How Can I Implement PlantStruxure architecture in ATEX environments?

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1 How Can I Implement PlantStruxure architecture in ATEX environments? Tested Validated Documented Architecture Advanced process control Develop your project

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3 Important information Notice People responsible for the application, implementation and use of this document must make sure that all necessary design considerations have been taken into account and that all laws, safety and performance requirements, regulations, codes, and applicable standards have been obeyed to their full extent. Schneider Electric provides the resources specified in this document. These resources can be used to minimize engineering efforts, but the use, integration, configuration, and validation of the system is the user s sole responsibility. Said user must ensure the safety of the system as a whole, including the resources provided by Schneider Electric through procedures that the user deems appropriate. This document is not comprehensive for any systems using the given architecture and does not absolve users of their duty to uphold the safety requirements for the equipment used in their systems, or compliance with both national or international safety laws and regulations. Readers are considered to already know how to use the products described in this document. This document does not replace any specific product documentation. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. The addition of this symbol to a Danger or Warning safety label indicates that an electrical hazard exists, which will result in personal injury if the instructions are not followed. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Failure to follow these instructions will result in death or serious injury. 3

4 WARNING WARNING indicates a potentially hazardous situation which, if not avoided, can result in death or serious injury. Failure to follow these instructions can cause death, serious injury or equipment damage. CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, can result in minor or moderate injury. Failure to follow these instructions can result in injury or equipment damage. Before you begin NOTICE NOTICE is used to address practices not related to physical injury. Failure to follow these instructions can result in equipment damage. Note: Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction, operation and installation of electrical equipment, and has received safety training to recognize and avoid the hazards involved. This automation equipment and related software is used to control a variety of industrial processes. The type or model of automation equipment suitable for each application will vary depending on factors such as the control function required, degree of protection required, production methods, unusual conditions and government regulations etc. In some applications more than one processor may be required when backup redundancy is needed. Only the user can be aware of all the conditions and factors present during setup, operation and maintenance of the solution. Therefore only the user can determine the automation equipment and the related safeties and interlocks which can be properly used. When selecting automation and control equipment and related software for a particular application, the user should refer to 4

5 the applicable local and national standards and regulations. The National Safety Council s Accident Prevention Manual also provides much useful information. Ensure that appropriate safeties and mechanical/electrical interlocks protection have been installed and are operational before placing the equipment into service. All mechanical/electrical interlocks and safeties protection must be coordinated with the related automation equipment and software programming. Note: Coordination of safeties and mechanical/electrical interlocks protection is outside the scope of this document. START UP AND TEST Following installation but before using electrical control and automation equipment for regular operation, the system should be given a start up test by qualified personnel to verify the correct operation of the equipment. It is important that arrangements for such a check be made and that enough time is allowed to perform complete and satisfactory testing. WARNING EQUIPMENT OPERATION HAZARD Follow all start up tests as recommended in the equipment documentation. Store all equipment documentation for future reference. Software testing must be done in both simulated and real environments. Failure to follow these instructions can cause death, serious injury or equipment damage. Verify that the completed system is free from all short circuits and grounds, except those grounds installed according to local regulations (according to the National Electrical Code in the USA, for example). If high-potential voltage testing is necessary, follow recommendations in the equipment documentation to prevent accidental equipment damage. Before energizing equipment: Remove tools, meters, and debris from equipment Close the equipment enclosure door Remove ground from incoming power lines Perform all start-up tests recommended by the manufacturer 5

6 Operation and adjustments The following precautions are from NEMA Standards Publication ICS (English version prevails): Regardless of the care exercised in the design and manufacture of equipment or in the selection and rating of components; there are hazards that can be encountered if such equipment is improperly operated. It is sometimes possible to misadjust the equipment and thus produce unsatisfactory or unsafe operation. Always use the manufacturer s instructions as a guide for functional adjustments. Personnel who have access to these adjustments should be familiar with the equipment manufacturer s instructions and the machinery used with the electrical equipment. Only those operational adjustments actually required by the operator should be accessible to the operator. Access to other controls should be restricted to prevent unauthorized changes in operating characteristics. WARNING UNEXPECTED EQUIPMENT OPERATION Only use software tools approved by Schneider Electric for use with this equipment. Update your application program every time you change the physical hardware configuration. Failure to follow these instructions can cause death, serious injury or equipment damage. Intention This document is intended to provide a quick introduction to the described system. It is not intended to replace any specific product documentation, nor any of your own design documentation. On the contrary, it offers information additional to the product documentation on installation, configuration and implementing the system. The architecture described in this document is not a specific product in the normal commercial sense. It describes an example of how Schneider Electric and third-party components may be integrated to fulfill an industrial application. A detailed functional description or the specifications for a specific user application is not part of this document. Nevertheless, the document outlines some typical applications where the system might be implemented. 6

7 The architecture described in this document has been fully tested in our laboratories using all the specific references you will find in the component list near the end of this document. Of course, your specific application requirements may be different and will require additional and/or different components. In this case, you will have to adapt the information provided in this document to your particular needs. To do so, you will need to consult the specific product documentation of the components that you are substituting in this architecture. Pay particular attention in conforming to any safety information, different electrical requirements and normative standards that would apply to your adaptation. It should be noted that there are some major components in the architecture described in this document that cannot be substituted without completely invalidating the architecture, descriptions, instructions, wiring diagrams and compatibility between the various software and hardware components specified herein. You must be aware of the consequences of component substitution in the architecture described in this document as substitutions may impair the compatibility and interoperability of software and hardware. CAUTION EQUIPMENT INCOMPATIBILITY OR INOPERABLE EQUIPMENT Read and thoroughly understand all hardware and software documentation before attempting any component substitutions. Failure to follow these instructions can result in injury or equipment damage. 7

8 This document is intended to describe how to implement a PlantStruxure architecture in ATEX environments. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION Only qualified personnel familiar with low and medium voltage equipment are to perform work described in this set of instructions. Workers must understand the hazards involved in working with or near low and medium voltage circuits. Perform such work only after reading and understanding all of the instructions contained in this bulletin. Turn off all power before working on or inside equipment. Use a properly rated voltage sensing device to confirm that the power is off. Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power. Assume that all circuits are live until they have been completely de-energized, tested, grounded, and tagged. Pay particular attention to the design of the power system. Consider all sources of power, including the possibility of back feeding. Handle this equipment carefully and install, operate, and maintain it correctly in order for it to function properly. Neglecting fundamental installation and maintenance requirements may lead to personal injury, as well as damage to electrical equipment or other property. Beware of potential hazards, wear personal protective equipment and take adequate safety precautions. Do not make any modifications to the equipment or operate the system with the interlocks removed. Contact your local field sales representative for additional instruction if the equipment does not function as described in this manual. Carefully inspect your work area and remove any tools and objects left inside the equipment. Replace all devices, doors and covers before turning on power to this equipment. All instructions in this manual are written with the assumption that the customer has taken these measures before performing maintenance or testing. Failure to follow these instructions will result in death or serious injury. 8

9 The TVDA collection Tested Validated Documented Architecture (TVDA) guides are meant to help in the implementation of specified solutions. TVDA guides provide a tested and validated example of the proposed architecture to help project engineers and Alliance System Integrators during the design and implementation of a project. The TVDA helps users analyze their architectures, confirm the feasibility of their systems and speed up system implementation. Each TVDA provides users with: A reference architecture based on Schneider Electric s PlantStruxure solution Documentation of the system requirements of the architecture response times, number of devices, features Design choices for the application software and hardware architectures Test results to confirm the requirements are met All explanations and applications have been developed by both Schneider Electric experts and system integrators in our PlantStruxure labs. TVDAs are not intended to be used as substitutes for the technical documentation related to the individual components, but rather to complement those materials. Development environment Each TVDA or STN has been developed in one of our solution platform labs using a typical PlantStruxure architecture. PlantStruxure, the process automation system from Schneider Electric, is a collaborative architecture that allows industrial and infrastructure companies to meet their automation needs while at the same time addressing their growing energy efficiency requirements. In a single environment, measured energy and process data can be analyzed to yield a holistically optimized plant. 9

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11 Table of contents 1. Introduction Purpose About this Document ATEX Principles What Is an Ex Atmosphere? ATEX Directives Workplace Classification Equipment Classification Equipment Protection Level (EPL) Types of Protection Marking Selection Selected Architectures Selected Hardware Configuration Quantum PAC Configuration Stahl Remote I/O Configuration Implementation Hardware Implementation in ATEX Environments Software Implementation Operation and Maintenance Hardware Software Validation Memory Consumption of the DTMs in Unity Pro Performance Test

12 8. Conclusion Appendix Glossary Bill of Material and Software Reference Documents How Do I Work With Collaborative Automation Technology Partners? ATEX Products Catalog

13 1. Introduction OOOOOOO 1 Introduction 1.1. Purpose The purpose of this document is to provide information to build basic knowledge about the ATEX certification and its marking. It will also provide guidelines to implement PlantStruxure architectures in explosive (Ex) environments where ATEX compliance is required. Many workplaces may contain, or have activities that produce, explosive or potentially explosive atmospheres, such as in the oil and gas, water, and food and beverage industries. Domains where work activities create or release flammable gases or vapors, or combustible dusts include: Metal surface grinding, especially aluminum dust and particles Oil refineries, rigs and processing plants Gas pipelines and distribution centers Printing industries, paper and textiles Aircraft refueling and hangars Chemical processing plants Grain handling and storage Sewage treatment plants Surface coating industries Underground coal mines Woodworking areas Sugar refineries Vessels / ships Power plants Therefore, most countries have developed laws, regulations and standards to improve the level of safety in these workplaces. The mainstream certification schemes for electrical equipment in hazardous areas that are currently in operation around the world include ATEX, IECEx, CSA, GOST, ANZex, AUSEx, UL and FM. 13

14 OOOOOOO 1 Introduction This guide provides an example of how to implement a Schneider Electric Quantum Ethernet I/O system in an Ex area, and distributed remote I/Os of our partner Stahl, an Ex area equipment specialist. Note: Stahl is a member of Schneider Electric s Collaborative Automation Partner Program (CAPP). CAPP is a formal community of business partners through which Schneider Electric expands its capabilities. This document focuses on the ATEX directives only, which applies in the European Union. The other certification schemes mentioned previously are not addressed in this document About this Document This document does not replace intensive study of the relevant fundamentals and guidelines when planning and installing electrical systems in a potentially explosive environment. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION Implement the proper norms and use the corresponding documentation to select, design, configure, implement, operate and maintain your system in a potentially explosive environment. Failure to follow these instructions will result in death or serious injury. A glossary is available in the appendix chapter of this document. Please refer to it whenever necessary. 14

15 2. ATEX Principles OOOOOO 2 ATEX Principles The aim of this chapter is to describe the ATEX principles that are required to understand and decode the ATEX marking. The following principles are described: Explosive atmosphere definition ATEX directives 99/92/EC and 94/9/EC Workplace classification Equipment classification Equipment Protection Level (EPL) Types of protection Marking Certification Group and category Explosion protection Certificate number Mandatory documents Note that most of the information is extracted from the two ATEX directive guidelines listed on the European commission web site: What Is an Ex Atmosphere? An explosive atmosphere for the purposes of Directive 94/9/EC is defined as a mixture with the following characteristics: Flammable substances in the form of gases, vapors, mists or dusts With air Under atmospheric conditions After ignition, the combustion spreads to the entire unburned mixture Note that sometimes (mainly with dusts) only a part of the combustible material is consumed by the combustion 15

16 OOOOOO 2 ATEX Principles Effective ignition sources include: Lightning strikes Open flames Mechanically generated impact sparks Mechanically generated friction sparks Electric sparks High surface temperature Electrostatic discharge Radiation Figure 1: The Ex hazard triangle Adiabatic compression 2.2. ATEX Directives The name ATEX is derived from the French ATmosphères EXplosibles. Regarding the hazard caused by a potentially Ex atmosphere, European Union (EU) has adopted two directives on health and safety: The ATEX directive 99/92/EC workplace directive The ATEX directive 94/9/EC equipment directive The ATEX directives became mandatory in the E.U. member states on July 1, Workplace Classification Figure 2: Ex environment logo The ATEX Directive 99/92/EC, also known as ATEX 137 or ATEX Workplace Directive, is a directive set out to improve the health and safety protection of all workers potentially at risk from Ex atmospheres. The workplace directive classes the hazardous areas in terms of zones based on the frequency and duration of an Ex atmosphere occurrence. 16

17 In the ATEX workplace directive, two types of environment are considered: Gas - for gas, vapor and mist Dust OOOOOO 2 ATEX Principles Each environment is divided into three zones as described in the following tables. Figure 3: ATEX zones Zone Description A place in which an Ex atmosphere consisting of a mixture of air and flammable substances in the form of gas, vapor or mist is present continuously, for long periods or frequently. Example: Inside containers or plants (evaporators, reaction vessels, etc.), but can also occur near vents and other openings. A place in which an Ex atmosphere consisting of a mixture of air and flammable substances in the form of gas, vapor or mist is likely to occur occasionally in normal operation. Example: Immediate vicinity of zone 0, immediate vicinity of feed opening, the immediate area around inadequately sealed glands, such as at pumps and valves, etc. A place in which an Ex atmosphere consisting of a mixture of air and flammable substances in the form of gas, vapor or mist is not likely to occur in normal operation but, if it does occur, will persist for a short period only. Example: Places surrounding zones 0 or 1. Table 1: Gas, mist or vapor environments 17

18 OOOOOO 2 ATEX Principles Zone Description A place in which an Ex atmosphere in the form of a cloud of combustible dust is present continuously, for long periods or frequently. Example: Inside containers, pipes, vessels, etc., that is, usually only inside plants (mills, dryers, mixers, pipelines, silos, etc.). A place in which an Ex atmosphere in the form of a cloud of combustible dust is likely to occur occasionally in normal operation. Example: Places in the immediate vicinity of powder filling and emptying points and places where dust deposits occur. A place in which an Ex atmosphere in the form of a cloud of combustible dust is not likely to occur in normal operation but, if it does occur, will persist for a short period only. Example: Places in the vicinity of plants containing dust if dust can escape from leaks and form deposits in hazardous quantities. Table 2: Dust environments 2.4. Equipment Classification Figure 4: Ex equipment logo The ATEX Directive 94/9/EC, also known as ATEX 95 or ATEX Equipment Directive, is a directive adopted by the EU to facilitate free trade in the EU. It does this by aligning the technical and legal requirements in the member states for products intended for use in potentially Ex atmospheres. This directive applies to electrical and non-electrical equipment or components, and protective systems. Following is the equipment definition as described in the directive: Equipment means machines, apparatus, fixed or mobile devices, control components and instrumentation thereof and detection or prevention systems which, separately or jointly, are intended for the generation, transfer, storage, measurement, control and conversion of energy and/or the processing of material and which are capable of causing an explosion through their own potential sources of ignition. 18

19 OOOOOO 2 ATEX Principles The Equipment Directive contains group classifications, which are then sub-divided into categories. The equipment is divided into two groups; I for mining and II for all other industries: Group I II Description Comprises equipment intended for use in the underground parts of mines, and to parts of surface installations of such mines that are likely to become endangered by firedamp and/or combustible dust. Comprises equipment intended for use in other places likely to become endangered by Ex atmospheres. Table 3: Equipment directive groups Group I For group I (mining), the categorization depends (among other factors) on the state of the power supply of the product in the event of an Ex atmosphere forming: Category M1 M2 Description The equipment will be in an energized state when the atmosphere is present The equipment will be de-energized when the atmosphere is present Table 4: Group I categories Group II Categories For group II (non-mining industries), the categorization depends on the following factors: Where the product is intended to be used Whether a potential Ex atmosphere is always present, or is likely to occur for a long or a short period of time Group II is divided into three categories 1, 2, and 3 based on how frequently the Ex atmosphere will be present: Category Description 1 The Ex atmosphere is present continually or for long periods or frequently 2 The Ex atmosphere is likely to occur occasionally in normal operations 3 The Ex atmosphere is not likely to occur in normal operation but, if it does occur, it will persist for a short period only Table 5: Group II categories 19

20 OOOOOO 2 ATEX Principles Types of Fuel In group II described above, two types of fuel must be considered for the equipment classification: Fuel type G D Gas including gas, vapor and mist Dust Description Table 6: Types of fuel in group II Which Equipment Category for Which Zone? The following categories of equipment must be used in the indicated zones, provided they are suitable for gases, vapors or mists and/or dusts as appropriate: Gas Dust Equipment Category Protection Level Zone 0 Zone 20 1 Very High Zone 1 Zone 21 1 or 2 High Zone 2 Zone 22 1,2 or 3 Normal Table 7: Equipment categories and zones Equipment located outside potentially Ex atmosphere is also covered by the ATEX directive under the following conditions: The equipment is a safety device, controller or regulatory device And The equipment is required for the safe functioning of equipment or protective systems with respect to the risk of explosion 20

21 OOOOOO 2 ATEX Principles Minimum Ignition Energy and Explosion Groups Minimum Ignition Energy Temperature Classes The minimum ignition energy is the minimum amount of energy sufficient to ignite the most ignitable mixture. This characteristic has to be considered when selecting the equipment. For dust, the maximum permissible surface temperature measured in the laboratory is directly indicated on the ATEX marking of the equipment in C. For gases, the maximum surface temperature of the equipment is specified in temperature classes from T1 to T6. Temperature Class Ignition Temperatures Range of an Inflammable Mixture Maximum Admissible Surface Temperature on Group II Electrical Equipment T1 >450 C 450 C T2 > C 300 C T3 > C 200 C T4 > C 135 C T5 > C 100 C T6 > C 85 C Table 8: Maximum surface temperature for equipment in gas The above table states that the surface temperature of a piece of electrical equipment with a T5 temperature classification should not exceed 100 C in an environment at an ambient temperature (Ta). The equipment that fulfils the requirements of the T3 temperature class is also suitable for use in an Ex atmosphere in the temperature class T1 and T2. The ambient temperature (Ta) is often marked as x C Ta y C, after the minimum ignition energy indicator. If no Ta is indicated, the ambient temperature to consider is -20 C Ta +40 C. 21

22 OOOOOO 2 ATEX Principles Explosion Groups Gas groups For Group I (mining), it is assumed that the only flammable gas that can be present is methane. For Group II (non-mining), the dangerousness of the gases increases from explosion group IIA to IIC. Group Typical Gas Ignition Energy I Methane 280 µj IIA Propane >180 µj IIB Ethylene µj IIC Hydrogen <60 µj Table 9: Gas minimum ignition energy groups The equipment approved for IIC is also approved for IIA and IIB. Dust groups The various types of dust are divided into three sub-groups according to the dust resistance: Group IIIA IIIB IIIC Dust Resistance Combustible flying Non-conductive dust Conductive dust Table 10: Dust resistance groups The equipment approved for IIIC is also approved for IIIA and IIIB. 22

23 OOOOOO 2 ATEX Principles 2.5. Equipment Protection Level (EPL) The EPL has been introduced as part of the IECEx certification requirements and has been adopted into the ATEX requirements to allow an alternative approach for selection of Ex equipment. The EPL consists of two letters. The first letter gives information on the type of explosive atmosphere G for gas, D for dust and the protection level is defined by the letters a, b or c. ATEX Category EPL Symbol Protection Level 1 G Ga Equipment for explosive gas atmospheres with a very high level of protection 2 G Gb Equipment for explosive gas atmospheres with a high level of protection 3 G Gc Equipment for explosive gas atmospheres with an enhanced level of protection 1 D Da Equipment for explosive dust atmospheres with a very high level of protection 2 D Db Equipment for explosive dust atmospheres with a high level of protection 3 D Dc Equipment for explosive dust atmospheres with an enhanced level of protection M1 M2 Ma Mb Equipment for installation in mines susceptible to firedamp with a very high level of protection Equipment for installation in mines susceptible to firedamp with a high level of protection Table 11: Link between ATEX categories and EPL 2.6. Types of Protection Where equipment contains electrical circuits, sparks or heat, or where short-circuits can be prevented from causing ignition of the Ex atmosphere, three approaches are commonly used: Sealing the enclosure to prevent the fuel from entering Filling the enclosure with a material which acts as a barrier (powder, liquid, solid or pressurized inert gas) Reducing the energy carried by the circuits to a point where sparks and arcs cannot transfer enough energy to ignite the atmosphere Each type of protection implemented on equipment is designated by a letter which is included in the ATEX marking of the equipment the ATEX marking is detailed in a section

24 OOOOOO 2 ATEX Principles Currently, the following ignition protections exist: Gas ignition protections: Flameproof Intrinsic safety Increased safety Encapsulation Powder filled Oil immersion Pressurization Type of protection n Non-sparking Sparking apparatus Energy limitation Restricted breathing Optical radiation Inherently safe optical radiation Protected optical radiation Blocking optical radiation Dust ignition protections: Protection by enclosures Pressurization Intrinsic safety Encapsulation These types of protection are described in the following subsections for electrical equipment. 24

25 OOOOOO 2 ATEX Principles Flameproof With flameproof equipment, the parts which could ignite an explosive atmosphere are located inside an enclosure which can withstand the pressure of the mixture exploding inside. Such equipment prevents the transmission of the explosion to the explosive atmosphere surrounding the enclosure. This type of protection is for category 2 equipment and is suitable for use in zone 1. Equipment Type Electrical in gas Marking Ex d Gb Table 12: Flameproof marking example Intrinsic Safety An electric circuit is intrinsically safe if no spark or thermal effect produced under specified test conditions (which include normal operation and specific detected fault conditions) is capable of causing ignition of a given explosive atmosphere. The intrinsic safety protection is used in measurement and control technology particularly because no high currents, voltage and power are usually required. An essential aspect of the intrinsic safety protection is to be able to reliably observe the voltage and current limit values, even if determined faults may occur. Intrinsically safe apparatus and intrinsically safe components from related equipment are classified in different protection levels: ia: for category 1 equipment and suitable for use in zones 0/20,1/21 and 2/22 ib: for category 2 equipment and suitable for use in zones 1/21 and 2/22 ic: for category 3 equipment and suitable for use in zone 2/22 Intrinsically safe apparatus designates electrical apparatus in which all circuits are intrinsically safe. Associated apparatus designates electrical apparatus which contains circuits, some of which are intrinsically safe and some are not. Therefore, square brackets are added in the marking as follows Ex [ia], Ex [ib] or Ex [ic], to indicate that the associated electrical apparatus contains an intrinsically safe electric circuit. 25

26 OOOOOO 2 ATEX Principles Equipment Type Intrinsically Safe Apparatus Marking Associated Apparatus Marking Electrical in gas Ex ia Ga/ib Gb/ic Gc Ex [ia Ga]/[ib Gb]/[ic Gc] Electrical in Dust Ex ia Da/ib Db/ic Dc Ex [ia Da]/[ib Db]/[ic Dc] Table 13: Intrinsically safe marking examples Increased Safety Additional measures are applied to increase the level of safety, preventing the possibility of excessive temperatures and the occurrence of sparks or electric arcs within the enclosure or on exposed parts of electrical apparatus, where such ignition sources would not occur in normal service. This type of protection is for category 2 equipment and suitable for use in zone 1. Equipment Type Electrical in gas Marking Ex e Gb Table 14: Increased safety marking example Encapsulation With encapsulation, the parts that are capable of igniting an explosive atmosphere, by either sparking or heating, are enclosed in a compound in such a way as to avoid ignition of an explosive atmosphere. The protection by encapsulation is classified in different levels of protection: ma: for category 1 equipment and suitable for use in zones 0/20,1/21 and 2/22 mb: for category 2 equipment and suitable for use in zones 1/21 and 2/22. mc: for category 3 equipment and suitable for use in zone 2/22. Equipment Type Electrical in gas Electrical in Dust Marking Ex ma Ga/mb Gb/mc Gc Ex ma Da/mb Db/mc Dc Table 15: Encapsulation marking examples 26

27 OOOOOO 2 ATEX Principles Powder Filled The enclosure of the electrical apparatus is filled with a fine granular packing material. This type of protection makes it impossible for an electric arc within the enclosure to ignite the Ex atmosphere outside. This type of protection is for category 2 equipment and suitable for use in zone 1 Equipment Type Electrical in gas Marking Ex q Gb Table 16: Powder filled marking example Oil Immersion Parts which might ignite an explosive atmosphere are immersed in protective fluid, e.g. oil, so that a potentially Ex atmosphere which exists over the surface or outside of the apparatus cannot be ignited. This type of protection is for category 2 equipment and suitable for use in zone 1 Equipment Type Electrical in gas Marking Ex o Gb Table 17: Oil immersion marking example Pressurization The formation of a potentially explosive atmosphere inside the enclosure is prevented by maintaining an ignition shield gas (air, inert or a different suitable gas) inside the enclosure at a pressure above atmospheric pressure. The overpressure is maintained with or without constant flushing of the protective gas. 27

28 OOOOOO 2 ATEX Principles Regarding the electrical equipment in a gas environment, this type of protection is divided into three levels: px: Reduces the classification within the protected enclosure from zone 1 to safe area py: Reduces the classification within the protected enclosure from zone 1 to zone 2 pz: Reduces the classification within the protected enclosure from zone 2 to safe area For electrical equipment in a dust environment, this type of protection is for category 2 equipment. Equipment Type Electrical in gas Electrical in Dust Marking Ex px Gb/py Gb/pz Gc Ex pd Db Table 18: Pressurization marking examples Type of Protection n n protection applies to electric equipment where, in normal operation and in certain specified regular expected occurrences, it is not capable of igniting a surrounding explosive gas. Furthermore, the requirements of this standard are intended to ensure that a malfunction capable of causing ignition is not likely to occur. It is divided into four sub-types: na non-sparking apparatus: The construction ensures reliable prevention of unacceptable high temperatures and sparks or electrical arcs, both on the internal or external equipment whose normal operation does not involve unacceptable high temperatures, sparks or arcs. nc sparking apparatus: The equipment is enclosed or hermetically sealed or encapsulated to ensure that it will withstand an internal explosion and will not lead to subsequent ignition of the surrounding gas atmosphere, or it will avoid ignition of the surrounding gas atmosphere reliably through non-incendive components. nr restricted breathing: The enclosures are designed in such a way that the ingress of gases is restricted. nl energy limitation: Energy limited circuits and components ensure that neither a spark nor a thermal effect is capable of igniting a flammable atmosphere. Equipment Type Electrical in gas Marking Ex na Gc/nC Gc/nR Gc/nL Gc Table 19: Type of protection n marking example 28

29 Optical Radiation OOOOOO 2 ATEX Principles Optical equipment (such as lamps, lasers, LEDs, optical fiber, and so on) is increasingly used for communications, surveying, sensing and measurement. The installation is often inside or close to potentially explosive atmospheres, and radiation from such equipment may pass through these atmospheres. Depending on the characteristics of the radiation, it might then be able to ignite the surrounding explosive atmosphere. Three types of protection can be applied to prevent ignitions by optical radiation in potentially explosive atmospheres: op is inherently safe optical radiation: It means visible or infrared radiation that is incapable of supplying sufficient energy under normal or specified fault conditions to ignite a specific explosive atmosphere. This level of protection is for category 1 equipment and suitable for use in zones 0/20,1/21 and 2/22. op pr protected optical radiation: This concept requires that radiations are confined inside optical fiber or other transmission medium based on the assumption that there is no escape of radiation from the confinement. In this case, the performance of the confinement defines the safety integrity level of the system. This level of protection is for category 2 equipment and suitable for use in zones 1/21 and 2/22. op sh blocking optical radiation: This type of protection is applicable when the radiation is not inherently safe with interlock cut-off if protection by confinement fails, and the radiation becomes unconfined on times scales suitably shorter than the ignition delay time. This level of protection is for category 3 equipment and suitable for use in zone 2/22. Equipment Type Intrinsically Safe Apparatus Marking Associated Apparatus Marking Electrical in gas Ex op is Ga/op pr Gb/op sh Gc Ex [op is Ga]/[op pr Gb]/[op sh Gc] Electrical in Dust Ex op is Da/op pr Db/op sh Dc Ex [op is Da]/[op pr Db]/[op sh Dc] Table 20: Optical radiation marking examples Protection by Enclosures The protection by enclosure for dust environments works by limiting the maximum surface temperature of the enclosure and by limiting dust infiltration. The enclosure is sealed so tight that no combustible dust can enter. 29

30 OOOOOO 2 ATEX Principles ta: For category 1 equipment and suitable for use in zones 20, 21 and 22 tb: For category 2 equipment and suitable for use in zones 21 and 22 tc: For category 3 equipment and suitable for use in zone 22 only Equipment Type Electrical in Dust Marking Ex ta Da/tb Db/tc Dc Table 21: Protection by enclosure marking example 2.7. Marking The following minimum data shall be affixed to each piece of equipment or protective system, according to the ATEX Directive 94/9/EC: Name and address of the manufacturer CE marking Product name Serial number Year of manufacture ATEX certificate number Specific marking for explosion protection associated with ATEX logo Equipment group and category Letter G or/and D for equipment group II Type(s) of protection the equipment fulfils Certification Manufacturers and suppliers (or importers if the manufacturers are outside the EU) must ensure that their products meet essential health and safety requirements and undergo appropriate conformity procedures. This usually involves testing and certification by a third-party certification body (known as a Notified Body e.g. Ineris, Sira, TUV). Nevertheless, manufacturers and suppliers can self-certify category 3 equipment and category 2 non-electrical equipment. Once certified, the equipment is marked by the Ex equipment symbol to identify it as approved under the ATEX directive see Figure 4: Ex equipment logo. 30

31 Marking summary OOOOOO 2 ATEX Principles The following table is a summary of the marking you can find on ATEX-certified products (the type of protection is omitted in this table): Atmosphere Group Zone Category EPL Explosion group Temperature class Mining I M1 M2 Ma Mb I Gas 0 1G Ga IIA, IIB, IIC 1 2G Gb IIA, IIB, IIC T1 to T6 II 2 3G Gc IIA, IIB, IIC 20 1D Da IIIA, IIIB, IIIC Dust 21 2D Db IIIA, IIIB, IIIC 22 3D Dc IIIA, IIIB, IIIC Temperature in C Table 22: ATEX marking summary Group and Category Marking To complete the ATEX marking, near the ATEX symbol, you can find the symbols of the group, the category and, the following details relating to group II: The letter G, regarding explosive atmospheres caused by gas, vapor or mist and/or The letter D, regarding explosive atmospheres caused by dust The following table presents examples of an ATEX marking with their literal decryption: ATEX marking II 2 GD I M2 Decryption Non-mining equipment (Group II), suitable for use in zone 1 (category 2) for gas or dust potentially explosive atmosphere Mining equipment (Group I), suitable for use in mining applications, but does not operate when an Ex atmosphere is present Table 23: ATEX marking examples Furthermore, many products are approved for use in more than one category, or are designed for boundary installation (where they span a bulkhead between two zones), or are placed in a zone that is different from the classification of the zone they operate in. Therefore, additional signs complete the category to display this specificity, such as (...),... /... or

32 OOOOOO 2 ATEX Principles The following table presents some examples of variants of the ATEX marking: ATEX marking II (1) D II 2(1) G II (2)G (1) G II 1/2 G II 3/- D Decryption Non-mining device with intrinsically safe circuits (indicated by the category number in round brackets) suitable for use with equipment installed in zone 20 (category 1 in dust atmosphere) but which itself cannot be installed in an Ex zone Non-mining equipment, suitable for use in zone 1 (category 2), containing a safety device (indicated by the category number in round brackets) for connection to equipment in zone 0 (category 1), for use in gas, vapor or mist atmosphere Non-mining device with intrinsically safe circuit which protects equipment both in zone 0 and in zone 1, but which itself cannot be installed in an Ex zone, for use in gas, vapor or mist atmosphere Non-mining device installed on the boundary of zone 0 and zone 1, such as a level gauge installed in a tank wall Non-mining device handling dust from zone 2, but which itself cannot be installed in an Ex zone II -/1 G Non-mining device handling non-explosive gas, but installed within zone 0 Table 24: Examples of variants of the ATEX marking Explosion Protection Marking This marking indicates the protection concepts and approved environments in which the equipment can be used. It always begins with Ex or EEx denoting respectively that the product has been marked as stated in the new IEC/EN 600xx standard or in the older European EN 500xx standard. Then the protection concept is detailed, showing what measures the equipment uses to improve safety. The gas group or dust group to which this classification refers is then identified. Then the temperature class (using the temperature class or Temperature value in C code + in some cases, the ambient temperature range (Ta)) is shown. Finally, the equipment protection level (EPL) is usually last in the marking sequence. 32

33 Marking Example OOOOOO 2 ATEX Principles The following example shows how to analyze a simple marking: II 3 GD. Group II: The product can be installed in non-mining industry only Category 3 G: The product is suitable for use in zone 2 gas, potentially Ex atmosphere Category 3 D: The product is suitable for use in zone 22 dust, potentially Ex atmosphere Note: The product markings used in this document are analyzed in the products catalog located in the appendix chapter, see section ATEX Certificate Number In some cases, the ATEX certificate number contains an additional letter X or U at the end of the number, e.g. the ATEX certificate number of the Quantum and M340 products range contains the U letter, respectively 12ATEX3001U and 12ATEX3002U. Letter X U Description Indicates that the equipment is subject to special conditions for safe use that are specified in the Instruction Sheet presented in the next section Indicates that the assessed product is a component and may be subject to further assessment when incorporated into equipment Table 25: ATEX certificate number final letter 33

34 OOOOOO 2 ATEX Principles Documents Delivered With the ATEX Certified Products Attestation / Declaration of Conformity Manufacturers and suppliers of ATEX equipment are obliged to deliver the Attestation / Declaration of Conformity with the products. Figure 5: Quantum Attestation / Declaration of Conformity 34

35 OOOOOO 2 ATEX Principles Instruction Sheet The products are also accompanied by instructions for safe use. The manufacturers and suppliers shall provide the user with written instructions that include the information necessary to install, repair, maintain and/or overhaul of the concerned equipment. As mentioned at the top of the instruction sheet, the document provides important information on the use of certified ATEX modules in zones 2 and 22 classified Ex areas. Therefore, these instructions must be read carefully. Figure 6: Quantum Instruction Sheet Note: In addition to the instruction sheet, each Quantum and M340 power supply module is provided with an ATEX application note document that gives guidelines about ATEX installation. 35

36 OOOOOO 2 ATEX Principles 36

37 OOOOO 3 Selection 3. Selection 3.1. Selected Architectures Two architectures are selected: Quantum-based M340-based Note: The SCADA system and HMI are not covered in this document. Schneider Electric provides several ATEX-certified HMI products (Magelis XBT range) Quantum-Based Architecture Figure 7: Quantum-based architecture 37

38 OOOOO 3 Selection In the Quantum-based architecture, we implement a Quantum Ethernet I/O system in Ex zone 2. The Quantum Ethernet I/O system provides automatic network recovery of less than 50 ms and deterministic remote I/O performance. Several sensors and actuators are implemented in Ex zones 0, 1 and 2, and connected to the Quantum Ethernet I/O system. In zone 2, specific instruments are directly connected to the I/O modules of the system (4-20mA), while the instruments in zones 0 and 1 communicate through the Stahl ISPac intrinsically safe barriers. Note: The ATEX certified Quantum and X80 I/O modules are not intrinsically safe components. Therefore, the connections between ATEX instruments located in zone 2 and these modules must either pass through intrinsically safe barriers or be directly connected in this last case, the instruments must have the Increased safety (Ex e type of protection). Deported I/Os in Ex zone 1 are implemented by using a Stahl IS1 remote I/O island controlled by the Quantum PAC. In this architecture, the Stahl IS1 remote I/O island communicates via Ethernet. A Stahl media converter (copper to optical fiber) is used to link the Stahl system to the Quantum Ethernet I/O system via the service port of the Quantum drop. A 140 NOE Ethernet communication module is implemented on the Quantum local rack to scan the Stahl remote I/Os. This architecture is allowed in Ex atmosphere when the appropriate hardware hardware certified for this kind of atmosphere is selected. The selected hardware is described in section 3.2. Transparency between the control network and the device network is available by connecting the control network to the service port of the CRP module, as illustrated in the picture on the right. Figure 8: Quantum PAC Ethernet connections 38

39 OOOOO 3 Selection This transparency allows the configuration and diagnostics of field devices such as the Stahl remote I/Os and instruments using Device Type Managers (DTM) directly from a computer connected to the control network. Figure 9: Transparency between the control network and the field devices Note: We do not recommend connecting the control network to the CRP module service port when using the global data service between functional units. 39

40 OOOOO 3 Selection M340-Based Figure 10: M340-based architecture In the M340-based architecture, we implement a M340 PAC with four Modicon STBs in Ex zone 2. Several sensors and actuators are implemented in Ex zones 0, 1 and 2, and connected to the M340 system. In zone 2, specific instruments are directly connected to the I/O modules of the system (4-20mA) while the connection with the instruments in zones 0 and 1 pass through the Stahl ISPac intrinsically safe barriers. Note: The Modicon STB I/O ATEX modules are not intrinsically safe components. Therefore, the connections between ATEX instruments located in zone 2 and these modules must either pass through intrinsically safe barriers or be directly connected in this last case, the instruments must have the Increased safety Ex e type of protection. 40

41 OOOOO 3 Selection Remote I/Os in Ex zone 1 are implemented by using a Stahl remote I/O island controlled by the M340 PAC. In this architecture, the Stahl remote I/O island communicates on Ethernet. A Stahl media converter (copper / optical fiber) is used to link the Stahl system to the M340. A BMX NOC 0401 module with its embedded switch is implemented on the M340 local rack to scan the Stahl remote I/Os. This architecture is allowed in Ex atmospheres when the appropriate hardware is selected, that is, hardware certified for this kind of atmosphere. The selected hardware is described in section 3.2. Transparency between the control network and the device network is available by connecting the control network to the NOC module on the M340 local rack, as illustrated in the picture on the right. Figure 11: M340 PAC Ethernet connections 41

42 OOOOO 3 Selection This transparency allows the configuration and diagnostics of field devices such as the Stahl remote I/Os and instruments using DTMs directly from a computer connected to the control network. Figure 12: Transparency between the control network and the field devices 42

43 Quantum Architecture IP Addresses OOOOO 3 Selection The following table details the IP addresses used to implement the Quantum architecture. Device IP Address Sub-Net Mask Quantum NOE Quantum CRP Modicon x80 CRA Drop Quantum CRA Drop Stahl CPU Table 26: Selected IP addresses Only the Quantum-based architecture is described in this guide the M340-based architecture is not described, so the configuration and implementation should be adapted for a M340 architecture Selected Hardware The hardware selection is performed using the ATEX certified products list presented in the previous appendix 9.5. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION Equipment must be specified by suitably qualified personnel. Failure to follow these instructions will result in death or serious injury. 43

44 OOOOO 3 Selection Quantum-Based The products selected to implement the Quantum-based architecture are detailed below. Enclosure The Spacial S3XEX stainless steel enclosure is selected to install the Quantum main rack and its two RIO drops. The products are attached to a plain mounting plate. Figure 13: NSYS3XEX10830 : Enclosure 1000mm x 800mm x 300mm Figure 14: NSYMM108 plain mounting plate Main Rack The Quantum PAC is composed of the following elements: 140 XBP C 140 CPS C 140 CPU C 140 NOE C 140 CRP C Figure 15: Quantum PAC 140 XCP (empty module) 44

45 OOOOO 3 Selection Note: At the time this guide was written, the 140 NOC and 140 NOC modules were not yet ATEX certified. Therefore, the Ethernet wiring shown on the right is implemented to allow transparency between the control and device networks. Figure 16: Quantum PAC Ethernet connection with NOE When the 140 NOC and 140 NOC are ATEX certified, the preferred architecture will be the one presented on the right side. Figure 17: Quantum PAC Ethernet connection with NOC 45

46 OOOOO 3 Selection Quantum Drop The Quantum drop is composed of the following elements: 140 XBP C 140 CPS C 140 CRA C 140 DDI C 140 DDO C Figure 18: Quantum drop 140 AVI C 140 ACO C 140 XTS (four modules, one per I/O module) Modicon X80 Drop The Modicon X80 drop is composed of the following elements: BMX XBP 0600H BMX CPS 3020H Figure 19: Modicon X80 drop BMX CRA 31210C BMX DDI 1602H BMX DDO 1602H BMX AMI 0410H BMX AMO 0210H BMX FTB 2020 (four modules, one per I/O module) BMX XEM 010 (protective cover for the empty slot) 46

47 OOOOO 3 Selection M340-Based The products selected to implement the M340-based architecture are detailed below. Enclosure The Spacial S3XEX stainless steel enclosure is selected to install the M340 main rack, the extension rack and the four Modicon STB islands. The products are attached to a plain mounting plate. For images of these products, see subsection Main Rack The M340 PAC is composed of the following elements: BMX XBP 0400H Figure 20: M340 PAC BMX CPS 3020H BMX P H BMX NOC 0401 BMX DDI 1602H BMX XEM 010 (protective cover for the empty slot) Extension Rack The M340 extension rack is composed of the following elements: BMX XBE 2005 (Backplane expansion kit) Figure 21: M340 extension rack BMX CPS 3020H BMX DDI 1602H BMX DDO 1602H BMX AMI 0410H BMX AMO 0410H 47

48 OOOOO 3 Selection Modicon STB Islands All four Modicon STB islands are composed of the following elements: STB NIP 2311 STB PDT 3105 STB DDI 3610 (two modules) Figure 22: ST islands STB DDO 3600 (two modules) STB ACI 1225 (two modules) STB ACO 1225 (two modules) All four Modicon STB islands are composed of the same modules Stahl Products The picture below shows the physical location of the Stahl products in the architecture implemented in this guide. Figure 23: Stahl products 48

49 OOOOO 3 Selection Media Converter An ATEX certified 9721/ copper / optical fiber media converter connects the PAC located in zone 2 to the Stahl remote I/O CPU located in zone 1. This media converter is installed in zone 2, in the same enclosure than the PAC. Figure 24: 9721/ media converter ISPac Isolator To control and monitor devices located in zone 1 and zone 0 from the Quantum or M340 system, we install intrinsically safe barriers. These barriers are installed in zone 2 in the same enclosure as the PAC. The ISPac isolator is composed of the following elements: 9170/ : Digital input two channels 9160/ : Analog input 4-20mA two channels 9165/ : Analog output 4-20mA two channels Figure 25: ISPac isolator Power Supply and CPU for Remote I/O in Zone 1 The Stahl power supply and CPU bloc is composed of the following elements: 9492/ : Socket for CPU and power module 9444/12-11: Power module 9441/ : Modbus/TCP CPU module Figure 26: Stahl power supply and CPU 49

50 OOOOO 3 Selection IS1 Remote I/O Island in Zone 1 The Stahl IS1 remote I/O island is composed of the following elements: 9470/ : Digital input module 16 channels 9461/ : Analog input module Hart 8 channels 9480/ : Temperature Input module 8 channels 9466/ : Analog output module HART 8 channels Figure 27: IS1 Remote I/O Instruments The instruments should be selected by you depending on your process. Therefore, we will not describe any instruments in this document. For your information, we connected the following instruments as an example: Endress+Hauser Cerabar M PMC41 KROHNE Optitemp TRA-S11 / TT51 C As described for the other devices in the architecture, make sure you select ATEX-certified instruments that correspond to your process and to the Ex zone they will be placed in. 50

51 Copper and Optical Fiber Cables OOOOO 3 Selection The European Electrical Committee categorized the fire performance of the cables into three classes, namely IEC , IEC and IEC IEC : Used to assess the resistance to vertical flame propagation for a single vertical electrical insulated conductor or cable, or optical fiber cable, under fire conditions IEC : Used to assess the resistance to vertical flame propagation for a single small vertical electrical insulated conductor or cable, or optical fiber cable, under fire conditions IEC : Used to assess the flame spread of vertically-mounted bunched wires or cables For applications in zones 1 and 2, the cables must meet the flame propagation requirements of IEC This certification only concerns the cables that need to go outside the cabinets. No certification is required for the cables inside the cabinets. Note: For further information regarding cables in Ex environments, please refer to the ATEX EN standard. You should also apply any additional local standard (e.g. in France cables must be rated for 1000 V or more). Note: Choose and install your cables according to the environment of your plant, which includes the above-mentioned standards along with resistance to electromagnetic perturbations. 51

52 OOOOO 3 Selection 52

53 4. Configuration OOOO 4 Configuration This chapter describes the different steps required to configure the system. Note: Only the Quantum-based architecture is addressed Quantum PAC Configuration Hardware Configuration In this subsection, we configure the main rack and the RIO drops with Unity Pro by using the hardware selected in the previous chapter. The coated version of the Quantum PAC elements are the only ATEX certified elements. Therefore, only the coated version must be used in the configuration of a Quantum ATEX system. However, in the Unity Pro catalog, both coated and uncoated versions of the PAC elements use the same product reference. For the Quantum main rack, the following configuration is performed: Figure 28: Quantum PAC configuration For the Modicon X80 Ethernet I/O drop, the following configuration is performed: Figure 29: Modicon X80 Ethernet I/O drop configuration Note: When creating a new Modicon X80 drop, the BMX CRA adapter module is inserted by default. This module BMX CRA is not ATEX certified and should be replaced by the BMX CRA adapter module. 53

54 OOOO 4 Configuration For the Quantum Ethernet I/O drop, the configuration is the following: Figure 30: Quantum Ethernet I/O drop configuration The location of the 140 CRA and BMX CRA Ethernet remote I/O adapter modules should now be configured using the rotary switches on the front of the modules: Figure 31: CRA rotary switches 54

55 CRP Configuration OOOO 4 Configuration The Quantum 140 CRP module is dedicated to the management of remote I/O drops. The following table describes how to configure the corresponding IP parameters. Step Action In Unity Pro, open the local configuration editor of the CRP module and select the IPConfig tab. Modify the default IP address A field with the selected IP address: Modify the default Subnetwork mask field with the selected subnet mask: Figure 32: CRP IP configuration Note: The IP addresses of the CRA modules have been automatically generated during the hardware configuration by using the device name suffix numbers. Nevertheless, you can modify these IP addresses if needed from this tab. In our case, we do not change anything. 55

56 OOOO 4 Configuration Step Action Select the RSTP tab to check the bridge priority. The bridge priority can be defined if the CRP module is Root Bridge, Backup Root Bridge or Participant in the RSTP loop. In a QEIO architecture, the CRP is always defined as a Root bridge. Therefore, the priority is set to Root(0). 2 Figure 33: CRP RSTP priority CRA Configuration The Quantum 140 CRA and BMX CRA modules exchange data with the 140 CRP remote I/O head module. The exchanges are deterministic, which means that the time it takes to resolve a remote I/O logic scan is predictable. For each module, we need to configure the holdup time and RSTP bridge priority parameters. Holdup Time The holdup time represents the time (in milliseconds) during which device outputs are maintained at their current state after a communication disruption and before taking their fallback value. WARNING UNINTENDED EQUIPMENT OPERATION The holdup time must be set to at least 4 times the MAST task watchdog value. Failure to follow these instructions can cause death, serious injury or equipment damage. In our case, the MAST task watchdog is set to 250 ms. Therefore, the holdup time must be set to at least 1000 ms. 56

57 OOOO 4 Configuration Step Action Expand the EIO bus in the Unity Pro project browser, double-click the EIO Modicon X80 drop and select the Parameter tab. 1 Figure 34: EIO Modicon X80 drop in the project browser In the Hold up time area, modify or check the holdup time is set to at least 1000ms. 2 Figure 35: Holdup time configuration Repeat these steps for the EIO Quantum drop. 57

58 OOOO 4 Configuration RSTP Priority Step Action Expand the EIO Modicon X80 drop and double-click the CRA module. 1 Figure 36: CRA Module in the project browser Select the RSTP tab and set the Bridge Priority of the CRA as Participant(32768). 2 Figure 37: RSTP priority configuration Repeat these steps for the EIO Quantum drop. 58

59 NOE Configuration OOOO 4 Configuration In this guide, we use a 140 NOE C module to scan the Stahl remote I/O island from the PAC. Step Action Create a new network 1 Figure 38: New network creation 2 Link the new network to the NOE Enter the IP parameters. The following IP parameters are configured in our case: 3 Figure 39: NOE Device network IP Parameters The configuration of the NOE is not yet complete: the I/O Scanning service of this module must be configured to allow communication with the Stahl remote I/O island. At this stage, we only activate the service, and we will come back to the I/O Scanning configuration during the configuration of the Stahl remote I/Os in the next section. Proceed as follows to activate the I/O Scanning service: Figure 40: I/O Scanning service activation 59

60 OOOO 4 Configuration 4.2. Stahl Remote I/O Configuration In this section, we configure the Stahl remote I/O island and the HART instruments connected to this island using Unity Pro as the FDT container. The DTMs presented on the right have to be configured. Figure 41: DTM configuration for Stahl and HART devices The Stahl IS1 remote I/O island communication DTM allows the workstation to communicate with the Stahl IS1 remote I/O island on the field station (green line). Under the Stahl IS1 remote I/O island DTM, the DTMs of the configured modules are instantiated to allow communication with each module. Finally, the gateway feature of the Stahl analog input HART module directly links HART instruments to this module (yellow lines). Once these DTMs are instantiated, the transparency from the workstation to the remote I/O island is available, allowing the configuration and diagnostics of the field devices. Figure 42: Network transparency from workstation to instruments 60

61 OOOO 4 Configuration IP Address Configuration of the Stahl IS1 Remote I/O Island To address a Stahl IS1 remote I/O island, the minimum following parameters must be set: IP address Subnet mask In this guide, we use the buttons and display on Stahl IS1 remote I/O island CPU to configure the selected IP address ( ) and subnet mask ( ). Note: The Stahl IS1 remote I/O island web server can also be used to change the IP parameters Stahl IS1 Remote I/O Island Hardware Configuration In this subsection, we configure the Stahl IS1 remote I/O island, i.e. Modbus TCP interface and the four I/O modules. The HART instruments are addressed in the subsection 0. Two configuration scenarios can be considered: Scenario 1: The Stahl IS1 remote I/O island is connected to the network, the digital/analog modules are plugged and the IP address is configured on the Stahl IS1 remote I/O island CPU. In this case, the Unity Pro DTM browser fieldbus discovery feature is used, allowing the appropriate modules to be automatically selected Scenario 2: The Stahl IS1 remote I/O island is not reachable. In this case, the I/O modules are manually selected via the Unity Pro DTM catalog To describe these two configuration scenarios, the Stahl IS1 remote I/O island DTM must be installed first, as explained below. Stahl IS1 Remote I/O Island DTM Installation The Stahl IS1 remote I/O island DTM is downloadable from the Stahl web site: A DTM is installed like traditional software, i.e. from an.exe file. Once the DTM is installed, the Unity Pro DTM catalog must be updated. If Unity Pro was closed during the DTM installation, it will automatically discover the new DTMs during the next launch and will propose to update the catalog. If Unity Pro was opened during the DTM installation, a manual update must be processed Open the Unity Pro Hardware Catalog and click the update button. 61

62 Configuration Common Part OOOO 4 Configuration Step Action 1 In the DTM browser, right click the Host PC folder, and select Add to open the DTM catalog. Select the 9441/ CPM Z1 24V Eth Modbus TCP/IP DTM, corresponding to the selected CPU, and click Add DTM to validate. 2 Figure 43: Stahl CPU DTM selection The Properties window opens. 62

63 OOOO 4 Configuration Step Action Change the Alias name if desired. In this guide we enter IS1 as alias name. 3 Figure 44: Stahl CPU alias name configuration Click OK to complete the instantiation. The DTM browser should look like the following picture: 4 Figure 45: Stahl CPU in the DTM browser 5 Double-click the IS1 instance to open the DTM. 63

64 OOOO 4 Configuration Step Action Enter the selected IP address of the IS1 module in the Address field: 6 Figure 46: Stahl CPU DTM Note: The configuration performed in this step allows the DTM to communicate with the actual device. Make sure the IP address you configure in the DTM is the same as the one you configured in the device in subsection Configure the watchdog time and timeout for the output modules. Apply the safety positions of the outputs in case of communication loss with the PAC. 7 Note: The safety position of each digital and analog output is configured directly on the output module DTM see subsection Analog Output Module 9468/ No digital output module is used in this example. Watchdog time: 2000 ms Timeout for output modules: 100ms With the configuration above, a communication loss with the PAC will lead to the safety positions of the outputs after 2000ms + 100ms. 8 Click OK to apply the modifications and to close the DTM. 64

65 OOOO 4 Configuration Scenario 1 In this scenario, we suppose the Stahl IS1 remote I/O island is connected to the network, the digital/analog modules are plugged on the bus rail and the selected IP address is configured on the Stahl IS1 remote I/O island CPU. The IS1 module must be reachable via a ping command from the machine where Unity Pro is launched. Step Action The fieldbus discovery service is available only when the DTM is connected to the corresponding physical device. Right click on the Stahl IS1 remote I/O island DTM instance and select Connect: 1 Figure 47: Connect to the Stahl CPU DTM Once connected, right click again and select Field bus discovery: 2 Figure 48: Starting fieldbus discovery on the Stahl CPU A fieldbus discovery dialog opens. 65

66 OOOO 4 Configuration Step Action Select the slot number to discover. We start by the first slot, corresponding to the first I/O module inserted in the bus rail. In our case, a 9470/ DIM 16 Stahl module is inserted in the Slot01. 3 Figure 49: Selection of the slot for fieldbus discovery Click OK to launch the discovery. 66

67 OOOO 4 Configuration Step Action The Field bus discovery dialog box is displayed. It lists the scanned and matched devices. The 9470/ DIM 16 Stahl module is proposed as matched DTM. 4 Figure 50: Discovered Stahl module From the Matched DTMs area, select the 9470/ DIM 16 DTM and click the + button to add this DTM in the Selected DTMs area as follows: 5 Figure 51: Selected DTM after fieldbus discovery 67

68 OOOO 4 Configuration Step Action Finally, click OK to insert the DTM in the Unity Pro DTM browser: 6 Figure 52: Stahl module added to the DTM browser Repeat the steps 2 to 6 with the following DTM/slot associations: 7 Slot 2: 9461/ AIM 8 DTM Slot 3: 9480/ TIM 8 DTM Slot 4: 9466/ AOM 8 DTM Once the DTMs are instantiated, the DTM browser should look like to the following picture: 8 Figure 53: DTM browser including all four Stahl modules The Stahl DTMs are now instantiated. 68

69 OOOO 4 Configuration Scenario 2 In this scenario, the Stahl IS1 remote I/O island is not reachable on the network. Therefore, the fieldbus discovery feature cannot be used and all the DTMs are selected manually. Step Action 1 Right click on IS1 instance and click the Add button to open the DTM catalog. Select the 9470/ DIM 16 DTM: 2 Figure 54: Selection of a Stahl module DTM from the list Click the Add DTM button to validate 69

70 OOOO 4 Configuration Step Action A window opens to select the slot number on the bus rail where the 9470/ DIM 16 DTM is physically inserted. 3 Figure 55: Slot selection for the new Stahl module DTM Click OK to confirm the slot number. The Properties window opens. In this window, you can change the alias name. In our case, we leave the default value unchanged. 4 Figure 56: Alias name configuration Click OK to complete the instantiation. 70

71 OOOO 4 Configuration Step Action The DTM browser should look like the following picture: 5 Figure 57: Stahl module added to the DTM browser Repeat the steps 1 to 5 with the following DTM/slot associations: 6 Slot 2: 9461/ AIM 8 DTM Slot 3: 9480/ TIM 8 DTM Slot 4: 9466/ AOM 8 DTM Once the DTMs are instantiated, the DTM browser should look like to the following picture: 7 Figure 58: DTM browser including all four Stahl modules The Stahl DTMs are now instantiated. 71

72 Hart Instruments on Stahl OOOO 4 Configuration To illustrate the configuration of HART instruments on a Stahl analog input HART module, we connect the following instruments to the module: Channel 0: Endress+Hauser Cerabar M PMC41 Channel 1: KROHNE Optitemp TRA-S11 / TT51 C Two configuration scenarios can be considered: Scenario 1: The Stahl IS1 remote I/O island is connected to the network, the digital/analog modules are plugged and the HART instruments are connected. In this case, the Unity Pro DTM browser fieldbus discovery feature automatically selects the appropriate instruments Scenario 2: The Stahl IS1 remote I/O island is not reachable. In this case, the HART instruments are selected manually via the Unity Pro DTM catalog The Endress+Hauser and KROHNE DTMs must be installed first. They can be downloaded from the manufacturers web sites: and Scenario 1 In this scenario, the Stahl IS1 remote I/O island is connected to the network, the digital/analog modules are plugged and the HART instruments are connected. In this case, the Unity Pro DTM browser automatically discovers the appropriate instruments. The instantiation of the Endress+Hauser Cerabar M PMC41 is used as an example to illustrate this scenario: Step Action The fieldbus discovery service is available only when the DTM is connected to the corresponding physical device. Right click the module where HART instruments are physically connected and click Connect: 1 Figure 59: Connect to the Stahl module DTM 72

73 OOOO 4 Configuration Step Action Once connected, right click again and select Field bus discovery: 2 Figure 60: Starting fieldbus discovery A fieldbus discovery dialog opens. Select the channel number to discover. Start with the first channel of the analog input module where the Endress+Hauser Cerabar M CPM41 is wired. 3 Figure 61: Selection of the slot for fieldbus discovery Click OK to start the discovery. 73

74 OOOO 4 Configuration Step Action The following Field bus discovery dialog box is displayed. It lists the scanned and matched devices. The Cerabar M / PMx 4x instrument is proposed as a matched DTM. 4 Figure 62: Discovered Endress+Hauser instrument From the Matched DTMs area, select the Cerabar M / PMx 4x DTM and click the + button to add this DTM in the Selected DTMs area as follows: 5 Figure 63: Selected DTM after fieldbus discovery 74

75 OOOO 4 Configuration Step Action Finally, click OK to complete the instantiation. 6 Figure 64: DTM browser including the Endress+Hauser instrument Scenario 2 In this scenario, the Stahl IS1 remote I/O island is not reachable. In this case, the HART instruments are selected manually via the Unity Pro DTM catalog. The instantiation of the KROHNE Optitemp TRA-S11 / TT51 C is used as an example to illustrate this scenario: Step Action Right click the module where HART instruments are physically connected and click the Add button to open the DTM catalog. 1 Figure 65: Add a new DTM 75

76 OOOO 4 Configuration Step Action Select the KROHNE TT51 DTM: 2 Figure 66: Select the KROHNE DTM from the catalog Click the Add DTM button to validate. 76

77 OOOO 4 Configuration Step Action A window opens to select the channel number on the analog input module where the instrument is physically connected. 3 Figure 67: Slot selection for the new KROHNE instrument DTM In our case, we select channel 1. Click OK to confirm the channel number. The Properties window opens. In this window, you can change the alias name. In our case, we do not change the alias name. 4 Figure 68: Alias name configuration Click OK to complete the instantiation. 77

78 OOOO 4 Configuration Step Action The DTM browser should look like the following picture: 5 Figure 69: DTM browser including the KROHNE instrument DTM 78

79 Modules Configuration OOOO 4 Configuration In this subsection, we configure the Stahl modules and retrieve the register numbers required to configure the I/O Scanning service. Digital Input Module 9470/ Step Action In the DTM browser, double-click the Stahl digital input module DTM to open it. 1 Figure 70: Stahl digital input module DTM The following parameters are set: Operation mode: DIM+Sta With this mode, the PAC retrieves the digital input value and the digital input status (open/short circuit detection) Diagnosis message of module: On 2 In the Register/Coil column, we retrieve the register numbers allocated to the digital input values and statuses. Digital input value: Register 32 Digital input statuses: Register 33 79

80 OOOO 4 Configuration Step Action For each digital input, the following parameters can be customized, according to your process: 3 Figure 71: Digital inputs parameters 80

81 Analog Input Module 9461/ OOOO 4 Configuration Step Action In the DTM browser, double-click on the Stahl analog input DTM to open it: 1 Figure 72: Stahl analog input module DTM The following general parameters are set in our case: Operation mode: AIM HV With this mode, the PAC retrieves the eight analog input values, but also four HART values. Diagnosis message of module: On 81

82 OOOO 4 Configuration Step Action HART configuration In the same configuration area, assign the channel numbers where your HART instruments are wired. Choose the HART variable associated to each HART variable number. For our project, we configure the following elements: 2 Figure 73: HART variables association In the general parameter window, in the Register/Coil column, we retrieve the register numbers allocated to the eight analog values and the four HART values. 3 Figure 74: Stahl analog inputs and HART values registers Analog input values: Register 34 to 41 HART values: Register 42 to 48 These four values are in real format (two registers are required per HART value) 82

83 OOOO 4 Configuration Step Action For each analog input, the following parameters can be customized, according to your process: 4 Figure 75: Analog inputs parameters 83

84 OOOO 4 Configuration Temperature Input Module 9480/ Step Action In the DTM browser, double-click on the temperature input module DTM to open it: 1 Figure 76: Stahl temperature input module DTM Using one channel, the following general parameters are set in our case: Diagnosis message of module: On Operation mode: 2 inputs With this mode, the signals are updated faster 84

85 OOOO 4 Configuration Step Action In the general parameter window, in the Register/Coil column, we retrieve the register numbers allocated to the eight temperature input values. 2 Figure 77: Stahl temperature input module registers Temperature 0 to 7: Register 50 to 57 We selected the two-input mode, so only the two first temperature inputs TI_0 and TI_1 are operational For each temperature input, the following parameters can be customized, according to your temperature sensor type and application: 4 Figure 78: Temperature inputs parameters 85

86 Analog Output Module 9468/ OOOO 4 Configuration Step Action In the DTM browser, double-click on the Stahl analog output module DTM to open it: 1 Figure 79: Stahl analog output module DTM The following general parameters are set in our case: Operation mode: AOM 8 With this mode, the PAC sends the eight analog output values. Diagnosis message of module: On 86

87 OOOO 4 Configuration Step Action In this general parameter window, in the Register/Coil column, we retrieve the register numbers allocated to the eight analog values. 2 Figure 80: Stahl analog outputs and HART values registers Analog output values are mapped from register 32 to 49 For each analog output, the following parameters can be customized, according to your process: 3 Figure 81: Analog outputs parameters In our example application, we configure the safety position to 0% for all analog outputs. For each module, refer to the associated Stahl documentation for more information regarding the configuration I/O Scanning Service Configuration The Stahl remote I/O device is configured. You can now configure the I/O Scanning service of the NOE. The I/O Scanning service uses the following functions: To read/write: Modbus function 23 (multiple register) To read: Modbus function 3 (multiple register) To write: Modbus function 16 (multiple register) 87

88 OOOO 4 Configuration Note: If the distant device does not support function 23, the functions 3 and 16 are automatically used by the I/O Scanning service instead. Register Allocation of I/O Data in the Stahl IS1 Remote I/O Island The following table is an extract from the Description of Modbus TCP Interface for IS1 field station Stahl documentation. Modbus Address on Interface Register Coil Address Address Modbus Address in Automation System and IS1 DTM Register Coil Address Address Allowed Modbus Functions Read 02 (input coil) Data Block Input Signals (input register) Optional: 03 (multiple register) with register offset Read Data Block Output Signals (output coil) 03 (holding register) Write: 05, 15 (coil) 06, 16 register Table 27: Modbus functions allowed on the Stahl CPU Register Address Allocations in our System Using the above information, we can define the register address allocations for our system. The following Stahl IS1 remote I/O island is configured in our system: Module type: CPU DIM 16 AIM HART TIM 8 AOM 8 Slot Table 28: Stahl CPU slot configuration 88

89 OOOO 4 Configuration With this configuration, the register addresses allocated to the signals are as follows: Slot Module Type Signals Modbus Address Unity Pro Address 1 DIM 16 DI0 DI15 Status DI0 DI %MW100 %MW101 AI %MW102 AI %MW103 AI %MW104 AI %MW105 AI %MW106 2 AIM HART AI 5 AI %MW107 %MW108 AI %MW109 HART %MW110-%MW111 HART %MW112-%MW113 HART %MW114-%MW115 HART %MW116-%MW117 TI %MW118 TI %MW119 TI %MW120 3 TIM 8 TI 3 TI %MW121 %MW122 TI %MW123 TI %MW124 TI %MW125 AO 0 31 %MW150 AO 1 32 %MW151 AO 2 33 %MW152 4 AOM 8 AO 3 AO %MW153 %MW154 AO 5 36 %MW155 AO 6 37 %MW156 AO 7 38 %MW157 Table 29: Stahl digital I/Os registers 89

90 OOOO 4 Configuration I/O Scanning Configuration All the information is now ready for communication with the Stahl remote I/O island to be enabled via the I/O Scanning service of the NOE. The input data is mapped into registers 1031 to 1056: 26 The output data is mapped into registers 31 to 38: 8 Figure 82: I/O Scanning service configuration WARNING UNINTENDED EQUIPMENT OPERATION Configure the I/O Scanning service carefully and double check your configuration. Failure to follow these instructions can cause death, serious injury or equipment damage Store Configuration to Stahl IS1 Remote I/O Island Once the configuration is completed, you need to store it to the Stahl IS1 remote I/O island. Right click on the Stahl IS1 remote I/O island DTM instance and select Store data to device Figure 83: Store configuration to the Stahl CPU A progress bar is displayed during the operation. 90

91 5. Implementation OOO 5 Implementation 5.1. Hardware Implementation in ATEX Environments Important electrical and implementation rules must be respected to have a certified ATEX installation. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION The hardware wiring and implementation must be performed by suitably qualified personnel. Failure to follow these instructions will result in death or serious injury In Zone 2 The Quantum I/O modules can be directly connected to ATEX instruments which have the increased safety protection. To connect to ATEX instruments which have the intrinsically safe protection only, an intrinsically safe barrier is mandatory In Zone 1 The intrinsically safe barrier is mandatory to connect any ATEX instrument to a Quantum I/O module. The Stahl I/O modules used in this project do not need any additional barrier to connect an ATEX instrument. 91

92 Implementation in our Lab OOO 5 Implementation In our lab, we worked with suitably qualified personnel from an external company to wire and implement the hardware in our virtual ATEX zones. PAC Cabinet Zone 2 The following pictures show the PAC cabinet (zone 2), which includes the PAC, a Mx80 RIO drop and the ISPac: Figure 84: Quantum PAC installed in the PAC cabinet including the empty module in the last slot Figure 86: PAC cabinet (zone 2) general view Figure 85: X80 drop installed in the PAC cabinet including the protective cover on the last slot 92

93 OOO 5 Implementation In the picture to the left, you can see the three Stahl ISPac modules. At the top of these modules, the wires come from the I/O modules of the Quantum I/O system. At the bottom of these modules, the wires are directly connected to the instruments located in zone 0 or 1 in our example. Figure 87: ISPac installed in the PAC cabinet In the picture to the right, you can see the glands installed in the cabinet. The glands must be ATEX certified and it is forbidden to pass more than one cable per gland. Furthermore, all unoccupied glands must be sealed like the four glands at the right. Figure 88: Glands in the PAC cabinet Instrumentation Cabinet Zone 1 The following picture shows the instrumentation cabinet located in zone 1: Figure 89: Instrumentation cabinet zone 1 93

94 OOO 5 Implementation 5.2. Software Implementation The floating point HART variables values retrieved from the I/O Scanning service are stored in two integers. Therefore, the following implementation converts the HART variables values so that they can be used easily in the PAC: Figure 90: HART real value conversion 94

95 6. Operation and Maintenance OO 6 Operation & Maintenance 6.1. Hardware Operation In nominal operation, no intervention is required on the equipment located in the Ex environment: the process is controlled from the SCADA, which is located in the safe area in our architecture Maintenance Unlike the operation phase, the maintenance phase may require interventions on ATEX zones to repair or replace devices, for instance. DANGER HAZARD OF ELECTRIC SHOCK, BURN OR EXPLOSION The hardware maintenance in ATEX environment must be performed by suitably qualified personnel. Failure to follow these instructions will result in death or serious injury. Quantum Cabinet The instructions below must be followed before any intervention on the Quantum cabinet. These instructions are an extract from the instruction sheet provided with the ATEX-certified Quantum products. Confirm that the location is free from explosively hazardous gases or dust before connecting or disconnecting equipment, using any USB connection, replacing or wiring module, replacing any batteries or fuses, using the restart button, the key switch or the communication parameter slide switch Confirm that the power supply has been turned off before disconnecting, replacing or wiring modules Stahl Cabinet Thanks to the implemented intrinsically safe protection, the Stahl modules can be connected to and disconnected from the bus rail while the power is on. 95

96 OO 6 Operation & Maintenance 6.2. Software Quantum Diagnostics You can diagnose the Quantum PAC via its embedded web server by using a standard web browser. Figure 91: Quantum web browser diagnostics interface main page Figure 92: Quantum web browser diagnostics interface controller status 96

97 Stahl Diagnostics OO 6 Operation & Maintenance Thanks to the transparency between the control network (in the safe area) and the device network (in the Ex area), you can easily diagnose the I/O devices from the Unity Pro workstation placed in the safe area. Stahl IS1 Remote I/O Island CPU In Unity Pro, open the DTM browser and right click on the Stahl IS1 remote I/O island DTM to open the contextual menu. Click on Connect and double-click the DTM to open it. The following picture shows the general diagnostics of the module: Figure 93: Stahl IS1 remote I/O island CPU diagnostics 97

98 OO 6 Operation & Maintenance I/O Modules In Unity Pro, open the DTM browser and right click on the I/O module DTM to open the contextual menu. Click on Connect and double-click the DTM to open it. From these DTMs, you can read the signal values, signal statuses and also diagnose the module itself. The following picture shows the Signals/Diagnosis page of the HART analog input module: Figure 94: HART analog module diagnostics 98

99 Endress+Hauser and KROHNE DTMs OO 6 Operation & Maintenance You can also diagnose the HART instruments connected to the Stahl analog input module: Figure 95: Endress+Hauser instrument diagnostics Figure 96: KROHNE instrument diagnostics 99

100 HART Values in Unity Pro OO 6 Operation & Maintenance With the conversion blocks implemented in the Unity Pro application, you can read the HART values in your process application. In the Unity Pro screenshot below, you can read bar on the Cerabar sensor and C on the TT51 sensor. Figure 97: HART instruments values in Unity Pro 100

101 O 7 Validation 7. Validation 7.1. Memory Consumption of the DTMs in Unity Pro The memory area occupied by the data of the DTMs is the Upload Information area, represented in yellow on the picture below: Figure 98: Memory usage example The upload information contains the non-executable code such as project upload information, comments, animation tables and data of the DTMs. Note: The Memory Usage window is accessible from the Tool\Memory Consumption menu. The table below shows the memory consumption of the DTMs used in this guide. DTM Upload Information Memory Consumption (Kb) Stahl IS1 Modbus/TCP 17 Stahl 9470/ DIM 16 module 3 Stahl 9461/ AIMH 8 module 3 Stahl 9480/ TIM 8 module 1 Stahl 9466/ AOMH 8 module 2 Endress+Hauser Cerabar PMC41 5 KROHNE TT51 C 4 Table 30: DTMs memory consumption 101

102 O 7 Validation 7.2. Performance Test In this section, we cover the performance tests we executed, and analyze the results of these tests. NOTICE EQUIPMENT DAMAGE Your actual performance will vary, depending on environment, duty cycle, load type and other factors. Perform your own functional and performance tests with the system you are designing and implementing. Failure to follow these instructions can result in equipment damage Test Tools Additional tools used for our tests include the following: Modicon M340 PAC This PAC is used with a digital I/O module so that we can manage measurement start and stop signals. Figure 99: M340 PAC Hilscher NetAnalyzer This device can analyze and record Ethernet traffic. It can also manage physical digital inputs and is very accurate its timestamp has a resolution of ten nanoseconds. Figure 100: NetAnalyzer 102

103 Application Response Time O 7 Validation The Application Response Time (ART) is the time taken for the system to react to a stimulus. Test Methodology We start the ART measurement by sending a physical signal (using an external M340 PAC) to a digital input of the Stahl remote I/O island. The Quantum PAC receives this information and copies it by program to a digital output of the Stahl remote I/O island, which signals the end of the ART measurement. The start and stop signals are read by the NetAnalyzer device. Figure 101: ART measurement architecture For our ART performance tests, we replace the analog output module with a digital output module in the Stahl remote I/O island. 103

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