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Fieldbus Accessing all Areas
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Safe Area Applications Non-Incendive Systems Intrinsic Safety Systems
Scope of presentation Safe Area Applications Non-Arcing Systems Zone 2 Non-Incendive Systems Zone 2 FNICO Intrinsic Safety Systems Zone 2,1,0 FISCO
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Generalised Fieldbus connection
Non-hazardous area T Fieldbus Host Hub 18-30 volt Power General fieldbus application in safe area terminated at both ends of bus
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Generalised Fieldbus connection
Non-hazardous area T Fieldbus Host Hub 18-30 volt Power Need for hazardous area protection suitable certified interface applied Hazardous area Non-hazardous area T Fieldbus Host
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MTL5995 Power Supply For general purpose applications in kbit/s fieldbus systems terminate at both ends of fieldbus switched internal terminator option Isolated power conditioning 19V, 350mA output Suitable for Safe Area & Hazardous Area applications Certified for installation in Zone 2 hazardous areas Needs suitable certified interface eg, MTL791, for intrinsically safe field connection ATEX II 3 G EEx n A IIC T4
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Redundant Fieldbus Power System
Backplane connects to : bus terminator input power supplies host system fieldbus trunk alarm circuitry Load sharing by redundant supplies Up to 8 units may be daisy-chained with common alarm carrier jumper supplied version without segment terminator available
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Redundant Fieldbus Power System
Host System Alarm Supply ‘A’ 18-30 volt Power ‘B’ Redundant Fieldbus Power System Power Conditioning high impedance to fieldbus network Redundant DC Power Inputs Power Isolation to fieldbus 250 V ac galvanic isolation Redundant Output Power 25 Volt, 350mA output per module LED indicates bus is powered Hot-swappable modules & / or input supply can be replaced without affecting fieldbus operation Alarm Circuitry input power or unit failure galvanic isolation from other functions Certification FM Class 1 Div2 ATEX II 3 G EEx nA IIC T4 Zone 2 Mounting
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Redundant Fieldbus Power System
Common connections within addressing limitations 18-30 volt Power T Fieldbus Host System Alarm Supply ‘A’ ‘B’ T Fieldbus Host
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Redundant Fieldbus Power System
Note : the fieldbus connection is certified as non-arcing EEx nA IIC T4 It is NOT a FISCO / FNICO field connection an added interface would be necessary to achieve this end
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MTL5053 Isolator / Power Supply
The MTL5053 extends 31.25kbit/s fieldbus networks into hazardous areas Provides power to the highway & for communication to field devices Separate power may be required for safe-area field devices Supply voltage 20 to 35Vdc Isolation : 250V ac between safe area fieldbus circuits hazardous area fieldbus circuits power supply Provides 18.4 volts at max 80 mA Safety description 22V, 102, 216mA Isolator transparent to fieldbus, hence termination at isolator is not a pre-requisite Switchable safe area terminator 31.25kbit/s fieldbus Safe area Hazardous area T MTL5053 Ex II (1) GD [EEx ia] IIC
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MTL951 Live Disconnect for Zones 1 & 2
Ideal for EEx nA ‘non-arcing’ EEx d ‘flameproof’ EEx e ‘increased safety’ Versions : Fieldbus signal 40V dc 2 Amps 110/230V ac 50/60 Hz power Amps Disconnect without need for prior isolation ATEX II 2 G EEx de IIC T4
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Non-Incendive Systems
Some definitions Zone 2 Zone 1 Zone 0 Safe area Division 2 Division 1 Safe Area system NA system NI system Non-Arcing Systems Non-Incendive Systems 11
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Resistive Curves Current Power = volts x amps Voltage The principle of
live working Limit the energy in the circuit Ethylene group Propane group Current Hydrogen group Methane group Power = volts x amps Resistive Curves Voltage
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components not required for Zone 2
Safety Factor Unity : Zone 2 : Intrinsic Safety Fault-tolerant components not required for Zone 2 Hydrogen group Current 230 mA 24 Volts Apply a Safety Factor Resistive Curves Voltage
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Types of circuit in Zone 2
NON-ARCING CIRCUITS : High energy & mains circuits No systems concept Not live-workable NON-INCENDIVE CIRCUITS : Energy-limited Unity Safety Factor Low energy circuits Systems concept Live-workable User must NOT permit arcing
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Complete hazardous area capability
Safe area Zone 2 Zone 1 Zone 0 Unclassified location Division 2 Division 1 Safe Area system NA system NI system IS system Zone 0 system 11
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Safe Area or Non Arcing Installation
Installation in => IP54 Live working NOT permitted in a hazardous area Max output : 32 V 1.5 A MTL5995 FPS-I ‘nA’ All trunks & spurs EEx nA IIC T4 Vmax 32 V Imax 1.5 A ‘nA’ System Certification : Ex nA IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 FF-816 specification : 32 V 1.5 A Terminator : FBT-1 Vmax 32 V
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Non Incendive / ‘Spurguard’ legs
Installation in => IP54 Live working NOT permitted on ‘nA’ trunk Max output : 32 V 1.5 A MTL5995 FPS-I ‘nA’ Main trunks : EEx nAL IIC T4 Vmax 32 V Imax 1.5 A ‘nL’ Spurguard legs : EEx nL IIC T4 Vmax 32 V Imax 60 mA ‘nA’ ‘nL’ Live working safe on ‘NI’ spurs System Certification : Ex nA [nL] IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 FF-816 specification : 32 V 1.5 A Terminator : Vmax 32 V
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Non Incendive System ‘nL’ ‘nL’ ‘nL’ ‘nL’
Installation in => IP54 Live working permitted throughout MTL9111 Max output : 14 V 233 mA ‘nL’ ‘nL’ All trunks & spurs EEx nL IIC T4 Vmax 14 V Imax 233 mA ‘nL’ MTL9112 option for IIB with appropriate safety parameters ‘nL’ System Certification : Ex nL IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : Vmax 32 V
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Non Incendive >> ‘Spurguard’ legs
Installation in => IP54 Live working permitted throughout MTL9111 Max output : 14 V 233 mA ‘nL’ All trunks & spurs EEx nL IIC T4 Vmax 14 V Imax 233 mA ‘nL’ Spurguard legs EEx nL IIC T4 Vmax 14 V Imax 60 mA ‘nL’ MTL9112 option for IIB with appropriate safety parameters ‘nL’ System Certification : Ex nL IIC T4 Class 1, Div 2, Groups A,B,C,D, T4 Terminator : Vmax 32 V
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Intrinsically Safe (Non-FISCO) Installation
Installation in => IP54 Live working permitted throughout ‘IS’ MTL5053 ‘IS’ Available output : 18.4 V 80 mA Safety parameters : 22 V 216 mA ‘IS’ into Zone 0 ‘IS’ System Certification : Ex ia IIC T4 Class 1, Div 1, Groups A,B,C,D, T4 Terminator : Vmax 24 V Imax 250 mA FF-816 specification : 24 V 250 mA
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FISCO
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Intrinsically Safe (FISCO) Installation
Installation in => IP54 Live working permitted throughout ‘IS’ MTL9121 IS : IIC 14.0 V 180 mA MTL9122 IS : IIB 14.8 V 380 mA ‘IS’ Megablock rating : Vmax 14.8 V Imax 380 mA ‘IS’ ‘IS’ System Certification : Ex ib IIC T4 Class 1, Div 1, Groups A,B,C,D, T4 Use in appropriate gas group Limited to Zone 2 & 1 All devices to be approved for FISCO Terminator : Vmax 24 V Imax 250 mA
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Network Calculations
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Multiple power supply configuration
Host Sufficient current capacity ? T T
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if 20 mA consumption each device
Host Basic configuration 9121 & 9122 L N E 24V supply T Host trunk 2- 3+ S 6+ T T Safe Area S 9 - Zone 1 / Div1 Hazardous Area 6 devices (120 mA) in IIC 13 devices (260 mA) in IIB if 20 mA consumption each device T
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Power & data Host 24V supply
N E The Fieldbus signal, which is superimposed on the IS voltage, is fed via the interface device to & from the field devices 24V supply T 2- 3+ The 24 volt power supply is converted to an intrinsically safe supply to feed the IS trunk T T Safe Area S 9 - Zone 1 / Div1 Hazardous Area T
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Mains or 24-volt power supply Host
Zone2 / Div2 Safe Area 8913 8914 Power Units 5991 Unit Mains Mains or 24-volt power supply Host Power consumption 9121 : 190mA 9122 : 300mA 8914 : 10 A 5991 : 2 A T T
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FISCO cable parameters
Design Parameters System design determined from : power supply output voltage power supply available current knowledge of current consumption of each field device survey shows a range of 10 to 28 mA 20 mA is assumed application of Ohm’s Law to the cable network assessment for adequate voltage at each field device Line resistance of 50 /km is assumed within the FISCO range of 15 to 150 /km Model Apparatus Useable Number Class Output V mA 9121-IS IIC 9122-IS IIB Parameter Value Loop resistance 15 ohm to 150 ohm / km Loop inductance 0.4 mH to mH / km Capacitance 80 nF to nF / km Spurs are in addition to permitted maximum cable length FISCO cable parameters
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Idealised Bus waveforms : IEC 61158 - 2
Bit-synchronous Manchester Encoding 1 bit (32µs) Current drawn (typical values) ‘1’ ‘1’ ‘0’ ‘0’ ‘1’ 30mA Transition : from high to low = ‘1’ from low to high = ‘0’ Typical Quiescent level 20mA 10mA Time Fixed bit rate 31.25 kbit/s Bus voltage + 1.0V nominal Average voltage ( 9V min ) Time
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Typical IIC calculation field devices at end of trunk
Hydrogen Gas Group 5 connected field devices at end of trunk Model 9121-IS : IIC Useable Output V mA 12 120 Eg : I = 100 mA 600 metres 30 = 3 volts 12 volts If current drawn < 20 mA then instrument population can be increased 3 volts 100 mA 600 metre IS trunk 30m spur = 1.5 carrying 20 mA volt drop = 30 mV NODE 9 volts each instrument draws 20 mA 600 metre IS trunk T
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Typical IIC calculation
Hydrogen Gas Group 5 distributed field devices Model 9121-IS : IIC Useable Output V mA 12 120 I = 100 mA 12.5 = 1.25 volts 12 volts each instrument draws 20 mA 250 metres I = 80 mA 12.5 = 1.0 volt 10.75 V 250 metres I = 40 mA 12.5 = 0.50 volts 9.75 V 250 metres 750 metre IS trunk 9.25 V T
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316 metres Typical IIB calculation 316 metre max IS trunk
Ethylene Gas Group 12 connected field devices at end of trunk Model 9122-IS : IIB Useable Output V mA I = 240 mA = 3.8 volts drop thru 316 metres of 15.8 12.8 volts 316 metres 3.8 volts 240 mA 316 metre max IS trunk 12 instruments each drawing 20 mA NODE 9 volts Trunk length will increase if device population is reduced T
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Power Supply as a IIB Repeater
Safe Area Zone 2 / Div 2 Zone 1 / Div 1 316 metres Power & Ex protection only 24 volts 316 metres 1.8 kms Power, Repeater & Ex protection 24 volts 12 instruments Power drawn in either direction Cable protection required A similar scenario exists for a IIC repeater
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Power Supply as a Repeater
Safe Area Zone 2 / Div 2 Zone 1 / Div 1 Host probably has no Ex protection in powering the 912x device : Cable is a non-arcing circuit due to incendive level of energy Cable protection required - hazardous area wiring may not be disconnected to reveal floating wires Repeater terminals carry limited energy; hence circuit is non-incendive and power plug may be removed 912x device may power host equipment (max 30 mA) and power plug may be removed Power, Repeater & Ex protection 1.8 kms Power drawn in either direction
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Isolation of Power Supply
Zone 2 / Div 2 MTL8913 MTL8914 Zone 1 / Div 1 Non-arcing circuit MTL951 Cable is a non-arcing circuit due to potential incendive level of energy Cable protection required : hazardous area wiring may not be disconnected to reveal floating wires Repeater terminals carry limited energy; hence circuit is non-incendive and plug may be removed
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Mounting of Units in Zone 2 / Div 2
The fundamental requirement of mounting these units in Zone 2 or Div 2 is that they should be adequately protected from environmental effects, which can adversely affect their safety Among the effects normally considered are : weather protection contamination by dust or corrosive atmospheres ambient temperature, solar radiation mechanical impact unauthorised interference If in a normal outdoor industrial location the requirement is : an enclosure having a minimum ingress protection of IP54 an impact rating of at least 7Nm adequate resistance to corrosion The usual solution is to use an Exn, Exe, or Div 2 compliant enclosure, since this covers for the effects of static & provision for bonding, etc There are situations where a greater level of ingress protection is required; eg, IP67 offshore to withstand the deluge test can be expected
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ex The ‘CE’ Mark The ‘Explosive Atmosphere’ Mark ATEX Certification
Confirms compliance with all relevant Community directives Conformite European ex Confirms compliance with ATEX or previous Flammable Atmosphere Directive The ‘Explosive Atmosphere’ Mark
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Equipment Marking - 9121 Power Supply
CENELEC / IEC [E Ex ib] IIC T OC < Tamb < +70 OC Conformity with European Standard Explosion protection symbol Type of protection code Apparatus Group (Hydrogen) Temperature Class (Group II) Referenced to ambient of -20 to +40 OC unless indicated as above T1 : 450 OC T2 : 300 OC T3 : 200 OC T4 : 135 OC T5 : 100 OC T6 : 85 OC
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Equipment Marking - 9121 Power Supply
CENELEC / IEC [E Ex ib] IIC T OC < Tamb < +70 OC Conformity with European Standard Explosion protection symbol Type of protection code Apparatus Group (Hydrogen) Temperature Class (Group II) [ ] indicates the apparatus is safe area mounted ‘associated apparatus’ suitable for connection to Ex ib equipment Referenced to ambient of -20 to +40 OC unless indicated as above T1 : 450 OC T2 : 300 OC T3 : 200 OC T4 : 135 OC T5 : 100 OC T6 : 85 OC
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Equipment Marking - 9121 Power Supply
ATEX G : Gas, vapour, mist D : Dust II (2) GD 0600 CE mark Ref to Notified Body responsible for testing EU Explosive Atmosphere Symbol Equipment Group Equipment Category Type of explosive atmosphere (Group II) M1 : energised M2 : de-energised 1 : Zone 0, 20 2 : Zone 1, 21 3 : Zone 2, 22 I : Mining II : Non-Mining
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9121 - BASEEFA Certification
II (2) GD 0600 ATEX [E Ex ib] IIC T OC < Tamb < +70 OC CENELEC / IEC BAS 02 ATEX 7276 EC-type examination certificate ATEX Category 2 certification Additional information on product : Safety parameters, where applicable Year of manufacture & Serial No. Name & address of manufacturer Manufacturers type identification
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9121 - MTL Declaration of Conformity
II GD ATEX E Ex nA IIC T OC < Tamb < +70 OC CENELEC / IEC MTL 02 ATEX 9121X MTL Declaration of Conformity ATEX Category 3 certification justifying mounting the 9121 power supply in Zone 2 9121X refers to special conditions of use : > power supply is installed in an appropriate enclosure > it must be protected from large supply transients
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BAS 02 ATEX 7277 9122 - BASEEFA Certification II (2) GD 0600 ATEX
[E Ex ib] IIB T OC < Tamb < +70 OC CENELEC / IEC BAS 02 ATEX 7277 EC-type examination certificate ATEX Category 2 certification
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MTL 02 ATEX 9122X 9122 - MTL Declaration of Conformity II 3 GD ATEX
E Ex nA IIB T OC < Tamb < +70 OC CENELEC / IEC MTL 02 ATEX 9122X MTL Declaration of Conformity ATEX Category 3 certification justifying mounting the 9122 power supply in Zone 2
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Applicable Standards Safety Standards Design Standards
Ingress Protection : IP20 to BS EN 6529 Corrosive Atmospheres : Class G3 environment to ISA SP71.04 EMC compliance : EN 61326:1998 Electrical Safety : EN Safety Standards Factory Mutual : Class No for Intrinsic Safety Factory Mutual : Class No for Division 2 hazardous areas EN : : Electrical apparatus for potentially explosive atmospheres, general requirements EN : : Electrical apparatus for potentially explosive atmospheres, intrinsic safety EN : : Electrical apparatus for potentially explosive atmospheres, type ‘n’ protection EN : : Electrical apparatus for potentially explosive atmospheres, intrinsically safe systems IEC/TS : 2003 FISCO Standard EC Directive 94/9/EC (ATEX 100A)
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Fieldbus Intrinsically Safe Concept (FISCO)
Adopting FISCO raises the issue : Can Entity certified fieldbus equipment (non-FISCO) be incorporated into a FISCO network ? 9321-SC YES 9323-SC
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I.S. Entity Spur Connections
(non-FISCO devices) 9121-IS : IIC output safety parameters : 14 V; 180 mA; W deliver 12.0 V; 110 mA 9321-SC Entity spur connector EEx ib IIC T4 II 2 (2) G Live working throughout 9321-SC Entity IS certified device Zone 1 An Entity device certified to FF-816 must have an input safety description of : 24 V; 250 mA; 1.2 watts. The 9121-IS has output safety parameters of : 14 V; 180 mA; W Therefore the 9321-SC is required to limit the available power to 1.2 watts. This is achieved by a fuse in each leg rated at 50 mA. The rupturing value of either fuse is 1.7 x 50 = 85 mA 14 V x 85 mA = 1.19 watts; hence restricts the power available to the required Entity value. The 9321 cannot be used with a 9122-IS because the voltage & current available from the latter is 14.8 V & 359 mA, respectively. (14.8 V x 81 mA = 1.2 watts) To bring this down to 81 mA would require 2 fuses plus 2 series resistors of 182 ohms. Assuming an instrument current of 20 mA. This would then bring the spur voltage available under normal operation down to 12.8 V - (2 x 182 x 20 mA) = 7.28, which is clearly below the minimum instrument operating voltage 12.8 V - (2 x 39 x 85 mA) = FISCO devices HUB Entity device to FF-816 has an input safety description of 24 V; 250 mA; 1.2 watts T
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MTL9321-SC & 9121-IS Entity Spur Connector
II 2 (2) G EEx ib IIC T4 9121-IS has output safety parameters of : 14 V; 180 mA; W 50 mA Entity device to FF-816 has an input safety description of 24 V; 250 mA; 1.2 watts The 9321-SC is required to limit the available power to 1.2 watts Achieved by a fuse in each leg rated at 50 mA The rupturing value of either fuse is 1.7 x 50 = 85 mA 14 V x 85 mA = 1.19 watts; hence restricts the power available to the required Entity value
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Fieldbus Intrinsically Safe Concept (FISCO)
The use of active current limitation restricts the categorisation to ‘EEx ib’, ie, connection to Zone 1 only Can a fieldbus device be installed in a Zone 0 by adding further protection to achieve ‘ia’ status ? 9322-SC YES
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Zone 1 Networking into Zone 0 9322-SC Zone 0 spur connector Useable
with either 9121-IS : IIC 9122-IS : IIB II 2 (1) G EEx ib IIC T4 II (1) G EEx [ia] IIC 9322-SC ia : Zone 0 energy limit Zone 1 Zone FISCO devices NODE T
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Wiring Components
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Wiring Components - Megablock Series
DIN-rail mounting Fieldbus network hubs connect multiple field devices to trunk network minimise hand wiring network integrity maintained during connection / disconnection of individual devices LED indicates minimum 9 volts present at hub Megablocks available in 2, 4 & 8-way (10-way) versions Megablock terminator available Terminator Short-circuit protection option using SpurGuard
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8-way Megablock Megablock Series Optional Trunk / Home run
Power LED >= 9V Field device connection Optional SpurGuard short circuit protection - visual indication of fault Trunk / Home run Securable, pluggable connectors 8-way Megablock
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suitable for environment
Megablock Series Choice of junction box Use site standard suitable for environment trunk 4 + 8 drop = 12 drop Easy to retrofit Junction box for specific application standard instrument cable spur terminator
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Relcom SpurGuards™ System reliability and availability may be affected
by the shorting of the fieldbus highway, by the failure of any individual fieldbus device, thus interrupting data communication across the entire bus segment could occur during installation or routine instrument maintenance A SpurGuard™ is a current-limiting device that provides short circuit protection to the fieldbus segment By attaching a SpurGuard™ at each point where a field device is attached to the segment home run cable, isolation of the network from individual device failures is achieved SpurGuards™ are available with any Megablock a red LED indicates when a SpurGuard™ is providing overcurrent protection Because a SpurGuard™ leg draws power from the segment when in short circuit mode, their short circuit current consumption must be taken into account during segment design The SpurGuard™ short-circuit current is nominally 60 mA Trunk to Spur max. voltage drop = 0.4 volts
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Lightning Strikes Handling the effect
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Lightning Strikes There is no remedy for direct lightning strikes
the energies involved are too high but measures can be taken to minimize the effects of near-lightning strikes on Fieldbus networks Lightning is a short burst of very intense voltage and current. Even when a direct lightning strike is shunted to ground by a lightning rod, it induces high voltages and currents in metal components nearby eg, the conductors & shield of Fieldbus cable The purpose of lightning surge protection in Fieldbus wiring is to minimize the induced voltages & currents and hence to minimise damage to Fieldbus equipment a lightning strike might produce ,000 Amps in a lightning rod induced currents in nearby grounded metal objects may be several thousand Amps induced current in the shield of a fieldbus cable might be several hundred Amps 90% 50% 10% I (100 kA) PK 8µs 20µs t
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Principles & Practicalities
Fieldbus High potential across insulation on field instrument Flash-over 100kA Local Ground Strike High local potential on building earth system Local ‘ground’ Induced Voltage V = L x I/ t
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Transient Surge Suppression
The shield of the Fieldbus cable is grounded but according to the installation standard, in only one place Single-point grounding eliminates current loops in the shield reduces induced noise in the signal concerned is a pre-requisite for an intrinsically safe circuit the shield is normally grounded at the control room Any lightning strike in the field could produce a large current in the shield that needs to travel to the control room to pass to ground in a long network a large shield voltage could occur by capacitive coupling a large voltage might appear on the internal twisted pair A surge may be minimized by using a Transient Surge Suppressor Shield Transient Surge Suppressor Centralised control equipment
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Differential Voltage Suppression
The next consideration is to minimize the voltage that might be induced in the twisted-pair inside the shield Due to the capacitance between the shield & each of the wires in the twisted pair, a voltage change on the shield will induce a voltage on the wires Using twisted-pair cable, the shield-to-wire capacitances for the two wires are nearly equal hence the voltage induced in each of the wires in the twisted pair will be identical (Common Mode Voltage effect) The Fieldbus standard requires that the common mode immunity of Fieldbus devices should be of a high order, eg, Surge Protection Devices : FP32 = 225 volts DC trigger point TP32 = 120 volts DC trigger point
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Protection Devices FP32 TP32
The FP32 surge protection device prevents surges & transient overvoltages conducted along the Trunk or Spurs of fieldbus systems from damaging the associated electronics may be used at any point on a Trunk to safely divert any surges to ground The TP32 is the protection equivalent installed at an instrument Fully automatic in operation, the devices react instantly to make sure that equipment is never exposed to damaging surges between lines or between lines & earth Reacting instantaneously to surges they then reset automatically FP TP32
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Surge Protection Device
Gas discharge tube Line inductors Solid-state limiters Circuit fuses Signal lines Circuit earth Protected equipment I (100 kA) PK 90% The multi-stage elements of the FP32 / TP32 use a combination of solid state electronics and a gas filled discharge tube (GDT) to provide surge protection up to 20kA 50% 10% t 20µs
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Power problems due to transient spikes
Surge < 10% Sag < 10% Outage < 1% Transient 85% to 90%
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Generalised Fieldbus connection
Hub Power conditioner Trunk Terminator Power supply Power distribution panel Incoming AC supply
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Host System protection
Power conditioner Hub FP32 T T Trunk Terminator Power supply MA 4000 Power distribution panel Incoming AC supply
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Field Device Protection - ‘compact’
Hub FP32 Trunk T Terminator All spurs less than : 50m horizontal or 10m vertical Surge invasion from host end of trunk all devices are protected by one surge protection device in trunk Spurs < 50m horizontal < 10m vertical
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Field Device Protection - ‘widespread’
Hub FP32 Trunk T Terminator Spurs > 50m horizontal > 10m vertical Spurs greater than : 50m horizontal or 10m vertical surge invasion from Host end of trunk surge protection installed to each device
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