General-purpose and 2/2 Applications with SafetyNet

PAC8000 I/O - 2/2 I/O Modules General-purpose and 2/2 Applications with SafetyNet

Instruction Manual

INM8100A

Revised: Nov 2014 Issued: Feb 2010

INM8100A PAC8000 I/O – 2/2 I/O Modules Instruction Guide 2

This symbol indicates this manual must be consulted in all cases identified to determine the nature of potential hazards and any actions which must be taken to avoid them.

Contents PAC8000 I/O - 2/2 I/O Modules .............................................................................................................. 1

Contents .............................................................................................................................................. 2

Related Documents ............................................................................................................................. 5

Use of Equipment in Hazardous Areas ............................................................................................... 5

EMC Compliance ................................................................................................................................. 5

Introduction ............................................................................................................................................ 7

Process I/O .......................................................................................................................................... 7

General-purpose Applications ........................................................................................................ 7

Hazardous Area Applications .......................................................................................................... 7

Application Code ................................................................................................................................. 8

I/O Components ...................................................................................................................................... 9

Bus Interface Modules and Controllers .............................................................................................. 9

Bus Interface Modules .................................................................................................................... 9

Controllers ..................................................................................................................................... 11

I/O Modules and Carriers .................................................................................................................. 13

Carrier Extenders .......................................................................................................................... 14

Field Terminals .................................................................................................................................. 14

System Design ................................................................................................................................... 15

Enclosures ......................................................................................................................................... 15

Planning ............................................................................................................................................ 15

Summary ........................................................................................................................................... 15

Required Tools .................................................................................................................................. 16

Health and Safety .............................................................................................................................. 16

Underwriters Laboratories (UL) .................................................................................................... 16

Special Conditions of Safe Use .......................................................................................................... 17

System Types ........................................................................................................................................ 18

General-purpose (GP) ....................................................................................................................... 18

2/2 System ........................................................................................................................................ 19


Combined 2/2 and 2/1 System ......................................................................................................... 19

Installation ............................................................................................................................................ 21

Fitting Cable Trunking ....................................................................................................................... 21

Mounting Carriers ............................................................................................................................. 21

Flat Panel Mounting ...................................................................................................................... 21

DIN-rail Mounting ......................................................................................................................... 22

Fixing Carriers to DIN-rail .............................................................................................................. 22

Mounting Carriers ......................................................................................................................... 23

Power Supply Connections ............................................................................................................... 23

12 V DC System Supply ................................................................................................................. 23

Bussed Field Power (BFP) Connections ......................................................................................... 23

Connector Wiring .......................................................................................................................... 25

Fitting Coding Keys ........................................................................................................................ 27

Carrier Extenders .............................................................................................................................. 27

Right-hand and Left-hand Versions .............................................................................................. 28

Mounting ....................................................................................................................................... 29

Fitting Railbus Cables .................................................................................................................... 29

Continuing DC Power .................................................................................................................... 29

Carrier Earthing/Bonding .............................................................................................................. 29

Field Terminals .................................................................................................................................. 30

Terminal Types .............................................................................................................................. 30

Compatibility of Field Terminal and I/O Module .......................................................................... 30

Rotary Keys ................................................................................................................................... 30

Keyways ........................................................................................................................................ 31

Field Terminals Installation and Removal ..................................................................................... 32

Tagging Strip.................................................................................................................................. 32

Mass Termination Assemblies ...................................................................................................... 33

Switch/Proximity Detector Wiring Panel ...................................................................................... 33

Field Circuit Wiring ............................................................................................................................ 35

Cable Termination ......................................................................................................................... 35

Carrier Earth Bar ........................................................................................................................... 36

Fitting I/O Modules ........................................................................................................................... 36

Vacant I/O Module slots ............................................................................................................... 36

Wiring and Cabling Guidelines .............................................................................................................. 37


Installation and Cable Routing Guidelines ........................................................................................ 37

Inside a Building ................................................................................................................................ 37

Outside a Building ............................................................................................................................. 37

Protective Circuits for Inductive Field Devices ................................................................................. 37

Protecting DC Discrete Input Circuits ............................................................................................ 37

Protecting DC Discrete Output Circuits ......................................................................................... 38

AC Discrete Output Circuits .......................................................................................................... 38

Calculating Values for R-C Suppression Components ................................................................... 38

Maintenance ......................................................................................................................................... 39

Fuses ................................................................................................................................................. 39

Cleaning............................................................................................................................................. 39

Appendix A Mounting Dimensions ....................................................................................................... 40

Controllers......................................................................................................................................... 42

Appendix B Field Terminal Connections ............................................................................................... 47

Appendix C Glossary ............................................................................................................................. 49

Appendix D ATEX Information .............................................................................................................. 50


Related Documents The following documents are available upon request, or may be downloaded from www.ge-ip.com:

• INM8455 BIM Configuration Software

• INM8502 Profibus-DP BIM

• INM8505 Modbus BIM

• INM8521 Controller System Manual

• INM8512 HART Interface Module

• INM8200 Installing I/O Modules (2/1 Applications)

• INM8900 8000 Power Supplies Configuration and Installation

Use of Equipment in Hazardous Areas Consistent with all other electrical apparatus installed in hazardous areas, this apparatus must only be installed, operated and maintained by competent personnel. Such personnel shall have undergone training, which includes instruction on the various types of protection and installation practices, the relevant rules and regulations, and the general principles of area classification. Appropriate refresher training shall be given on a regular basis. Refer to clause 4.2 of EN 60079-17.

This instruction manual supplements the requirements of nationally accepted codes of practice, such as IEC/EN 60079-14 in Europe and the National Electrical Code, combined with ANSI/ISA-RP 12.6 in the USA and the Canadian Electrical Code (CSA C22.1) and CSA C22.2 No. 1010.1. All installations should comply with the relevant sections of these codes.

Additionally, particular industries or end users may have specific requirements relating to the safety of their installations, and these requirements should also be met. Refer to Appendix D ATEX Information.

EMC Compliance PAC8000 products are designed to be installed in Zone B as per IEC/EN 61131-2 or in the Industrial Electromagnetic environment as per IEC/EN 61326-1.

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Introduction

PAC8000 I/O modules provide the interface between the remote field sensors, or actuators, and the controller. They are capable of being located in the field close to the field devices, to allow the full benefit of distributed I/O.

8000 I/O Modules and Field Terminals on 8-way Carrier

Process I/O

Previous conventional wiring practice required individual cable pairs to be wired between each field device and the control room. This arrangement was inflexible, time-consuming and costly. Distributed I/O provides more flexibility and reduces installation time and cost. These benefits have been proven in factory automation applications with PLC-type I/O and the same benefits are now enjoyed in the process control industries with the use of 8000 Process I/O. Rugged, easy to maintain and capable of satisfying hazardous area applications, the 8000 I/O provides a solution for all process I/O within one family of products. Compatibility with emerging fieldbus types is ensured by a choice of bus and LAN interfaces, and many features, normally supplied only by means of add-ons, are engineered into the standard product.

General-purpose Applications

Process control has applications in many industries: water treatment, steel making, brewing, power generation, and such, all of which can have harsh plant environments. 8000 I/O is specifically designed to withstand such environments and these applications are referred to as general purpose.

Hazardous Area Applications

Industries, such as oil exploration and refining and chemical and pharmaceutical manufacturing have environments that may contain explosive gases. Use of equipment in such areas is referred to as a hazardous area application. GE is a world leader in technology and equipment for use in hazardous areas and that experience is of major value to users requiring process control equipment for such applications.


Application Code The differences between general-purpose and hazardous -area applications are illustrated in the following diagram. The applications can be mixed within a single system, and even in a single location.

Division 1Zone 0

Hazardous Area

Division 1Zone 1

Hazardous Area

Division 2Zone 2

Hazardous Area

Safe (Non-hazardous)

Area

a) General-purpose

b) Zone 2 / Division 2Field Wiring

c) Zone 2 / Division 2Mounting and Field Wiring

d) Zone 2 / Division 2 MountingZone 1 / Division 1 Field Wiring

e) Zone 2 / Division 2 MountingZone 0 / Division 1 Field Wiring

8000 I/O Application Options

Application code has been adopted to help users identify the type of 8000 I/O Series equipment for their particular application. As well as general-purpose, three equipment applications defined as 2/2, 2/1 and 1/1 are displayed in the following figure.

2 / 2

Location of Node Field Wiring Location

Division 2 or Zone 2

Division 2 or Zone 2

Equipment Application Codes

The two numbers and their usage have the following meaning:

• The first number represents the maximum hazardous type of area in which the

equipment can be mounted (without additional hazard protection)

• The second number represents the maximum hazardous type of area from which the field wiring can originate. Note that Division 1 field wiring applications also include Zone 0 and Zone 1.

The figure, Equipment Application Codes, illustrates these situations and, by understanding this terminology, the correct type of equipment can be chosen to suit a specific application.

This document applies to general-purpose and 2/2 applications ONLY; specifically types a, b, and c described in the figure, I/O Application Options.

Note: All general-purpose applications should use 2/2 products. This equipment represents a base level for all applications. It is used for all general-purpose work, even though it is designed to be mounted in Zone 2 or Division 2 hazard areas and will accept field wiring that originates in the same, or non- hazardous (safe) areas.


I/O Components

Bus Interface Modules and Controllers Bus Interface Modules (BIM) and Controllers provide the governing element for an 8000 I/O node. BIMs are currently available to operate as slaves under Modbus and Profibus-DP bus protocols. The more intelligent Controller provides a higher level of control and can assume the role of DCS or PLC operating directly off the Enterprise level LAN.

Bus Interface Modules

A Bus Interface Module (BIM) is used to communicate with a host controller, such as a PLC.

8505-BI-MB, Modbus Bus Interface Module

Different BIMs allow 8000 I/O to operate with popular fieldbus protocols. The Bus Interface Module is configured with dedicated software (part number 8455-CF-SW). This is used to set the parameters for communication with the host and configure the BIM and the IO Modules for the particular application.

The following versions of the BIM are currently available:

• 8502-BI-DP Profibus DP BIM • 8507-BI-DP Redundant Profibus BIM • 8505-BI-MB Modbus BIM

A range of carriers is available on which to mount the BIM. The carrier is selected to suit the BIM, then the application.

Available Carrier Types BIM Carrier Model Numbers

8502/8505 BIM only 8715-CA-BI

8502/8505 BIM + Node Services Module (NSM) 8718-CA-NS

8502/8505 BIM + DC/DC power supplies + 4 I/O modules 8711-CA-NS and 8712-CA-NS

8507 2 x BIM + DC/DC power supplies 8701-CA-BI


8715-CA-BI BIM Carrier

Details for installing BIMs and their carriers are provided in the manuals for the respective BIMs. Refer to the section, Related Documents.

The 8711, 8712 and 8718 carriers accommodate the 8510-MO-NS Node Services Module. This module has a number of roles. It can store the node configuration for transfer to another BIM. If necessary; it can be used to define the address of the node, through four rotary switches. Additionally, it can alert the BIM, and hence the Control System, to the failure of power supplies to the node.

8510-MO-NS Node Services Module


Controllers A PAC8000 controller connects to the Enterprise network through Ethernet and can assume the role of a DCS, a PLC or a Safety system, depending on the type of controller chosen.

Another version of the controller, an EBIM, uses Ethernet as a communication medium. The EBIM functions as a Bus Interface module.

Controller Type Part Number

Hybrid Controller 8521-HC-MT

Process Controller 8521-PC-MT

Logic Controller 8521-LC-MT

Ethernet Modbus Interface Module (EBIM) 8521-EB-MT

SafetyNet Controller (for SIL 2 safety applications) 8851-LC-MT

DNP RTU 8521-RT-MT

Controller Type 8521

Three controller carriers are available: 8750-CA-NS, 8751-CA-NS, and 8753-CA-NS. The 8750-CA-NS and 8751-CA-NS Dual carriers are very similar, except the 8751-CA-NS has a separate floating signal ground used when earth-leakage detection is required. Two Change State buttons are provided on the 8750-CA-NS and 8751-CA-NS Dual carriers, one for each controller or EBIM, to enable the user to change the state of a controller from Master to Standby, Standby to Offline, or Offline to Standby. The controller or EBIM affected by each Change State button is indicated on the circuit board. The state change depends upon the controller state before the button is pressed. Fire and gas applications are typical examples of such a requirement. The 8753-CA-NS Simplex carrier accommodates a single controller and provides a built-in power supply monitor (8410-NS-PS module is not required). The Change State button on the 8753-CA-NS Simplex carrier enables the user to change the state of the controller from the Failsafe state to Active/Normal state. It can also be used for the bootP operation.

Carrier Type Model Number

Dual Carrier + Power Supply Monitor 8750-CA-NS

Dual Carrier + Power Supply Monitor + floating ground option 8751-CA-NS

Simplex Carrier + Power Supply Monitor 8753-CA-NS


8750-CA-NS Dual Carrier

8753-CA-NS Simplex Carrier

The 8750-CA-NS and 8751-CA-NS Dual carriers also accommodate the Power Supply Monitor module (8410-NS-PS), which monitors the power fail signals available from power supplies such as the 8913-PS-AC and 8914-PS- AC models. Installation details for these carriers are provided in the Controller manual. Refer to the section, Related Documents for a list of documents.

8410-NS-PS Power Supply Monitor


I/O Modules and Carriers A wide range of I/O modules is available to handle digital and analogue field devices of all types, and careful attention to design has achieved a high channel density, between four and 32 I/O channels in a 42 mm width module.

No setup is required to establish a network address for a new module as this is automatically determined by its position on the carrier.

8115-DO-DC Discrete Output Module

8710-CA-04 Carrier, 4-module with Earth Bar

Carriers provide a mounting for the 8000 I/O modules. They support the I/O modules, the field terminals, and carry the address, data and power lines of the internal bus (Railbus). Most carriers can be fitted to standard T-section or G-section DIN rail, or may be surface mounted on a flat panel. Refer to the section, Installation.

Multi-pin connectors on their left and right edges enable carriers to be joined end-to-end without the need for additional wiring. A terminal rail/earth bar along the front edge of the carrier accommodates incoming cable screens/shields or protective earth connections.

Carrier types must be chosen to suit the controlling element. Bus interface modules (BIMs) support up to 32 I/O modules but controllers can communicate with up to 64 I/O modules and consequently require carriers that can support the extended address range. The following table identifies the module carrier types and their use.

Controlling Element 4-module Capacity 8-module Capacity

BIM 8502-BI-DP, 8505-BI-MB and 8507-BI-DP

8710-CA-04 8707-CA-08

Controller 8521-xx-MT† or 8851-LC-MT – 8709-CA-08 (extended addressing) † xx indicates the specific controller type


Carrier Extenders Where carriers forming a node cannot be joined end-to-end on a single length of DIN- rail, carrier extenders enable continuity of power and signal bus through flexible cables. The extenders are handed (left and right) to fit the I/O carriers and can support 32- or 64-way addressing. Carrier extenders suitable for general-purpose and 2/2 applications are:

• 8020-CE-RH Carrier Extender • 8021-CE-LH Carrier Extender

8021-CE-LH Carrier Extender

The connections between Carrier Extenders are made by Extender cables. These are available in a number of lengths. Cable Length Part Number 0.35m Carrier Extender Cable 8001-CC-35 0.85m Carrier Extender Cable 8002-CC-85 1.2m Carrier Extender Cable 8003-CC-12

Field Terminals

Field terminals (one per I/O module) snap onto the carrier and accept field wiring without the need for additional terminals or connections. They can be changed easily if damaged in the field.

A comprehensive mechanical keying system ensures that equipment safety is maintained.

The following field terminals can be used on carriers for general-purpose and 2/2 applications:

• 8601-FT-NI (non-incendive) • 8610-FT-NA (non-arcing)

• 8602-FT-ST (standard) • 8611-FT-FU (non-arcing fused)

• 8603-FT-FU (non-incendive fused) • 8615-FT-4W (4-wire transmitter)

• 8604-FT-FU (fused) • 8617-FT-NI (16/30-channel DI)

• 8605-FT-TC (4-channel thermocouple) • 8618-FT-MT (16-pin, IDC connector)

• 8606-FT-RT (4-channel RTD) • 8619-FT-MT (44-pin, IDC connector)

Field Terminals, 4/8-channel (Left), 16/30-channel (Middle) and 32-channel IDC (Right)


System Design When the equipment is ready for installation, it is assumed that the system has been designed in accordance with the System Specification Guide. This process establishes which I/O modules and field terminals are required, or suitable, for the application based upon the field sensors and actuators that will be wired to the node. Power supply requirements should be calculated to satisfy the needs of the I/O modules, plus any additional demand for field circuit power. The number of carriers to mount all of the modules should be calculated as well.

Enclosures

8000 I/O equipment can be located in the process plant. In this event, equipment will require some form of protection from the weather and the danger of physical damage. Enclosures for this purpose can be supplied on request by GE, but any enclosure that is designed to provide an adequate level of ingress protection and is capable of withstanding physical damage appropriate to the environment will be satisfactory.

Planning

Before beginning installation, consider the following points: • Additional carriers may be required at a later stage. When positioning the

trunking and 8000 I/O carriers, consider making provision for such extensions or modifications.

• Where possible, when routing the wiring and associated trunking, allow generous space for the carriers, carrier extenders and extension cables.

• Make adequate allowance for the working space to trim and insert cable-ends. • Make sure you have all the required parts on hand before

beginning installation. • Ensure you have a 3.5 mm flat-bladed screwdriver, a 2 mm flat-bladed

screwdriver, and all the necessary tools for mounting the enclosure, DIN rails (if used) and cable trunking. Tools are also required for preparing cable-ends.

Summary Depending on circumstances and work procedures, an 8000 I/O node may be constructed in a wiring shop and taken on site for installation or fully constructed and installed on site. A typical installation could proceed as follows (greater detail is available in-Later sections):

1. Install trunking, making allowance for 8000 I/O carriers and required clearance for trimming and fitting cable-ends.

2. Install the DIN rails (or if DIN rail mounting is not used, drill mounting holes in the mounting surface).

3. Fit the carriers (and any carrier extenders) to the DIN rails (or fit carriers to the mounting surface).

4. Fit the field terminals. 5. Switch off all power supplies to the node and make safe. 6. Trim field wiring cable-ends and connect into the field terminals (this could also

be done after the modules are fitted). Cable-ends should be tagged to identify the associated instrument/actuator.

7. Trim cable ends of power supplies and connect to the relevant terminals. 8. Fit carrier extender cables.


Required Tools 8000 I/O equipment can be installed with a minimum use of tools. Apart from tools for the mounting and preparation of the enclosure and preparing cable-ends, the only tools required to mount and cable the equipment are:

• 3.5 mm flat-bladed screwdriver

• 2 mm flat-bladed screwdriver

Health and Safety Before equipment installation, adhere to the following guidelines:

• Ensure installation is performed in accordance with all relevant local standards, codes of

practice and site regulations, and any special requirements stated in this manual.

• Verify that the module functions are correct for the applications.

• Take care to avoid damaging the pins at all connector interfaces.

• Ensure that all relevant power supplies have been made SAFE.

• Ensure that RS-485 cable used for installation is foil-shielded.

Refer to Appendix D ATEX Information for furthers details on each component, including any special conditions of use.

IMPORTANT: Identify any special conditions of use before installing.

For further electrical data, refer to the component’s Declaration of Conformity.

Underwriters Laboratories (UL)

Listing by Underwriters Laboratories to UL 61010-1 under control number 3MGU requires the following information to be provided:

If the equipment is used in a manner not specified by GE, the protection provided by the equipment may be impaired.

The Warning symbol displayed on system carriers indicates the following ratings apply:

System

The controller must be enclosed within a panel. Use NEC Class 1 wiring between terminals on field terminal assemblies and other circuits (sensor circuits). The equipment shall be marked with the maximum voltage and current rating of the branch-circuit overcurrent protective device corresponding to the size of the internal wire.

Field Terminal Assemblies and Screw Terminals

Field terminal assemblies with screw-clamp terminals have maximum ratings of 265 V ac, 3 A per channel, and where fitted a fuse rating of 2A. The actual limitations are further defined by the specifications of the I/O modules with which they are used. Copper wiring must be used with these field terminals, and the conductor sizes permitted are restricted to 26 to 14 AWG (0.13 to 2.1 mm2). The operating temperature range of insulation of the cables used shall be more than 75°C (167 °F). Tightening torque for wiring screws on screw terminals shall be 0.791 Nm (7 lb-in).

Bussed Field Power Connections

A single BFP connector on an 8000 2/2 carrier can provide two independent power rails, each rail supplying two adjacent modules. The maximum rating of this connector is 265 V ac and 15 A. Controllers are intended for panel mounting.


FM Approvals for US and Canada (Zone Markings Only Applicable to 8753-CA-NS Simplex Carrier) Class 1 Division 2 Group A, B, C, and D AEx ic nA for Class 1 Zone 2, Grp IIC for the US; Ex ic nA for Class 1 Zone 2, Grp IIC for Canada; T6 for -40°C (-40 °F) < Ta < +70°C (158 °F) for the US and Canada.

WARNING - EXPLOSION HAZARD Do not disconnect while the circuit is live unless the area is known to be non-hazardous.

AVERTISSEMENT - RISQUE D'EXPLOSION Ne pas debrancher tant que le circuit est sous tension. A moins qui’il ne s’agisse d’un emplacement non dangereaux.

Special Conditions of Safe Use Verify that the following installation requirements are met for Zone 2/Division 2 locations:

• The device must be mounted in an enclosure certified for use in Class I, Zone 2 or Division 2, Groups IIC and rated IP54 in accordance with IEC 60529 when used in Class I, Zone 2 or Division 2 environment.

• To comply with the transient requirements, the voltage for this apparatus must be provided by regulated power supply units complying with the requirements of European Community Directives.

• The communication cables (LAN) connected to the controller should not be removed during normal

operation or unless the location deemed to be non-hazardous location.

• This device is intended for installation within an area of not more than pollution degree 2, as defined in IEC 60664-1.

The following Special Conditions of Use are applicable only to 8753-CA-NS Simplex Carrier:

• The equipment shall be installed in a suitable equipment enclosure which is capable of accepting one or more of the Class I, Division 2 wiring methods specified in the National Electrical Code (ANSI/NFPA 70) or the Canadian Electrical Code (CSA C22.1) as appropriate, meets the requirements of ANSI/ISA 82.02.01 or CSA C22.2 No. 1010 and is in compliance with the enclosure, mounting, spacing and segregation requirements of the ultimate application.

• The equipment shall be installed in a suitable equipment enclosure which is capable of accepting one or more of the Class I, Zone 2 wiring methods specified in the National Electrical Code (ANSI/NFPA 70) or the Canadian Electrical Code (CSA C22.1) as appropriate, meets the requirements of ANSI/ISA 82.02.01 or CSA C22.2 No.1010 and is in compliance with the enclosure, mounting, spacing and segregation requirements of the ultimate application.


System Types

Before assembling the system, be aware of the type of system being installed. The assembly process can vary for each of the following installations:

• General -purpose (GP)

• 2/2 system

• Combined 2/2 and 2/1 system

The following sections provide a description of the key elements required to implement these types.

General-purpose (GP)

A PAC8000 I/O node used in a general-purpose environment may look similar to the installation in the figure. The installation may be larger or smaller, but most components parts will be used.

Construction of a node normally starts with the control element, such as the BIM or controller(s). Both types require a carrier; there is a choice of carrier according to the application. The I/O modules follow the “control” carrier and are fitted on four or eight-way carriers. However, 4-way carriers are not available for extended address (64-slot) applications.

General-purpose I/O Modules


Few mounting enclosures are wide enough to continue a long line of carriers and modules, so a second line can be started to house the additional modules. Carrier extenders are fitted, a right-hand version followed by a left-hand version, to extend the run of carriers onto a second row. A flexible cable carrying the Railbus signals links the two together and power supplies are maintained through cables connected to the screw terminals.

A 2/2 node requires a 12 V dc supply for the system power and, where used, most controllers require an additional direct connection to a 12 V dc supply. The 12 V dc system power can be sourced from any regulated bulk power supply, or the dedicated power supplies can be used 8913-PS-AC for all node types and 8920-PS-AC for 8000 I/O.

Note: SIL2 SafetyNet installations must use either: 8913-PS-DC power supplies for system and controller power and 8914-PS-DC power supplies for Bussed Field Power; or alternatives as defined in the TÜV approved safety manual SM8800, in order for the available certification to be valid.) For further details on the design of power supply systems for 8000 I/O, refer to INM8900 Instruction Manual.

Bussed Field Power (BFP) provides field power when it is required. Depending on the I/O module(s) selected, BFP may be any voltage from 2 to 60 V dc and 20 to 265 V ac. The selected supply is connected to the rear of the carrier and distributed to four modules on the carrier. The modules can route the power to the field devices through field terminals.

For applications requiring BFP at 24V DC, the 8914-PS-AC can be used (and must be used in SafetyNet applications).

2/2 System

The 2/2 system installation is similar to the general-purpose installation. Refer to the figure, General-purpose I/O Modules for the key features for this installation. However, some of the field terminals may have been specified as non-incendive or non-arcing to comply with safety regulations for the field wiring. This has no effect on the installation process.

Combined 2/2 and 2/1 System

Note: For further details on installing the 2/1 equipment and modules, refer to the document INM8200.

Some nodes accept Zone 2/Div 2 and Zone 1/Div 1 field wiring. This requires a combination of 2/2 and 2/1 8000 I/O equipment, which must always be installed in the following configuration:

Control element – 2/2 modules – Isolator – 2/1 modules

Installation begins with the control element and continues with 2/2 I/O module carriers, until all of the required 2/2 modules have been accommodated.

Next, a Railbus Isolator is installed to provide the necessary protective isolation for the IS field wiring that will follow; continue using 2/1 I/O modules on appropriate 2/1 carriers. (Refer to the Instruction Manual INM8200 for installation instructions for these components.)

If carrier extenders are required, the appropriate extenders (2/2 or 2/1) must suit the carriers involved. There is no possibility of using incorrect carrier extenders as the system is designed to prevent this.


General-purpose I/O Modules


Installation

The carriers can be installed directly to a flat panel or T- or G-section DIN rail.

Fitting Cable Trunking

Cable trunking is recommended for management of the power supply and field wiring. Space for this trunking must be considered when installing the carriers.

Refer to the figure, Recommended Minimum Clearance between Carriers and Cable Trunking, for the minimum spacing between a carrier and any adjacent cable trunking. Extra spacing for the power supply cabling allows for the insertion and removal of power connectors.

Mounting Carriers

Flat Panel Mounting

Prepare the carrier holes in the panel as follows: • Mount a flat washer on an M4 screw of the required length, and insert one

of these in each mounting hole.

• Ensure that the carrier is correctly orientated and then place it in position.

• Tighten the screws to fix it securely.

Carrier Hole Dimensions on Moulded Carriers

Refer to Appendix A for carrier dimensions and drilling positions.

Recommended Minimum Clearance between Carriers and Cable Trunking


DIN-rail Mounting Carriers may be mounted on T-section or G-section DIN rail. Refer to Appendix A for carrier dimensions.

Distance between Rail Fixings The following table lists the recommended distance between fixings for a fully loaded rail.

Spacing for Rail Fixings Rail Type Distance between Fixings (max)

G - section 500 mm

T - section 7.5 mm 150 mm

T - section 15 mm 500 mm

T - section A rail depth of 15 mm is recommended when it is the only means of support in the enclosure. Refer to the table, Spacing for Rail Fixings.

If a 7.5 mm rail is used, it must be mounted on a back panel with no spacers between the rail and the panel. Care should be taken to ensure that the screw heads of the fixings for this rail type do not interfere with the carrier mountings. Refer to the table, Spacing for Rail Fixings. G - section Care should be taken to ensure that the fixings for this rail type do not interfere with the carrier mountings. Refer to the table, Spacing for Rail Fixings.

Fixing Carriers to DIN-rail

Screw and swing nut fixings are used to fix the carriers to the DIN rail. The nut rotates to fit underneath the edge of the DIN rail and further tightening of the screw pulls the nut up against the rail.

The fixings are contained within the bodies of the carriers, and access to the screw head is through the holes in the PCB. The outer two screws are used for T-section rail, and the inner two for G-section.

DIN-rail Fixing Positions


IMPORTANT - BEFORE MOUNTING A CARRIER ON THE DIN-RAIL:

Give each of the required screws two 360° turns, anti-clockwise, with a screwdriver. (This ensures the nuts on the underside of the carrier have swung out of the way and are sufficiently retracted.)

ATTENTION!

Maximum torque for swing-nut fixing screws is 10 Nm (7.5 ft-lb)

Note: The spacing between each carrier is 3.0 mm

Refer to Appendix A for the dimensions for each carrier type.

Mounting Carriers When mounting carriers, adhere to the following:

• Ensure that the carrier is correctly orientated and then-Locate it on the rail.

• Press the carrier to the DIN-rail while tightening the fixing screws - do not exceed

torque shown above.

• Ensure that adjacent carriers have their Railbus multi-pin plug and socket fully engaged before tightening the fixing screws.

Power Supply Connections

12 V DC System Supply The 12 V dc power for the I/O modules is distributed through the Railbus multi-pin connector. This power is provided from the control carrier, such as the one housing the BIM or Controller, which precedes the I/O module carriers. Refer to the instruction manual INM8900 for details of 12 V dc power supplies and how to connect them, and also methods of redundancy. The Simplex carrier (8753-CA-NS) consumes a maximum current of 10 mA from the 12 V dc supply, apart from railbus consumption.

Bussed Field Power (BFP) Connections

Bussed Field Power enables field circuit power to be available direct from the field terminals, thus a simple supply rail connection at the rear of the carrier makes power available to a range of field terminals. This overcomes the inconvenient wiring arrangements associated with some I/O module systems. The system is capable of handling voltages of up to 230V AC (nominal) to the field circuits (depending upon the I/O modules in use). Refer to the instruction manual INM8900 for further details of bussed field power supplies and redundancy. If a module requires an additional power rail for the field circuit, this can be provided using the connectors(s) at the top/rear edge of the carrier.


Locations of Bussed Field Power Connectors

A single connector can provide two independent power rails, each rail supplying two modules. Viewing the carrier as shown above, Supply A will feed the two modules to the right of the connector (1 and 2) and Supply B will feed the two modules to the left (3 and 4). The second terminal for each connection enables the supply to be looped onwards.

The eight-module carrier has two of these connectors on its rear edge; the four-module and the Node Services carrier have only one.

BFP Connector Details

Note: The four broken lines linking adjacent terminals indicate links existing on the board.


Bussing Field Power to Additional Modules (Single Supply Voltage) When using a single BFP supply voltage, the BFP connector may be wired to loop the supply to the other half of the connector, and even-Loop it to another connector on the same carrier or an adjacent one.

If all four modules require the same supply, loop the connections onto the other half of the connector as displayed in the following figure.

The power supply may be further looped to another connector if it is capable of supplying sufficient current.

Single External Field Supply

Bussing Field Power to Additional Modules (Two Power Supplies) When two different BFP supply voltages are used on one BFP connector, they can also be looped to another BFP connector, as displayed in the following figure.

Dual external field supplies

Connector Wiring The connector must be wired before it is plugged into the carrier as follows:

• Trim back the insulation of each conductor by 15 mm • Check pin assignments • Insert each conductor in turn and tighten the connector screw. Over-tightening or applying

excessive pressure to the screw terminal is unnecessary and could damage the connector.


Coding key System

A coding key system is available to prevent the interchange of Bussed Field Power plugs that carry different voltage levels. The user fits one part of the key system to the header on the carrier and the other to the free plug (Refer to Figure 22).

As two different supplies or voltages can be provided on one plug, such as supply A for modules 1and 2 and supply B for modules 3 and 4, appropriate code keys should be fitted to each half of the plug and header.

The keying code chosen by the user should uniquely identify the different voltages that will be applied to the header.

The combination of keys in the plug and header (left) should also be chosen to ensure that a free plug cannot be plugged into the wrong header on the carrier. The plug and header will not connect if the same lettered keys are opposite each other. For example, A opposite a will not allow them to connect.

BFP Connector Key Coding

As an aid, a code is suggested here, that will uniquely identify the three most commonly used supply voltages. Bear in mind that the choice of key codes, and even the use of key coding, is entirely at the discretion of the user.

Bussed Field Power Supply Voltage

Code

24 V DC Header A B C -

Plug - - - d

115 V AC Header A B - D

Plug - - c -

230 V AC Header A - C D

Plug - b - -

Note: A - C D means keys are fitted to positions A, C and D on the carrier mounted header.


Fitting Coding Keys The plug and header can be either of two types, each having a particular coding key design. The illustrations at the top of the page show the types, (a) and (b), for both the free plug and the fixed header. The two should not be mixed, such as a type (a) plug should not be used with a type (b) header. The keys are supplied on their own plastic tool for ease of insertion.

• Identify the key's positions for the selected code.

• Using the insertion tool, slide the appropriate key into the appropriate position

on the free plug.

• When it is in place, separate it from the insertion tool by bending the tool backwards and forwards until the key breaks away from the insertion tool.

• Repeat the process on the fixed header using the keys for the header.

Note: There is no potential hazard from exposed Bussed Field Power pins on the carrier, as they carry no supply voltage.

Carrier Extenders Carrier extenders maintain the internal signal and power bus connections between the carriers when space does not allow the current line of carriers to be continued.

Carrier Extender


Right-hand and Left-hand Versions

The extenders are available in a right or left-hand versions, which relates to the end of the carrier to which they are fitted. The right hand extender is fitted to the end of the line of carriers that requires extending. The left hand one attaches to the 'new' line of carriers that requires the signal and power feed.

Cable Length Part Number Carrier Extender – Right hand 8020-CE-RH

Carrier Extender – Left hand 8021-CE-LH A flexible cable is used to connect a pair of Cable Extenders and thus maintain the bus connection. Extender cables for both application types are available in three lengths.

Cable Length Part Number Carrier extension cable, 0.35m 8001-CC-35

Carrier extension cable, 0.85m 8002-CC-85

Carrier extension cable, 1.2m 8003-CC-12

Connecting Carrier Extenders

Caution: Ensure that no undue strain is placed on extender cables/wiring when installed and the extender cables/wiring are secured with suitable cable clips or routed through adjacent trunking.


Mounting • Choose extenders, left and right hand, to suit the application

• Check Appendix 1 for fixing and mounting dimensions if panel mounting

• Mount each extender (engaging its multi-pin connector with that of the carrier)

• Tighten fixing screws on extenders

Fitting Railbus Cables

• Select a standard cable length that will interconnect the two extenders.

• Ensuring the connector genders are correctly orientated, attach cable to extenders and secure their connector fixing screws.

Continuing DC Power

The 12 V system power connection is continued through screw-terminal blocks on the carrier extenders. The following table identifies the terminal connections.

Note: The –ve connections cross from terminals 6 and 5 (8020) to terminals 1 and 2 (8021) and the signal ground connections do the opposite.

Terminal Connections Terminal number

Extender type 6 5 4 3 2 1 8020-CE-RH HVCC

– HVCC

– HVCC

+ HVCC

+ SGND SGND

8021-CE-LH SGND SGND HVCC +

HVCC +

HVCC –

HVCC –

• Identify the extender type (RH or LH) and the terminal block

• Trim back the insulation of each conductor by 6 mm, or 8 mm if the wires are to be

fitted with crimp ferrules.

• Check terminal numbering.

• Insert each conductor according to the terminal numbering and tighten the screw (clockwise). Do not over-tighten or apply excessive pressure to the terminal as damage could occur.

Carrier Earthing/Bonding

Recommendations on how best to ground the carriers for maximum EMC protection are provided in INM8900 – 8000 I/O Power Supplies. Refer to section, Related Documents.


Field Terminals

Terminal Types A range of terminal types is available to suit different I/O modules and applications. Some combinations are prohibited. For details, refer to the section, Compatibility of Field Terminal and I/O Module.

Attention: The installer must be aware of the essential difference between the following two types of field terminal:

2/2 Grey plastic housing is used for general-purpose and 2/2 use

2/1 Blue plastic housing is used only for 2/1 applications (not discussed here)

Further choices depend upon the type of field device. For example, there are specific ones for

use with analog input thermocouples (THCs), RTDs, and 16-channel DI modules.

Refer to the datasheets for further details.

Compatibility of Field Terminal and I/O Module Certain combinations of field terminal and module are intended to be

incompatible, because:

a) Field voltages applied to some terminals could damage certain modules,

and vice versa.

b) Unsuitable modules must not be fitted for hazardous area use.

The following two mechanical methods are used to prevent a module being fitted to a field terminal assembly for which it is unsuitable.

Rotary Keys

This method protects modules and field circuits from the application of voltages and currents incompatible with their function, and uses a pair of ‘D-shaped’, rotatable keys.

During installation the installer sets the keys on the field terminal to match the module code. When the keys on the module are correctly set, they engage with the keys on the field terminal.

Field Terminal Key Codes


Notes:

1. The field terminal keys are all shown in the A1 position for illustration only. This is a valid setting only for the general purpose field terminal. The arrows indicate which module types will fit on the respective field terminals. For example, all module types will fit any of the general purpose field terminals.

2. The module is coded during manufacture and no further action is required of the installer.

Keyways

In addition to the basic rotary keys, a key-and-keyway combination is used to prevent inadvertent fitting of unsuitable modules to field terminals when hazardous-area field wiring is employed. The additional keys are located on the rotary D-shaped keys and the keyways on the fixed D- shaped keys on the module. These do not require any form of setting and will be present, or not, depending upon the type of field terminal, and module, used. (The figure, Field Terminal Key Codes, displays the different types of field terminal and module.)

To set the rotatable keys

1. Obtain the field terminal code from the label on the side of the module

2. Using a screwdriver, set the two

rotatable keys on the field terminal to match the code.


Field Terminals Installation and Removal Field terminals must be fitted onto the carrier before the modules can be installed. It is recommended to decide on a keying system (refer to the section, Keyways) and set the locating key position of each field terminal (and its associated module) prior to fitting.

To fit a field terminal to the carrier

1. Locate the lugs in the holes provided on the

PCB. 2. Press the assembly flat onto the carrier. 3. Slide it towards the middle of the carrier until it

clicks into place.

To remove a field terminal

1. To release the locking mechanism at the rear of the terminal, use a screwdriver, or similar tool, to push the spring catch towards the carrier circuit board.

2. With the catch depressed,

slide the terminal towards the edge of the carrier until it reaches a stop.

3. Release the catch then-Lift (without tilting)

the terminal out of the fixing holes.

Note: Earlier field terminals did not have the locking mechanism. These were removed by pressing the terminal to the circuit board, then sliding it towards the edge of the carrier before removal.

Tagging Strip

A tagging strip is supplied with the field terminal assembly to assist with the identification of the field circuit connections. The strip has a ‘dovetail’ fitting tab to attach it to the field assembly, and once fitted it may be raised to obtain access to any field wiring fuses, or lowered and latched, to display the wiring identities.

The identity strip locates in the face of the tagging strip and a clear plastic cover is used to protect it.


Mass Termination Assemblies Mass Termination Assemblies (MTAs) offer the user a number of different ways to terminate field wiring. Two versions are available, 16-pin (8618-FT-MT) and 44-pin (8619-FT-MT), both of which provide IDC multi-pin connectors instead of screw terminals. The Mass Termination Assemblies are particularly useful when-Legacy systems are being replaced and connections must be made to existing field wiring, junction boxes and marshalling cabinets. Some standard 1, 2 and 3 meter cables are available from GE to assist the user; others can be made to order; or users can put together their own custom cables to suit their specific wiring termination requirements. Mass Termination Assemblies can also be used to interface to signal conditioning units. For example, with devices that require a drive current above the 1A capability of the 8115- DO-DC discrete output module, the 8618-FT-MT can be used to connect to high-current relays. Increasing the current handling capacity of the 8115-DO-DC module is discussed in Technical Support Note TSN112: Using the 8115-DO-DC with high-current loads, which is available from the website: www.ge-ip.com.

In particular, the 44-pin (8619-FT-MT) MTA is required for the 8125/8127 I/O modules to accommodate the full 32-channels and the 8121/8122 modules to accept sixteen 2-wire devices.

The user is recommended to consult the data sheets for individual IDC pinouts on the 8618-FT-MT and the 8619-FT-MT assemblies.

Switch/Proximity Detector Wiring Panel

The 8650-FT-PX provides a simple method to terminate up to 32 two-wire field devices. It is DIN-rail mountable and links to the 8619-FT-MT field terminal using a pair of ready terminated, IDC connector cables that have 20 and 24 pin connections. Consult the data sheet for individual IDC pinouts on the 8619-FT-MT.

8650-FT-PX Wiring Panel

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Refer to the following diagram to wire the switches or proximity detectors into the screw terminal connectors. For maximum convenience, there is also provision for cable screens to be terminated and grounded.

8650-FT-PX Field Wiring Terminals

Connect +ve terminals to the upper row, –ve to the middle and ground or cable screens to the lowest one. The GND terminals are linked to two M4 screw terminals on the circuit board to provide a convenient method for connecting them to a suitable ground.


Field Circuit Wiring

Field Terminal Wiring

Refer to Appendix B Appendix B Field Terminal Connections for further details.

Cable Termination

Field wiring is usually organized in pairs and a pair of cable ends will be wired into the Terminal Block one above the other. If I/O connections do not conform to this refer to the module datasheet.

As the connections are stepped, the lower wire (such as even numbered terminals) should be cut 12 mm shorter than the upper one.

• Trim back the insulation on each conductor by 6 mm, unless crimp ferrules are

being fitted, in which case the conductor length should be 8 mm.

• Check for correct terminal number.

• Insert each conductor, according to the terminal numbering, and tighten the screw. Over-tightening or applying excessive pressure to the screw terminal is unnecessary and could damage the connector.

• If a signal cable has a screen then this may be terminated in the same way to the

earth bar on the front edge of the carrier.

Note: The screen at the field end should be left unterminated.


Carrier Earth Bar The front edge of the carrier, adjacent to the field terminals, contains an earthing bar with screw terminals for the purpose of terminating cable screens, or protective mains earths from field wiring.

Although there is a connection point for every channel they are not always directly below the corresponding channel connection point. However, they are arranged in groups of eight, and therefore easily recognizable.

An additional terminal is provided at each end of the earth bar for interlinking carrier earths, or for connecting them to a central earth point.

Recommendations on how best to ground the carriers for maximum EMC protection are provided in INM8900 –8000 I/O Power Supplies. Refer to the section, Related Documents.

Fitting I/O Modules Once the field terminal assembly is installed, the I/O module can

be mounted. The installer MUST be aware of the following two

classifications of I/O module:

• 2/2 Grey plastic moulding with black legend

• 2/1 Grey plastic moulding with blue legend

The 2/1 type is used for hazardous area applications (not discussed here). The 2/1 type must be used if the associated field wiring, instruments and actuators are located, without any further protection, within a hazardous area that conforms to Zone 1 (European) or a Division 1(US) classification. An appropriate field terminal must also be used in conjunction with the I/O module.

To fit an I/O Module to the carrier

1. Confirm that the module is compatible

with the field terminal. (Refer to the section, Compatibility of Field Terminal and I/O Module.)

2. Locate the module on the carrier and field terminal connectors.

3. Push the module onto the connectors until it is fully seated.

4. Lock in place with the retaining screw.

Do not overtighten; otherwise damage could occur.

The maximum torque that can be applied safely is 0.11 Nm (1 in-lb).

NEVER attempt to force a module into place on the carrier or field terminal. This can damage the connector pins which may result in hazardous equipment. If a module does not appear to fit correctly, check the module type again and confirm it is the correct type to suit the field terminal and carrier.

Vacant I/O Module slots

I/O module slots can be left unoccupied, with or without field terminals fitted.


Wiring and Cabling Guidelines

Installation and Cable Routing Guidelines Power supply wiring is equally susceptible to induced voltage and current spikes as signal cabling. It should therefore be installed with the same precautions in mind.

Installation practices vary throughout the world and so local rules and practices must be observed. Some general rules for installation are offered below but local rules will always take precedence.

Inside a Building

To avoid interaction of signals and the influence of power spikes when-Laying cables and wiring inside a building, EMC rules for minimum clearances between adjacent cabling should be observed.

Outside a Building

The same rules that apply to wiring and cabling inside a building will apply to wiring outside of a building; however, some additional rules could also be observed:

• Cables should be laid on metal cable trays

• The trays should be electrically connected (preferably at the joints)

• The metal trays should be electrically grounded

• Appropriate measures should be taken, both inside and outside a building, to protect

installations from lightning strikes.

Protective Circuits for Inductive Field Devices Discrete inputs and outputs may be subjected to induced over-voltages when inductive field devices (such as relay coils and contactors) are being switched, or monitored, by them. A typical application might be when an Emergency Stop function is wired in series with critical electrical loads. It is advisable that the following protective measures be taken to avoid damage to modules.

Protecting DC Discrete Input Circuits

When discrete inputs are used to sense a contact closure in a field device, some form of arc suppression should be used at the contact of the field device. This could be an R-C suppression network, sometimes referred to as a snubber or a varistor. Sizing of the suppression component(s) is load dependent and reference should be made to the manufacturer’s literature. If manufacturer’s information is not available, refer to the section, Calculating Values for R-C Suppression Components.


Protecting DC Discrete Output Circuits While 8000 I/O DC output modules have their own built-in protection it is recommended that some additional form of suppression is added at the field device to avoid EMC problems from the field wiring. A reverse diode or an R-C suppressor (refer to the figure, R-C Suppression Network) is often used to protect a relay coil when being switched in a DC circuit.

AC Discrete Output Circuits

All of the AC discrete output modules in the 8000 I/O series use a zero-crossing technique for switching their outputs which greatly reduces the production of voltage spikes when switching inductive loads. The use of additional external suppression circuits is unlikely to be required.

Calculating Values for R-C Suppression Components

If manufacturer’s information is not available, the following suggestions may be used to calculate resistor and capacitor values for suppression networks. (The calculations are all based on units of volts and amperes.)

For DC applications:

R (ohms) is sized as R = VDC ÷ Iload

C (µF) is sized as C = Iload x 0.5

For example, when switching 24 V DC with a 500 mA steady state load

R = 24 ÷ 0.5 = 48 Ω

C = 0.5 x 0.5 = 0.25 µF

For AC applications:

R (ohms) is sized as R = Vrms ÷ 0.5

C is sized as 0.5 µF per VA of steady state load

For example, when switching 120 V AC with a 500 mA steady state load

R = 120 ÷ 0.5 = 240 Ω

C = 0.5 x 120 x 0.5 = 30 µF

The rating of these devices should be calculated on the basis of the applied voltages and the load current being switched. If you are in any doubt about choosing these components you are advised to consult GE or one of our local representatives.

Warning - Electrical installation of the 8000 I/O must always comply with all relevant local standards, codes of practice and site regulations. Additional rules will apply if the 8000 I/O is being used in hazardous environments (such as explosive gas or dust).

If the field wiring originates in, or passes through, a hazardous environment then the type of equipment installed, and the wiring practices used, will be very different and the user is referred to alternative installation guides which deal with these practices.


Maintenance

Do not perform control settings for which there is no guidance or documentation available.

Contact GE for assistance, or go to www.support.ge-ip.com for guidance.

Fuses

The only user-replaceable fuses in 8000 I/O Series products are those used in the fused Field Terminals. These fuses are marked with their rating and only replacements of the same rating may be used. Replacements are available.

All other fuses are located inside the products and specialist equipment is necessary to affect their replacement. Products suspected of having damaged internal fuses (or any other internal fault) should be returned for repair.

Cleaning

During routine cleaning of the equipment, liquid cleaning agents that may remove product markings should not be used. If product markings are inadvertently removed, contact GE for replacements.

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Appendix A Mounting Dimensions

To assist the panel designer in-Laying out a system, the carriers have been classified in the groups provided in the table, Carrier Groups.

The drawings for the individual types are shown on the following pages. Each carrier has a reference datum hole. The dimensioning table, Offset Dimensions between Carrier Datum Holes, has been constructed to show the required offset, in the x and y direction from one carrier’s datum hole to that of the following carrier.

Carrier Groups

CONTROLLERS

CONTROLLER / EBIM CARRIER

CONTROLLER / EBIM CARRIER – FLOATING EARTH CONTROLLER / EBIM CARRIER - HEALTH MONITOR

8750-CA-NS

8751-CA-NS 8753-CA-NS

8-UNIT WIDTH

I/O 8 MODULE CARRIER (32 SLOT ADDRESSING)


I/O IS 8 MODULE CARRIER (32 SLOT ADDRESSING)


NODE SERVICES CARRIER (MODBUS)

NODE SERVICES CARRIER (PROFIBUS)

8707-CA-08

8709-CA-08

8727-CA-08

8729-CA-08

8711-CA-NS

8712-CA-NS

4-UNIT WIDTH



NODE SERVICES CARRIER (NSM)

REDUNDANT BIM CARRIER

8710-CA-04

8720-CA-04

8718-CA-NS

8701-CA-BI

2-UNIT WIDTH

BIM CARRIER

PSU

RAILBUS ISOLATOR CARRIER

IS PSU

8715-CA-BI

8717-CA-PS

8723-CA-RB

8724-CA-PS

1-UNIT WIDTH CARRIER EXTENDER (LEFT HAND)

IS CARRIER EXTENDER (LEFT HAND)

8021-CE-LH

8031-CE-LH


Offset Dimensions between Carrier Datum Holes

Following Carrier

8- unit Width 4- unit Width 2- unit Width 1- unit Width

Leading Carrier

x + →

y + ↑

x + →

y + ↑

x + →

y + ↑

x + →

y + ↑

Controller 257.5 mm 67.5 mm 247 mm 67.5 mm 204.75 mm 63.5 mm 215.5 mm 65.75 mm

8- unit Width 339.5 mm 0 mm 329 mm 0 mm 286.75 mm 4 mm 297.5 mm 1.75 mm

4- unit Width 182 mm 0 mm 171.5 mm 0 mm 129.25 mm 4 mm 140 mm 1.75 mm

2- unit Width 140 mm 4 mm 129.5 mm 4 mm 87.5 mm 0 mm 98 mm 2.25 mm

1- unit Width 87.5 mm 0.5 mm 77 mm 0.25 mm 34.75 mm 3.75 mm – –

Example

An 8707-CA-08 (I/O module carrier) is to be followed by an 8723-CA-RB (Railbus Isolator carrier), as follows:

1. From the table, Carrier Groups, the 8707-CA-08 has an 8-unit width and the 8723-CA-RB has a

2-unit width.

2. From the table, Offset Dimensions between Carrier Datum Holes , select the 8-unit width row (leading carrier) and follow it across to the 2-unit width column (following carrier) to find the x offset of 286.75 mm and the y offset of 4 mm.

3. Mark the position of the 8707 carrier, based on the dimensions, and measure 286.75 mm to the

right of its datum hole position and 4mm up to locate the position of the datum hole for the 8723 carrier.


Controllers

Controller Carrier


8-unit Width Carrier


Appendix B Field Terminal Connections

Identify the terminal type in the following table and refer to the corresponding diagram for connection details.

Terminal Type Diagram # 8601-FT-NI 1 8602-FT-ST 1 8603-FT-FU 1 8604-FT-FU 1 8605-FT-TC 2 8606-FT-RT (2-wire) 3 8606-FT-RT (3-wire) 4 8606-FT-RT (4-wire) 5 8610-FT-NA 1 8611-FT-FU 1 8615-FT-4W 1 8617-FT-NI 6 or 7 8618-FT-MT Refer to Datasheet 8619-FT-MT Refer to Datasheet 8650-FT-PX Refer to Datasheet

Diagram 1

Diagram 2

Diagram 3

Diagram 4

Diagram 5


Diagram 6

Diagram 7 (for 8125 and 8127)


Appendix C Glossary

2/2, 2/1, 2/x Applications are available for general-purpose and hazardous areas. Refer to the section, Application Code.

Bussed Field Power

Some field circuits located in safe areas, Division 2 or Zone 2 hazardous areas, require electrical power for them to operate correctly. The 8000 I/O series I/O modules can provide this power directly at the field terminal assembly using Bussed Field Power (BFP). Connectors are provided at the top/rear of 2/2 carriers and power is routed directly to one or more field terminal assemblies as required. This avoids extra power supply wiring at the field terminals.

Intrinsic Safety

Intrinsic safety (IS) is a circuit protection technique used in I/O applications where there is a risk of explosive atmospheres. The IS components restrict the electrical energy available to the area, thus preventing sparks that might be capable of igniting the combustible atmosphere.

Railbus

Both a digital signal bus that carries control information between the BIM and the I/O modules, and a power supply bus that distributes 12 V dc supply rail to all modules. It is distributed to the modules through the carrier board, and continues from one carrier to the next through multi-pin connectors.

Railbus Isolator

When IS and non-IS field wiring is accommodated at a single node, an isolating barrier is required between the two sections to prevent fault voltages being carried to the IS section through the Railbus. The Railbus Isolator provides galvanic isolation between the two sections.


Appendix D ATEX Information

The Essential Health and Safety Requirements (Annex II) of the EU Directive 94/9/EC (ATEX Directive - Safety of Apparatus) requires the installation manual of all equipment used in hazardous areas shall contain certain information. This annex ensures this requirement is met and complements the information presented in this document. Note: This Annex is only relevant to those locations where the ATEX Directives are applicable.

1. General

a. Consistent with all other electrical apparatus installed in hazardous areas, this apparatus must only be installed, operated and maintained by competent personnel. Such personnel shall have undergone training, which included instruction on the various types of protection and installation practices, the relevant rules and regulations, and on the general principles of area classification. Appropriate refresher training shall be given on a regular basis. Refer to clause 4.2 of EN 60079-17.

b. This apparatus meets the requirements of protection 'n' in accordance with EN 60079-15. c. This apparatus has been designed and manufactured to provide protection against all the

relevant additional hazards referred to in Annex II of the directive, such as those in clause 1.2.7.

2. Installation a. The installation shall comply with the appropriate European, national, and local

regulations, which may include reference to the IEC code of practice IEC 60079-14. Particular industries or end-users may have specific requirements relating to the safety of their installations that must also be met. For the majority of installations the Directive 1999/92/EC (ATEX Directive - Safety of Apparatus) is also applicable.

b. This apparatus is normally mounted in a non-hazardous [safe] area; however, it also meets the requirements of Category 3 apparatus and may be installed in a Zone2 location providing that the relevant installation conditions are met.

c. This apparatus must not be subjected to mechanical and thermal stresses in excess of those permitted in the certification documentation, this manual, and the product specification. If necessary, the product must be protected by an enclosure to prevent mechanical damage.

d. The apparatus must not be installed in a position where it may be attacked by aggressive substances and must be protected by an enclosure from excessive dust, moisture, and other contaminants.

e. To avoid hazardous-area conditions, refer to ATEX Category 3 certificate, GE Intelligent Platforms Cat 3 Certificate 8753 (available at www.support.ge-ip.com).

3. Inspection and maintenance a. Inspection and maintenance should be carried out in accordance with European, national

and local regulations, which may refer to the IEC standard IEC 60079-17. Specific industries or end-users may have specific requirements which should also be met.

b. Access to the internal circuitry must not be made during operation. c. If the outer enclosure of the apparatus needs to be cleaned with a cloth lightly moistened

by a diluted mixture of detergent in water.

4. Repair The product cannot be repaired by the user and must be replaced with an equivalent certified product by the manufacturer or an authorized GE agent.

5. Marking The products are labelled as follows. Additionally, the serial number and/or date of manufacture are marked on the individual apparatus. This document applies to products manufactured and date-marked during or after the year 2005.

The following information is provided on each component:

Company Logo:

Company Name and Address: GE Intelligent Platforms, Inc. Charlottesville, VA

European compliance mark: 1725

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Note: Special conditions of use are not marked on the products, but are part of the product certification details.

8101-HI-TX 8-channel AI, 4-20mA with HART® II 3 G Ex ic nL IIC T3 @+70°C Ex ic nL IIC T4 @+60°C –40 to +70°C Special conditions of use: Apparatus must be used with the 8601-FT-NI, 8603-FT-FU or 8615-FT-4W field terminals.

8111-DI-AC 8-channel DI 115V AC isolated sinking

II 3 G Ex [ic] nA nL IIC T4 –40 to +70°C

8102-HO-IP 8-channel AO, 4-20mA with HART

II 3 G Ex ic nL IIC T4 –40 to +70°C Special conditions of use: Apparatus must be used with the 8601-FT-NI or 8603-FT-FU field terminals.

8112-DI-AC 8-channel DI 115V AC non-isolated module-powered


8103-AI-TX 8-channel AI, 4-20mA

II 3 G Ex ic nL IIC T3 @+70°C Ex ic nL IIC T4 @+60°C –40 to +70°C Special conditions of use: Apparatus must be used with the 8601-FT-NI or 8603-FT-FU field terminals.

8113-DI-AC 8-channel DI 230V AC isolated sinking


8104-AO-IP 8-channel AO, 4-20mA

II 3 G Ex ic nL IIC T4 –40 to +70°C Special conditions of use: Apparatus must be used with the 8601-FT-NI or 8603-FT-FU field terminals.

8114-DI-AC 8-channel DI 230V AC non-isolated module-powered


8105-TI-TC 4-channel THC/mV input

II 3 G Ex ic nL IIC T4 –40 to +70°C

8115-DO-DC 8-channel DO 2-60V DC non-isolated, module-powered


8106-TI-RT 4-channel RTD input

II 3 G Ex ic nL IIC T4 –40 to +70°C Special conditions of use: Apparatus must be used with the 8606-FT-RTfield terminal.

8116-DO-AC 8-channel DO 20-265V AC non-isolated, module-powered


8109-DI-DC 8-channel DI, 24V DC isolated, sinking


8117-DO-DC 8-channel DO 2-60V DC isolated, unpowered


8110-DI-DC 8-channel DI 24V DC non-isolated module-powered


8118-DO-AC 8-channel DO 2-65V DC isolated, unpowered

II 3 G Ex [ic] nA nL IIC T3@ +70°C Ex [ic] nA nL @ +60°C –40 to +70°C


Uo = 1.5 V Io = 1 µA Po = 1.5 µW Ui = 25 V Ii = N/A

Connection to Millivolts, Volts, or Thermocouples when Hazardous Area Contains Power Source Group Co (µF) Per Channel Lo (mH) Per Channel

IIC 1000 1000 IIB 1000 1000 IIA 1000 1000

Uo = 36 V Io =2µA Po = 7.2 µW Ui = N/A Ii = 25 mA

Connection to 4-wire Transmitters when Hazardous Area Contains Power Source Group Co (µF) Per Channel Lo (mH) Per Channel

IIC 1000 104 IIB 1000 415 IIA 1000 829

Uo = 20 V Io =75 mA Po = 1.5 µW

Connection to Any Combination of Four Terminals Group Co (µF) Per Channel Lo (mH) Per Channel

IIC 0.61 11.5 IIB 3.76 46 IIA 14.6 92

8521Controller Ex ic nL IIC T4 –40 to +70°C Special conditions of safe use: 1. The apparatus must be installed in an enclosure or an

environment that provides a degree of protection not less than IP54 when used in Zone 2.

2. In order to comply with the transient requirements, the voltage for this apparatus must be provided by regulated power supply units complying with the requirements of European Community Directives.

3. Where the interconnecting cable utilizes part of a multi-core cable containing other intrinsically safe circuits, then the multi-core cable shall be in accordance with the requirements of a multi-core cable type A or B, as specified in Clause 9 of IEC 60079-25.

4. A multi-core cable containing circuits classified as level of protection “ia”, “ib” or “ic” shall not contain non-intrinsically safe circuits.

8753-CA-NS Simplex Carrier Ex nA nL IIC T6 –40 to +70°C Special Conditions of Safe Use 1. The equipment shall be installed in a suitable equipment

enclosure which is capable of accepting one or more of the Class I, Division 2 wiring methods specified in the National Electrical Code (ANSI/NFPA 70) or the Canadian Electrical Code (CSA C22.1) as appropriate, meets the requirements of ANSI/ISA 82.02.01 or CSA C22.2 No. 1010 and is in compliance with the enclosure, mounting, spacing and segregation requirements of the ultimate application.

2. The equipment shall be installed in a suitable equipment enclosure which is capable of accepting one or more of the Class I, Zone 2 wiring methods specified in the National Electrical Code (ANSI/NFPA 70) or the Canadian Electrical Code (CSA C22.1) as appropriate, meets the requirements of ANSI/ISA 82.02.01 or CSA C22.2 No.1010 and is in compliance with the enclosure, mounting, spacing and segregation requirements of the ultimate application.

GE Intelligent Platforms 1-800-433-2682 1-434-978-5100 www.ge-ip.com

INM8100A

For Public Disclosure

General-purpose and 2/2 Applications with SafetyNet

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Transcript of General-purpose and 2/2 Applications with SafetyNet