 Host probably has no Ex protection in powering the 912x device : Cable is a non-arcing circuit due to incendive level of energy Cable protection required - hazardous area wiring may not be disconnected to reveal floating wires Repeater terminals carry limited energy; hence circuit is non-incendive and power plug may be removed 912x device may power host equipment (max 30 mA) and power plug may be removed Power, Repeater & Ex protection 1.8 kms Power drawn in either direction 35 Zone 1 / Div 1 Fieldbus ATEX Certification The ‘CE’ Mark Confirms compliance with all relevant Community directives Conformite European ex 38 The ‘Explosive Atmosphere’ Mark Confirms compliance with ATEX or previous Flammable Atmosphere Directive Fieldbus Equipment Marking - 9121 Power Supply CENELEC / IEC [E Ex ib] IIC T4 -40 OC < Tamb < +70 OC Referenced to ambient of -20 to +40 OC unless indicated as above Temperature Class (Group II) Apparatus Group (Hydrogen) Type of protection code Explosion protection symbol Conformity with European Standard 39 T1 : 450 OC T2 : 300 OC T3 : 200 OC T4 : 135 OC T5 : 100 OC T6 : 85 OC Fieldbus Equipment Marking - 9121 Power Supply CENELEC / IEC [E Ex ib] IIC T4 -40 OC < Tamb < +70 OC [ ] indicates the apparatus is safe area mounted ‘associated apparatus’ suitable for connection to Ex ib equipment Referenced to ambient of -20 to +40 OC unless indicated as above Temperature Class (Group II) Apparatus Group (Hydrogen) Type of protection code Explosion protection symbol Conformity with European Standard 40 T1 : 450 OC T2 : 300 OC T3 : 200 OC T4 : 135 OC T5 : 100 OC T6 : 85 OC Fieldbus Equipment Marking - 9121 Power Supply ATEX II (2) GD 0600 G : Gas, vapour, mist D : Dust Type of explosive atmosphere (Group II) Equipment Category Equipment Group M1 : energised M2 : de-energised 1 : Zone 0, 20 2 : Zone 1, 21 3 : Zone 2, 22 I : Mining II : Non-Mining EU Explosive Atmosphere Symbol Ref to Notified Body responsible for testing 41 CE mark Fieldbus 9121 - BASEEFA Certification 0600 II (2) GD ATEX [E Ex ib] IIC T4 -40 OC < Tamb < +70 OC CENELEC / IEC BAS 02 ATEX 7276 EC-type examination certificate ATEX Category 2 certification 42 Additional information on product : Safety parameters, where applicable Year of manufacture & Serial No. Name & address of manufacturer Manufacturers type identification Fieldbus 9121 - MTL Declaration of Conformity II 3 GD ATEX E Ex nA IIC T4 -40 OC < Tamb < +70 OC CENELEC / IEC MTL 02 ATEX 9121X MTL Declaration of Conformity ATEX Category 3 certification justifying mounting the 9121 power supply in Zone 2 43 9121X refers to special conditions of use : > power supply is installed in an appropriate enclosure > it must be protected from large supply transients Fieldbus 9122 - BASEEFA Certification 0600 II (2) GD ATEX [E Ex ib] IIB T4 -40 OC < Tamb < +70 OC CENELEC / IEC BAS 02 ATEX 7277 EC-type examination certificate ATEX Category 2 certification 44 Fieldbus 9122 - MTL Declaration of Conformity II 3 GD ATEX E Ex nA IIB T4 -40 OC < Tamb < +70 OC CENELEC / IEC MTL 02 ATEX 9122X MTL Declaration of Conformity ATEX Category 3 certification justifying mounting the 9122 power supply in Zone 2 45 Fieldbus Fieldbus Intrinsically Safe Concept (FISCO) Adopting FISCO raises the issue : Can Entity certified fieldbus equipment (non-FISCO) be incorporated into a FISCO network ? YES 47 9321-SC 9323-SC Fieldbus I.S. Entity Spur Connections (non-FISCO devices) 9121-IS : IIC 9321-SC Entity spur connector output safety parameters : 14 V; 180 mA; 2.52 W deliver 12.0 V; 110 mA EEx ib IIC T4 II 2 (2) G Live working throughout 9321-SC Zone 1 Entity IS certified device 48 Entity device to FF-816 has an input safety description of 24 V; 250 mA; 1.2 watts HUB T FISCO devices Fieldbus Fieldbus Intrinsically Safe Concept (FISCO) The use of active current limitation restricts the categorisation to ‘EEx ib’, ie, connection to Zone 1 only Can a fieldbus device be installed in a Zone 0 by adding further protection to achieve ‘ia’ status ? YES 9322-SC 50 Fieldbus Networking into Zone 0 9322-SC Zone 0 spur connector Useable with either 9121-IS : IIC 9122-IS : IIB II 2 (1) G EEx ib IIC T4 II (1) G EEx [ia] IIC 9322-SC Zone 1 ia : Zone 0 energy limit NODE Zone 0 51 T FISCO devices Fieldbus Wiring Components 52 Fieldbus Wiring Components - Megablock Series Megablocks : DIN-rail mounting Fieldbus network hubs connect multiple field devices to trunk network minimise hand wiring network integrity maintained during connection / disconnection of individual devices LED indicates minimum 9 volts present at hub Megablocks available in 2, 4 & 8-way (10-way) versions Megablock terminator available Terminator Short-circuit protection option using SpurGuard 53 Fieldbus Megablock Series Trunk / Home run Field device connection Power LED >= 9V Optional SpurGuard short circuit protection - visual indication of fault Trunk / Home run Securable, pluggable connectors 54 8-way Megablock Fieldbus Megablock Series Choice of junction box Use site standard suitable for environment trunk 4 + 8 drop = 12 drop Easy to retrofit Junction box for specific application standard instrument cable spur 55 terminator Fieldbus Relcom SpurGuards™ System reliability and availability may be affected by the shorting of the fieldbus highway, by the failure of any individual fieldbus device, thus interrupting data communication across the entire bus segment could occur during installation or routine instrument maintenance A SpurGuard™ is a current-limiting device that provides short circuit protection to the fieldbus segment By attaching a SpurGuard™ at each point where a field device is attached to the segment home run cable, isolation of the network from individual device failures is achieved SpurGuards™ are available with any Megablock a red LED indicates when a SpurGuard™ is providing overcurrent protection Because a SpurGuard™ leg draws power from the 56 segment when in short circuit mode, their short circuit current consumption must be taken into account during segment design The SpurGuard™ short-circuit current is nominally 60 mA Trunk to Spur max. voltage drop = 0.4 volts 57 Fieldbus Fieldbus Lightning Strikes Handling the effect 58 Fieldbus Lightning Strikes There is no remedy for direct lightning strikes the energies involved are too high but measures can be taken to minimize the effects of near-lightning strikes on Fieldbus networks Lightning is a short burst of very intense voltage and current. Even when a direct lightning strike is shunted to ground by a lightning rod, it induces high voltages and currents in metal components nearby eg, the conductors & shield of Fieldbus cable The purpose of lightning surge protection 59 in Fieldbus wiring is to minimize the induced voltages & currents and hence to minimise damage to Fieldbus equipment a lightning strike might produce 100,000 Amps in a lightning rod induced currents in nearby grounded metal objects may be several thousand Amps induced current in the shield of a fieldbus cable might be several hundred Amps I PK (100 kA) 90% 50% 10% 8µs 20µs t Fieldbus Principles & Practicalities Flash-over 100kA Local Ground Strike Flash-over Fieldbus High local potential on building earth system 60 Induced Voltage V = L x I/ t Local ‘ground’ High potential across insulation on field instrument Fieldbus Transient Surge Suppression The shield of the Fieldbus cable is grounded but according to the installation standard, in only one place Single-point grounding eliminates current loops in the shield reduces induced noise in the signal concerned is a pre-requisite for an intrinsically safe circuit the shield is normally grounded at the control room Any lightning strike in the field could produce a large current in the shield that needs to travel to the control room to pass to ground in a long network a large shield voltage could occur by capacitive coupling a large voltage might appear on the internal twisted pair A surge may be minimized by using a Transient Surge Suppressor Centralised control equipment Shield Transient Surge Suppressor 61 Fieldbus Differential Voltage Suppression The next consideration is to minimize the voltage that might be induced in the twisted-pair inside the shield Due to the capacitance between the shield & each of the wires in the twisted pair, a voltage change on the shield will induce a voltage on the wires Using twisted-pair cable, the shield-to-wire capacitances for the two wires are nearly equal hence the voltage induced in each of the wires in the twisted pair will be identical (Common Mode Voltage effect) The Fieldbus standard requires that the common mode immunity of Fieldbus devices should be of a high order, eg, Surge Protection Devices : FP32 = 225 volts DC trigger point TP32 = 120 volts DC trigger point 62 Fieldbus Protection Devices The FP32 surge protection device prevents surges & transient overvoltages conducted along the Trunk or Spurs of fieldbus systems from damaging the associated electronics may be used at any point on a Trunk to safely divert any surges to ground The TP32 is the protection equivalent installed at an instrument Fully automatic in operation, the devices react instantly to make sure that equipment is never exposed to damaging surges between lines or between lines & earth Reacting instantaneously to surges they then reset automatically FP32 63 TP32 Fieldbus Surge Protection Device Line inductors Circuit fuses Signal lines Protected equipment Gas discharge tube Circuit earth Solid-state limiters I PK (100 kA) 90% The multi-stage elements of the FP32 / TP32 use a combination of solid state electronics and a gas filled discharge tube (GDT) to 64 50% 10% t provide surge protection up to 20kA 20µs Fieldbus Power problems due to transient spikes Surge < 10% Sag < 10% Transient 85% to 90% 65 Outage < 1% Fieldbus Generalised Fieldbus connection Power conditioner Hub T Terminator T Trunk Power supply Power distribution panel Incoming AC supply 66 Fieldbus Host System protection Power conditioner Hub FP32 T Terminator T Trunk Power supply MA 4000 Power distribution panel Incoming AC supply 67 Fieldbus Field Device Protection - ‘compact’ Hub FP32 Trunk T Terminator Spurs < 50m horizontal < 10m vertical All spurs less than : 50m horizontal or 10m vertical Surge invasion from host end of trunk all devices are protected by one surge protection device in trunk 68 Fieldbus Field Device Protection - ‘widespread’ Hub FP32 Trunk T Terminator Spurs > 50m horizontal > 10m vertical Spurs greater than : 50m horizontal or 10m vertical surge invasion from Host 69 end of trunk surge protection installed to each device 70 Fieldbus