Installing Intrinsic Safety Termination Panels and Barriers

Transcription

1 Installing Intrinsic Safety Termination Panels and Barriers Installation Manual PH2.1:CL6340 Revision D July 2003 This manual supercedes the issue dated November D3P

2 See CE Statement in Section 1 ABC Batch, ConfiguWrite, DeltaV, DOCVUE, ENVOX, FIELDVUE, Fisher-Rosemount, Instrument Information System, Managing The Process Better, microprovox, MOMENTUM, PROFLEX, ProjectDelta, PROVOX, PROVUE, RNI, RS3, and ValveLInk are marks of one of the Fisher-Rosemount group of companies. All other marks are the property of their respective owners. 2000, 2003 Fisher-Rosemount Systems, Inc. All rights reserved. Printed in USA The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time without notice.

3 Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) Your Evaluation Please... iii Name: Company: Title and Department: Years of Experience: Instrumentation Distributed Control Telephone: ( ) Education: High School Years College Degree Job Responsibility: Please indicate your evaluation of this manual. Attach extra sheets if needed. 1. How and when do you use this manual? Read entire manual before attempting task Read selected sections before attempting task Read while attempting task Attempt task first Read as last resort 2. How well is the manual s content organized? Please explain. Understandable Excellent parallels product s operation, very usable Good representative of the product s operation, usable Average usable but can be improved Fair not very usable, should be improved Poor not usable, must be improved No Opinion Applicable 3. Is the manual s content understandable and applicable to the product s operation? Please explain. 4. How well do the manual s illustrations convey product information? Please explain. Excellent very easy to understand, very applicable Good easy to understand, applicable Average applicable but some sections not easy to understand Fair not very understandable/applicable, should be improved Poor not understandable/applicable, must be improved No Opinion Excellent very easy to understand, extremely usable Good easy to understand, very usable Average fairly easy to understand, usable Fair not easy to understand, should be improved, not very usable Poor cannot understand, must be improved, totally unusable No Opinion

4 iv Your Evaluation Please... Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) 5. Describe the amount of usable information in this manual including tables. Please explain. Sections Too much information not all required to perform task Proper amount provided not too much nor too little Too little information needed additional information to perform task No Opinion Index 6. How well is information cross-referenced in the manual s individual sections and index? Please explain. Excellent very easy to locate information, extremely usable Good easy to locate information, very usable Average fairly easy to locate information, usable Fair not easy to locate information, should be improved, not very usable Poor cannot locate information, must be improved, totally unusable Did Not Use No Opinion 7. How useful is the Glossary? Useful Useful but not complete/accurate Not Useful Did Not Use No Opinion 8. What is your overall impression of this manual? Please explain. Excellent met all needs, extremely usable Good met most of my needs, very usable Average usable Fair should be revised, not very usable Poor must be revised, totally unusable No Opinion Please FAX or MAIL this form to: Emerson Process Management Technical Documentation Editor FAX Number: (512) Mopac Expressway North Attention: Technical Documentation Editor Austin, TX 78759

5 Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) Contents v Contents 1 Introduction Intended Audience CE Statement Structure of this Manual Manual Conventions Warnings, Cautions, and Notes Related IS Product Documentation Related PROVOX Documentation Where to Find Answers for Product and Document Questions. 4 2 Product Overview Available Termination Panels Available Intrinsic Safety Barriers Determining the Quantity of Barriers and Termination Panels for Your Application Physical and Electrical Pre-Installation Installation Special Considerations Planning the Physical Installation I/O Cards and Card File Termination Panel Installation Barrier Dimensions Termination Cables Cabling for Simplex I/O Cards Cabling for 1 for 1 Redundant I/O Cards Cabling 1 for N Configurations Termination Cable Connectors Planning the Electrical Installation Termination Panel Power Shield Grounding DC Grounding Connecting Field Wiring to Barriers A Barrier Specifications A.1 Type CL6351 IS High-Level Analog Input Isolating Barrier (HART compatible) A.2 Type CL6352 IS Millivolt Input, Type CL6353 IS RTD Input, and Type CL6354 IS Thermocouple Input Isolating Barriers A.3 Type CL6355 IS Analog Output Isolating Barrier A.3.1 Conventional Analog Output Application A.3.2 Smart Device Output Application

6 vi Contents Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) A.4 Type CL6356 IS Discrete Input Isolating Barrier (With and Without Debounce) A.5 Type CL6357 IS Discrete Output Isolating Barrier A.5.1 Solid State A.5.2 Relay Output A.6 Type CL6358 IS Pulse Count Input Isolating Barrier A.7 Cross-Reference Between CL6350-Series Type Numbers and MTL Model Numbers B Panel and Cable Specifications B.1 Termination Panel Specifications B.2 Termination Panel Current Requirements B.3 Cable Lengths B.4 Field Wiring Specifications B.5 MTL Installation Tools Glossary Index

7 Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) Contents vii Figures Figure 2-1. Typical CL6340-Series Termination Panel Connections with CL6350-Series Intrinsic Safety Barriers Figure 3-1. Type CP6701 Card File Arrangement Figure 3-2. CL6340-Series Termination Panel Dimensions Figure 3-3. CL6350-Series Barrier Dimensions Figure 3-4. Cabling for Two Simplex Analog Output Cards Figure 3-5. Cabling for One Simplex Analog Input Cards and for a Smart Input Termination Panel with a Smart Input Card. 14 Figure 3-6. Cabling for Two Simplex Discrete Input Cards Figure 3-7. Cabling for Simplex Discrete Output Cards Figure 3-8. Cabling for Simplex Pulse Count Inputs Figure 3-9. Cabling for 1 for 1 Redundant Analog Input Cards and for Smart Input Termination Panel with Smart Input Cards. 16 Figure Cabling for 1 to 1 Redundant Analog Output Cards Figure Cabling for 1 to 1 Redundant Discrete Input Cards Figure Cabling for 1 to 1 Redundant Discrete Output Cards Figure Cabling for 1 to 1 Redundant Pulse Count Inputs Figure Cabling for 1 for 4 Redundant Analog Input Cards and Smart Input Termination Panel with Smart Input Card.. 22 Figure Cabling for 1 for 2 Redundant Analog Output Cards Figure Cabling for 1 to 2 Redundant Discrete Input Cards Figure Cabling for 1 for 3 Redundant Discrete Output Cards Figure Cabling for 1 to 2 Redundant Pulse Count Inputs Figure Barrier and Terminal Connections Figure A-1. Typical Connections for Type CL Figure A-2. Typical Connections for Type CL6352, Type CL6353, and Type CL Figure A-3. Typical Connections for Type CL Figure A-4. Typical Connections for Type CL6355 (Smart Application) 39 Figure A-5. Typical Connection for Type CL Figure A-6. Typical Connections for Type CL6357 (Solid State) Figure A-7. Typical Connections for Type CL Figure A-8. Typical Connections for Type CL

8 viii Contents Installing Intrinsic Safety Termination Panels and Barriers (Revision D July 2003) Tables Table 2-1. Maximum Number of Channels Supported by I/O Cards.. 8 Table 2-2. System Planning Documents Table 3-1. D-Shell Connector Pin Assignments Table A-1. Type CL6353 Range Specifications Table A-2. Type CL6354 Range Specifications Table A-3. Cross-Reference Between CL6350-Series Type Numbers and MTL Model Numbers Table B-1. Current Requirements for Termination Panels Table B-2. Maximum Cable Parameters (FM) Low-Level Signal Table B-3. Maximum Cable Parameters (FM) Other Signal Table B-4. Maximum Cable Parameters EECS (ATEX 100) Table B-5. Installation Tools Ordering Information

9 Introduction Section 1 1 Figure 1-Table Introduction 1 This installation planning manual describes the installation of CL6340-Series termination panels and CL6350-Series Intrinsic Safety barriers. This manual also describes physical characteristics, electrical characteristics, and wiring required for the termination panels and barriers. Before developing and installing an intrinsically safe system, consult the guidelines set forth by the country of installation. 1.1 Intended Audience The information in this manual is written for the installation and maintenance technician who is familiar with process control systems, intrinsic safety systems, and the attendant field wiring. 1.2 CE Statement If you intend to have your PROVOX system certified for compliance to appropriate European Union directives, the following statement is extremely important to your ability to achieve that compliance. This manual describes installation and maintenance procedures for products which have been tested to be in compliance with appropriate CE directives. To maintain compliance, these products must be installed and maintained according to the procedures described in this document. Failure to follow the procedures may compromise compliance.

10 2 Section 1 Introduction 1.3 Structure of this Manual 1 This manual contains the following sections and appendixes: Section 1 Introduction: includes an overview of this manual, the intended audience, the stylistic and typographical conventions used, and lists additional related documents. Section 2 Product Overview: provides an overview of the installation process, and describes the criteria for determining the intrinsic safety system design. Section 3 Installation: describes the physical and electrical installation of CL6340-series Termination Panels and the CL6350-Series Intrinsic Safety Barriers. Appendix A Barrier Specifications: provides barrier specifications and field wiring diagrams. Appendix B Panel and Cable Specifications: provides terminal panel specifications, cable specifications, and lists helpful cable installation tools available from MTL Incorporated. 1.4 Manual Conventions This document uses the following conventions. Abbreviations Standard abbreviations and symbols are used in this document. Instances where non-standard abbreviations or acronyms are used, will be explained at the first usage. Revision Control The title page of each document lists the revision level and the printing date. When the manual is revised, the revision level and the printing date are changed. Cross Referencing References to other documentation for additional information list the document name and number.

11 Introduction Section Warnings, Cautions, and Notes Warnings, Cautions, and Notes attract attention to essential or critical information in this manual. The types of information included in each are explained in the following: 1 Warning... All warnings have this form and symbol. Do not disregard warnings. They are installation, operation, or maintenance procedures, practices, conditions, statements, and so forth, which if not strictly observed, may result in personal injury or loss of life. Caution... All cautions have this form and symbol. Do not disregard cautions. They are installation, operation, or maintenance procedures, practices, conditions, statements, and so forth, which if not strictly observed, may result in damage to, or destruction of, equipment or may cause a long term health hazard. Note... Notes have this form and symbol. Notes contain installation, operation, or maintenance procedures, practices, conditions, statements, and so forth, that alert you to important information which may make your task easier or increase your understanding.

12 4 Section 1 Introduction 1.6 Related IS Product Documentation 1 Note... Reading and understanding the vendor s manual for installing intrinsic safety barriers is very important, especially sections 3, 5, and 9 which describe various precautions and warnings to heed prior to and during installation. Be sure that you have the latest version of the instruction manual, MTL4000 Series Isolating IS interface units, INM Related PROVOX Documentation For detailed information for planning a system installation, including requirements for ac power, system grounding, and adequate system environment, consult the documents listed below. Use these related documents to complete the overall system installation planning before beginning the planning for subsystem installation. Planning the Installation, PN1:002 AC and DC Power and Ground Wiring, PN1:003 Signal Wiring and Highway Signal Guidelines, PN1:004 Environmental Conditions for Instrumentation Systems, PN1:006 Lightning Protection Guidelines for Instrumentation Systems, PN1:007 Installing Type CP7043 Series Cabinets, PN4.4:CP7043 Product Bulletin, CL6340-Series Termination Panels and CL6350-Series Intrinsic Safety Barriers, BU4.2:CL Where to Find Answers for Product and Document Questions If you believe that this product is not performing as expected, or if you have comments about this manual, please contact your Emerson Process Management representative or sales office. You may also complete and send in the Reader Evaluation Form located in the front of this manual. We also appreciate your suggestions on ways to improve any page of the manual. Please mark your suggestions on a copy of the page and include it with the evaluation form. Thank you for providing this information.

13 Product Overview Section 2 5 Figure 2-Table Product Overview CL6340-Series termination panels can hold as many as sixteen CL6350-Series IS barriers. Figure 2-1 shows a typical IS termination panel configuration with barriers. To Control I/O Cards in Safe Area Front View CL6340-Series Termination Panel CL6350-Series IS Barriers Cable Tray/Control Room Hazardous Side (BLUE) Signal Wiring Side View Termination Panel Barrier PSC 24V DC PRI 24V DC SEC SHLD 2.0 (50.8) Cable Tray/Control Room Safe Side (WHITE) Signal Wiring Power Connection From Power Bus Bar in CP7043 Cabinet Notes: For important precautions and warnings, see the vendor s instruction manual, MTL4000 Series Isolating IS interface units, INM Field wiring must not be routed from the end of the blue cable tray. See field wiring instructions in section 3. 2 A blue horizontal cable tray is provided with each CL6340-Series termination panels. Figure 2-1. Shield Ground Bar (optional) 2 Blue Cable Tray on Termination Panel Typical CL6340-Series Termination Panel Connections with CL6350-Series Intrinsic Safety Barriers INCH (mm)

14 6 Section 2 Product Overview 2.1 Available Termination Panels Available CL6340-Series termination panels are: 2 Type CL6341 Analog Input Termination Panel Type CL6342 Analog/Smart Device Output Termination Panel (HART Compatible) Type CL6343 Discrete Input/Output Termination Panel Type CL6344 Pulse Count Termination Panel Type CL6345 Smart Device Input Termination Panel (HART Compatible) Note... System designers must follow certain requirements when designing an intrinsic safety system using CL6340-Series termination panels. Refer to the vendor s instruction manual, MTL4000 Series Isolating IS interface units, INM4000 and Section 3 of this manual for an overview of these requirements. Table A-3 in this manual provides a cross reference between the PROVOX type number and the MTL model number. 2.2 Available Intrinsic Safety Barriers CL6350-Series Intrinsic Safety (IS) Barriers plug into CL6340-Series termination panels and provide field voltage and current limitations required by an intrinsically safe I/O system. Available barriers are: Type CL6351 IS High-Level Analog Input Isolating Barrier (HART compatible) [4-20 ma] Type CL6352 IS Millivolt Input Isolating Barrier Type CL6353 IS RTD Input Isolating Barrier Type CL6354 IS Thermocouple Input Isolating Barrier Type CL6355 IS Analog Output Isolating Barrier This barrier is available in a 4 to 20 ma version for analog output signals and a HART-compatible version for smart device output signals. Type CL6356 IS Discrete Input Isolating Barrier Type CL6357 IS Discrete Output Isolating Barrier

15 Product Overview Section 2 7 Type CL6358 IS Discrete Pulse Count Input Isolating Barrier Refer to the vendor s instruction manual, MTL4000 Series Isolating IS interface units, INM4000 and Appendix A of this manual for descriptions and specifications of CL6350-Series barriers. 2.3 Determining the Quantity of Barriers and Termination Panels for Your Application 2 The quantity and type of barriers, and termination panels, used for an application depend on the field signals and backup strategy. CL6350-Series barriers for the following signals are available: Analog Input (AI) Analog Output (AO) Smart Device Input (HART compatible) Smart Device Output (HART compatible) Discrete Input (DI) Discrete Output (DO) Pulse Count Input (PCI) Types of backup strategies you may choose are: Simplex (No backup) 1 for 1 Redundancy 1 for N Redundancy First, determine the number of barriers your system requires. Each signal that you want to connect to the PROVOX system from the hazardous area must connect to a barrier. All CL6350-Series barriers, except Type CL6356, accept one signal from a hazardous area. The Type CL6356 IS discrete input isolating barrier accepts two input signals. Therefore, you need a barrier for each type of signal except a discrete input signal, for which you need one barrier for every two signals. Secondly, determine the number of termination panels required. Each termination panel can accept as many as 16 barriers carrying the same kind of signals, except for the Discrete Input termination panel, which can accept 32 signals (16 barriers with two inputs each.) You cannot mix major barrier types (AI, AO, DI, DO, PCI, Smart Input, and Smart Output) on a termination panel. For example, you cannot put

16 8 Section 2 Product Overview 2 analog input barriers on the same panel as analog output barriers. Also, you cannot mix analog barriers and smart device barriers on the same panel. However, you can put the Type CL6353 RTD and Type CL6354 Thermocouple IS Input Isolating Barriers on the same panel because they are both analog input barriers, using the same analog I/O card. Next, determine the number of I/O cards needed. To relate the number of termination panels and barriers to the number of I/O cards, consider the number and type of channels an I/O card can have. For example, an Analog I/O card can have as many as 16 analog input channels or as many as 8 analog output channels; a Discrete I/O card can have as many as 16 discrete inputs, 16 discrete outputs, or 8 pulse count input channels. Do not mix input and output signals on the same card. The signals must be all input, or all output, or all pulse count input. Table 2-1 shows the maximum number of input or output channels supported by I/O cards. Knowing the number of channels you wish to use, up to the maximum, you can calculate the number and type of I/O cards you need. Table 2-1. I/O Card Type Maximum Number of Channels Supported by I/O Cards Maximum Number of Input Channels Maximum Number of Output Channels Type CL6721 Discrete I/O 16 (1) 16 8 Type CL6821 Analog I/O 16 8 Type CL6824 Analog Input 16 Type CL6825 Smart Input 16 Type CL6826 Smart Output input channels permits 32 input signals, two input signals per input barrier. Maximum Number of Pulse Count Input Channels 2.4 Physical and Electrical Pre-Installation For detailed system planning information before installing the intrinsic safety system, consult the documents listed in Table 2-2. Table 2-2. System Planning Documents INM4000 MTL4000 Series Isolating IS interface units (vendor s manual) PN1:002 Planning the Installation PN1:003 AC and DC Power and Ground Wiring PN1:004 Signal Wiring and Data Highway Guidelines PN1:006 Environmental Conditions for Instrumentation Systems PN1:007 Lightning Protection Guidelines for Instrumentation Systems PN4.4:CP7043 Installing Type CP7043 System Cabinets

17 Installation Section 3 9 Figure 3-Table Installation 3 Before a system is installed, both physical planning and electrical planning is required. This section provides information for both. The manuals listed in Table 2-2 describe other pre-installation physical and electrical planning. 3.1 Special Considerations Appropriate precautions must be taken when using control instrumentation in areas where explosive gases or vapors are present. Precautions include special handling and special wiring. Simply installing CL6340-Series termination panels and CL6350-Series barriers does not necessarily provide a certifiable intrinsically safe system. A certifiable system is a matter of design. To be certifiable, a system must be designed and installed according to guidelines relevant to the country of installation and provided by the locally approved certifying authority. Regulations governing intrinsic safety applications may preclude, or make difficult, the mounting of CL6340-Series and CL6350-Series products in cabinets which contain other equipment, such as Control I/O termination panels and MUX I/O files. Consult your certification authority if combined mounting is essential. Also see the vendor s instruction manual, MTL4000 Series Isolating IS interface units, INM4000, especially sections 3, 5, and 9 which describe various precautions and warnings to heed prior to and during installation. 3.2 Planning the Physical Installation The following subsections describe how to install the physical elements of an intrinsically safe system I/O Cards and Card File The I/O cards can be installed in any one of the 14 l/o card slots in the Type CP6701 Control I/O Card File (Figure 3-1). An l/o card can be configured either as simplex, or for a redundant configuration, as the

18 10 Section 3 Installation primary card or backup card. One backup can provide redundancy for a maximum of eight primary cards (1 for 8). Primary Power/Communication Card Secondary Power/Communication Card Backplane 3 Space for 14 I/O Cards Power Connection Card Figure 3-1. Type CP6701 Card File Arrangement X00751 A The three left card slots of the l/o card file are reserved for the power connection card, the primary power/communication card, and the secondary power/communication card. Refer to installation manual, Installing the Control I/O Subsystem, PN4.4:CP6701, for detailed information regarding the installation of an l/o card file. Note... See installation manual, Installing Type CP7043 System Cabinets, PN4.4:CP7043, for termination panel location guidelines in relation to the I/O card file, SR90 controller, door-mounted fans, and other PROVOX equipment Termination Panel Installation Termination panels mount on standard 19-inch EIA rails. The panels require no operator access and should be mounted in cabinets or equipment rooms with access for maintenance personnel only. The Type CP7043 System Cabinet is designed specifically to house these products. For more information about the cabinet, refer to product bulletin, BU4.4:CP7043. Figure 3-2 shows the dimensions of a CL6340-Series termination panel with barriers installed.

19 Installation Section 3 11 Termination Panel Barrier 7.0 (177) (482.6) 4.96 (126) INCH (mm) Note: 1 Fits standard 19 rack. Figure 3-2. CL6340-Series Termination Panel Dimensions Barrier Dimensions Figure 3-3 shows the overall dimensions for CL6350-Series barriers. 1.4 (18) ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ ÈÈÈÈÈÈÈÈÈÈÈÈÈÈÈ Hazardous Area Connector Top View Hazardous Area Connector Location INCH (mm) 3.53 (89.6) Figure (104.5) CL6350-Series Barrier Dimensions 0.64 (16.2)

20 12 Section 3 Installation Termination Cables Termination cables connect the I/O cards to CL6340-Series termination panels. The cables can be a maximum of 200 feet (60 m) long. For details on available cables and approved lengths, and a table which lists helpful cable installation tools, refer to Appendix B of this manual. 3 Note... Compliance with electromagnetic compatibility legislation may be compromised through the use of cables other than those supplied with the product. You must make sure that cable ducting does not become too full. With a maximum of ten panels possible on one side of a Type CP7043 cabinet, and a maximum of four cables for each term panel, there can be potentially 40 cables in the ducting; however, the number of cables should not exceed 30. Note... The number of cables in the ducting of the Type CP7043 System Cabinet should not exceed 30. Also, for a Type CL6741, Type CL6841, or Type CL6842 cable interface panel, at least one rack-unit of space between the top of the panel and the next panel above it must be left open. Cables are routed out of the top of the interface panels and require the space to make a proper radius bend Cabling for Simplex I/O Cards The number of cables and connections you require depends on the type of I/O card and the type of redundancy strategy you are using. For example, assume you have a termination panel that contains 16 Type CL6355 IS Analog Output Isolating Barriers which you are connecting to two Analog cards (with 8 channels each). To implement this example in a simplex system, you need two cables: one to connect each analog I/O card to the termination panel. (The cables for connecting the analog cards to the termination panel are supplied with the termination panel).

21 Installation Section 3 13 Figure 3-4 shows the connections between the two analog output cards and the termination panel in a simplex system. Analog I/O Cards I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cables Card #1 Channels 1-8 (Barriers 1-8) Card #2 Channels 1-8 (Barriers 9-16) J1 J2 1 2 CL6342 Termination Panel Figure 3-4. Cabling for Two Simplex Analog Output Cards Figure 3-5 shows the cable connections for a single analog input card in a simplex system and for a smart termination panel with a smart input card. This combination of one card and one termination panel can contain as many as 16 analog inputs.

22 14 Section 3 Installation Analog I/O Card I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cable Channels 1-16 J1 1 2 CL6341 Termination Panel Figure 3-5. Cabling for One Simplex Analog Input Cards and for a Smart Input Termination Panel with a Smart Input Card Figure 3-6 shows the cable connections for two discrete Input cards in a simplex system. This combination of cards and termination panels can contain as many as 32 discrete inputs. (The termination panel can contain as many as 16 barriers which can accept two discrete inputs each.) Discrete I/O Cards I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cables Card #1 Channels 1-16 (Barriers 1-8) Card #2 Channels 1-16 (Barriers 9-16) J1 J2 1 2 CL6343 Termination Panel Figure 3-6. Cabling for Two Simplex Discrete Input Cards

23 Installation Section 3 15 Figure 3-7 shows the cable connections for discrete output cards in a simplex system. This combination of one card and one termination panel can contain as many as 16 discrete outputs. Discrete I/O Card I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cable Channels 1-16 J1 1 2 CL6343 Termination Panel Figure 3-7. Cabling for Simplex Discrete Output Cards Figure 3-8 shows the cable connections for discrete input cards used for Pulse Count Input Signals in a simplex system. Discrete I/O Cards I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cables Card #1 Channels 1-8 Barriers 1-8 Card #2 Channels 1-8 Barriers 9-16 J1 J2 1 2 CL6344 Termination Panel Figure 3-8. Cabling for Simplex Pulse Count Inputs

24 16 Section 3 Installation Cabling for 1 for 1 Redundant I/O Cards 3 When your system has 1 for 1 redundancy, every primary I/O card has an associated backup I/O card. The following figures show examples of each type of I/O card and termination panel combination for 1 for 1 redundancy. Although the following figures show the primary and backup I/O cards installed in the same card file, you can install them in separate files. The termination cables must not exceed 200 feet (60m). Figure 3-9 shows cable connections for an analog input card with 16 inputs in a 1 for 1 redundant system. This combination of cards and termination panels can accept as many as 16 analog inputs. Primary Analog I/O Card Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File I/O Card to Termination Panel Cables Channels 1-16 J1 J2 1 2 CL6341 Termination Panel Figure 3-9. Cabling for 1 for 1 Redundant Analog Input Cards and for Smart Input Termination Panel with Smart Input Cards

25 Installation Section 3 17 Figure 3-10 shows cable connections for two analog output cards with 8 outputs each in a 1 for 1 redundant system. This combination of cards and termination panels can contain as many as 16 analog outputs. Primary AIO Card #1 Primary AIO Card #2 Backup Card #1 Backup Card #2 Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File I/O Card to Termination Panel Cables Card #1 Channels 1-8 (Barriers 1-8) Card #2 Channels 1-8 (Barriers 9-16) J1 J2 J3 J4 2 CL6342 Termination Panel 1 Figure Cabling for 1 to 1 Redundant Analog Output Cards

26 18 Section 3 Installation Figure 3-11 shows cable connections for two discrete Input cards in a 1 for 1 redundant system. This combination of cards and termination panels can accept as many as 32 discrete inputs. (The termination panel can contain as many as 16 barriers which can accept two discrete inputs each.) 3 Primary DIO Card #1 Primary DIO Card #2 Backup Card #1 Backup Card #2 Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File I/O Card to Termination Panel Cables Card #1 Channels 1-16 (Barriers 1-8) Card #2 Channels 1-16 (Barriers 9-16) J1 J2 J3 J4 2 CL6343 Termination Panel 1 Figure Cabling for 1 to 1 Redundant Discrete Input Cards

27 Installation Section 3 19 Figure 3-12 shows cable connections for discrete output cards in a 1 for 1 redundant system. This combination of cards and termination panels can contain as many as 16 discrete outputs. Primary Discrete I/O Card Backup I/O Card I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card to Termination Panel Cable Channels 1-16 J1 J3 1 2 CL6343 Termination Panel Figure Cabling for 1 to 1 Redundant Discrete Output Cards

28 20 Section 3 Installation Figure 3-13 shows cable connections for discrete input cards used for Pulse Count Input Signals in a 1 for 1 Redundant system. 3 Primary DIO Card #1 Primary DIO Card #2 Backup Card #1 Backup Card #2 I/O Card File Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections 2 Power connections. See Section I/O Card to Termination Panel Cables Card #1 Channels 1-8 (Barriers 1-8) Card #2 Channels 1-8 (Barriers 9-16) J1 J3 J2 J4 2 CL6344 Termination Panel 1 Figure Cabling for 1 to 1 Redundant Pulse Count Inputs

29 Installation Section Cabling 1 for N Configurations Cabling for 1 for N redundancy (where N = 2 to 8 primary I/O cards) requires a Cable Interface Panel. The panel allows 1 backup I/O card to provide redundancy for two to eight primary I/O cards. The Cable Interface Panel is not required 1 for 1 redundancy. The cable length between the primary I/O card and the termination panel must not exceed 200 feet (60m). Also, the overall length of the cables connecting the I/O card, the Cable Interface Panel, and the termination panel must not exceed 200 feet (60m). 3 All termination panels and cable interface panels have either two or three terminals labeled SHLD. One SHLD terminal on each panel must be connected to the cabinet ground. Note... Cabinet mounting rails are grounded so that a short grounding strap attached to the rail and a mounting bolt or grounding stud on the back plate will provide adequate grounding. The following examples show some multiple card and termination panel combinations. Not every possible redundancy combination is shown. Use these examples to help you determine the correct wiring for your redundancy strategy and card application.

30 22 Section 3 Installation Figure 3-14 shows cable connections for an analog input card with 16 analog inputs in a 1 for N redundant system. In this example, N is 4. That is, 1 card backs up 4 primary cards. 3 Primary Card #1 Primary Card #2 Primary Card #3 Primary Card #4 Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File Analog In Cable Interface Panel SHLD Channels 1-16 J1 J2 1 2 CL6341 Termination Panel Channels 1-16 J1 J2 1 2 CL6341 Termination Panel Channels 1-16 J1 J2 1 2 CL6341 Termination Panel Channels 1-16 Figure J1 J2 2 CL6341 Termination Panel Cabling for 1 for 4 Redundant Analog Input Cards and Smart Input Termination Panel with Smart Input Card 1

31 Installation Section 3 23 Figure 3-15 shows cable connections for two analog output cards with 8 outputs each in a 1 for 2 redundant system. This combination of cards and termination panels can contain as many as 16 analog outputs. Primary AIO Card #1 Primary AIO Card #2 Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections 2 Power connections. See Section I/O Card File Analog Out Cable Interface Panel SHLD Card #1 Channels 1-8 (Barriers 1-8) Card #2 Channels 1-8 (Barriers 9-16) J1 J2 J3 J4 2 CL6342 Termination Panel 1 Figure Cabling for 1 for 2 Redundant Analog Output Cards

32 24 Section 3 Installation Figure 3-16 shows cable connections for two discrete Input cards in a 1 for 2 redundant system. This combination of cards and termination panels can accept as many as 32 discrete inputs. (The termination panel can contain as many as 16 barriers which can accept two discrete inputs each.) 3 Primary DIO Card #1 Primary DIO Card #2 Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File Discrete I/O Cable Interface Panel SHLD Card #1 Channels 1-16 (Barriers 1-8) Card #2 Channels 1-16 (Barriers 9-16) J1 J2 J3 J4 1 2 CL6343 Termination Panel Figure Cabling for 1 to 2 Redundant Discrete Input Cards

33 Installation Section 3 25 Figure 3-17 shows cable connections for discrete output cards in a 1 for 3 redundant system. This combination of cards and termination panels can contain as many as 16 discrete outputs. Primary DIO Card #2 Primary DIO Card #1 Primary DIO Card #3 Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connection 2 Power connections. See Section I/O Card File Discrete I/O Cable Interface Panel SHLD Channels 1-16 J1 J3 1 2 CL6343 Termination Panel Channels 1-16 J1 J3 1 2 CL6343 Termination Panel Channels 1-16 J1 J3 1 2 CL6343 Termination Panel Figure Cabling for 1 for 3 Redundant Discrete Output Cards

34 26 Section 3 Installation Figure 3-18 shows cable connections for discrete input cards used for Pulse Count Input Signals in a 1 for 2 redundant system. 3 Primary DIO Card #1 Primary DIO Card #2 Backup I/O Card Notes: 1 Wiring from field instruments connect to terminals located on the barriers. See Appendix A for details of these connections. 2 Power connections. See Section I/O Card File Discrete I/O Cable Interface Panel SHLD Card #1 Channels 1-8 (Barriers 1-8) Card #2 Channels 1-8 (Barriers 9-16) J1 J3 J2 J4 2 CL6344 Termination Panel 1 Figure Cabling for 1 to 2 Redundant Pulse Count Inputs Termination Cable Connectors Termination cables longer than 20 feet (6m) are supplied with a spare D-shell connector. If the connector is too large to fit through a conduit or other limited access area, you can cut the cable and remove the connector and then attach the spare connector after routing the cable. You should attach the spare connector to the end of the termination cable according to the instructions provided with the connector. Refer to Table 3-1 for D-shell connector pin assignments (37-pin and 25-pin). Note... If you find it necessary to route the cable through a small area, cut the cable near the connector that you will attach to the termination panel. An extra connector is provided with cables of 50, 100, or 200 feet (15, 30, or 60m) for this purpose.

35 Installation Section 3 27 Table 3-1. D-Shell Connector Pin Assignments 37-pin D-shell Connector 25-pin D-shell Connector Pin Color Pin Color 1 Red 1 Red 2 White 2 White 3 Green 3 Green 4 Blue 4 Blue 5 Yellow 5 Yellow 6 Brown 6 Brown 7 Orange 7 Orange 8 White 8 White 9 Green 9 Green 10 Blue 10 Blue 11 Yellow 11 Yellow 12 Brown 12 Brown 13 Orange 13 Orange 14 White 14 through 20 Black 15 Blue 21 through 25 Red 15 Blue Shell Silver (Shield) 16 Yellow 17 Brown 18 Orange 19 Blue Shell Silver (Shield) 20 through 26 Black 27 through 32 Red 33 through 36 Green N/C N/C Green White 37 No wire 3

36 28 Section 3 Installation 3.3 Planning the Electrical Installation Each element in the installation has specific electrical requirements that must be considered. The following subsections provide planning information and electrical requirements for the elements. 3 The supplied wiring kit includes pre-terminated wires of the correct gauge and length to make the required connections when the panels are mounted in a Type CP7043 System Cabinet Termination Panel Power Termination panels are supplied with nominal 24 Vdc power. Each panel is protected by a fuse. Screw terminals on the panels can accommodate two 14 AWG wires or a single 22 AWG wire. Four screw terminals provide connections for primary and secondary +24 Vdc and Power Supply Common. The primary and secondary power terminals are labeled PRI +24 V and SEC +24 Vdc, respectively. Two redundant Power Supply Common terminals are labeled PSC. Refer to Figure 2-1 to see the location of the power connector on the termination panel. To connect power to the termination panels: Step 1: Step 2: Connect the positive wire from your 24Vdc supply to the terminal labeled PRI +24 V. If you have a secondary power supply, connect the positive line to the terminal labeled SEC +24 Vdc. Note... If redundant power supplies are not used, place a jumper between the terminals labeled PRI +24V and SEC +24V. Step 3: Connect the screw terminal labeled PSC to the return, or negative, line of the 24Vdc power supply. Both simplex and redundant termination panels have two screws labeled SHLD that provide shield grounding for the termination cables. Use the short black wire in the wiring kit to connect one of these terminals to the stud on the metal chassis. For more information about grounding, refer to subsection

37 Installation Section Shield Grounding A ground bar kit containing grounding terminals is optional and available where field cable shield grounding is required at the termination panel. For detailed information on grounding, refer to the following documentation: AC and DC Power and Ground Wiring, PN1:003 Signal Wiring and Highway System Guidelines, PN1:004 Installing Type CP7010 Cabinets, PN4.4:CP7010 Installing Type CP7043 Cabinets, PN4.4:CP Warning... If your system uses shield grounding, ground shields at one end only. The other ends must be carefully insulated to prevent possible sparks or possible current flow between different potential ground points DC Grounding The Power Supply Common (PSC) circuitry must be grounded through a local ground bus (LGB) or a master ground bus (MGB) to the designated system earth ground. For specific DC grounding information, refer to the documentation listed in subsection Connecting Field Wiring to Barriers Hazardous area field wiring is connected to the BLUE terminal blocks that plug into the front of the barrier. Either connect the wires using the screws on the terminal block (maximum gauge 12 AWG) or by using an optional push-in and crimp type block. Figure 3-19 shows the barrier and terminal connections. For detailed information about barrier field wiring connections, refer to the specifications for the individual barriers in Appendix A and the vendor s instruction manual, MTL4000 Series Isolating IS interface units. INM4000.

38 30 Section 3 Installation Field Wiring Connections Top View of plug-in terminal block 3 Figure Side View This end of the barrier connects to the termination panel Barrier and Terminal Connections

39 Barrier Specifications Appendix A 31 Figure A-Table A Appendix A A Barrier Specifications The vendor s instruction manual, MTL4000 Series Isolating IS interface units, INM4000, and this appendix contain specifications for CL6350-Series barriers. Table A-3 in this manual provides a cross reference between the PROVOX type number and the MTL model number. A CL6340-Series termination panels provide the power and signal requirements specified for the termination-panel side of the barriers. General Specifications for CL6350-Series Intrinsic Safety Barriers Location of Units Long Term Drift Safe Area No recalibration necessary Electromagnetic Compatibility Approvals Complies with European Standards EN and EN50014:1977 plus amds 1 and 2. ATEX, CSA, and FM Maximum Safe-Area Voltage Hazardous- Area Connectors U M = 250V rms or dc Screw-clamp connector accommodates conductors of 14 AWG (2.5mm 2 ) maximum. Crimp-contact header accommodates wire crimps for conductors of AWG, or wire crimps for conductors of AWG. Humidity Ambient Temperature Limits Mounting Indicators 5% to 95% RH 20 C to +60 C continuous working 40 C to +80 C storage Barriers mount on CL6340-Series termination panels which can be surface or EIA-rail mounted Green power indicator on each barrier Weight 100 g approximately

40 32 Appendix A Barrier Specifications A.1 Type CL6351 IS High-Level Analog Input Isolating Barrier (HART compatible) The Type CL6351 IS High-Level Analog Input Isolating Barrier provides a fully floating dc supply for energizing a 2- or 3-wire, 4 to 20 ma conventional analog transmitter or smart transmitter located in a hazardous area, and repeats the current in another floating circuit to drive a safe-area load. Figure A-1 contains the connections for the CL6351 Barrier. A Notes: 1 The type of communicator must be such that it does not send a signal out to the field that will infringe on safety regulations. 4/20mA 4/20mA HART Hand-held Communicator 1 Hazardous Area Safe Area I I /20 ma Barrier Termination Panel Vs Vdc Vs Figure A-1. Load Typical Connections for Type CL6351 IS007 M

41 Barrier Specifications Appendix A 33 For smart transmitters, the unit allows bi-directional transmission of digital communication signals superimposed on the 4 to 20 ma signal so that the transmitter can be interrogated either from the operator station or by a hand-held communicator (HHC). The barrier can also be used with hazardous-area current sources. There are two versions of this barrier. The following table contains specifications for both versions. Type CL6351 Barrier Specifications (Standard and High Power) Number of Channels Location of Transmitter One Zone 0, IIC, T4-T6 if suitably certified Div. 1, Group A, hazardous location Power Requirement (Vs) Power Dissipation Within Unit 65 ma at 24 Vdc with 20 ma signal 75 ma at 20 Vdc 50 ma at 35 Vdc 1.2 W at 24 Vdc with 20 ma signal 1.4 W at 35 V A Voltage Available for Transmitter and Lines Input and Output Signal Range Digital Signal Bandwidth Safe-Area Response Time Transfer Accuracy at 20C Temperature Drift Standard: 15 V minimum at 20 ma High Power: 16.3 minimum at 20 ma Note: Maximum open-circuit voltage is 28 V 4 to 20 ma 10 Hz to 8 khz Circuit Load Resistance: Conventional transmitters: 0 to 650 Ω. Smart transmitters: 250 Ω ± 10% Circuit Output Resistance: >1 MΩ Circuit Ripple: <50 µa peak-to-peak Settles within 200 µa of final value after 20 ms Better than 20 µa <1 µa/ C Isolation Safety Description FM Entity Parameters 250 Vac between safe and hazardous-area circuits Terminals 2 to 5 and 6: Standard: 28 V, 300 Ω, 93 ma High Power: 28 V, 240 Ω, ma Terminals 5 to 6: Standard & High Power: Non-energy storing apparatus 1.2 V, 0.1 A, 20 µj, and 25 mw; can be connected without further certification into any IS loop with open-circuit voltage not more than 28 V Standard: Terminals 2, 5, 6 Terminals 2, 4, 5 Voc = 28 Vdc Voc = 28 Vdc Isc = 141 ma Isc = 93 ma Ca = 0.13 µf Ca = 0.13 µf La = 1.94 mh La = 4.2 mh High Power: Terminals 2, 5, 6 Terminals 2 6 Voc = 28 Vdc Voc = 28 Vdc Isc = 118 ma Isc = 166 ma Ca = 0.14 µf Ca = 0.14 µf La = 2.76 mh La = 1.41 mh LED Indicator Green: One provided for power indication. Note: All values are applicable to both standard and high power versions unless noted otherwise.

42 34 Appendix A Barrier Specifications A.2 Type CL6352 IS Millivolt Input, Type CL6353 IS RTD Input, and Type CL6354 IS Thermocouple Input Isolating Barriers The Type CL6352, Type CL6353, and Type CL6354 IS barriers convert a low-level dc signal from a temperature sensor mounted in a hazardous area into a 4 to 20 ma current for driving a safe-area load. A These barriers are based on a barrier which is available in several standard thermocouple and RTD temperature ranges. These temperature ranges can be customer modified with a pocket data terminal available from Measurement Instruments Limited (MTL). Figure A-2 shows the connections for the Type CL6352, Type CL6353, and Type CL Wire 3-Wire 4-Wire Hazardous Area Safe Area mv Socket for Configuration I /20 ma Load Barrier Termination Panel Vs Vdc Vs Figure A-2. Typical Connections for Type CL6352, Type CL6353, and Type CL6354 The following table specifies the resistance temperature detector ranges which can be used with the barriers.