Application note

October 2016
MTL fieldbus networks AN9026 Rev 4

FISCO Intrinsically
Safe Fieldbus System
Contents AN9026 Rev 4

1 INTRODUCTION ........................................................................................................................................................ 1
1.1 About this document ................................................................................................................................................................. 1
1.2 Background ............................................................................................................................................................................... 1
1.3 Principle ..................................................................................................................................................................................... 1
1.4 Cables ......................................................................................................................................................................................... 1
1.5 Power supplies ........................................................................................................................................................................... 1
1.6 Field devices............................................................................................................................................................................... 2
1.7 Documentation and inspection ................................................................................................................................................. 2
1.8 Conclusion ................................................................................................................................................................................. 2

2 POWER SUPPLIES ..................................................................................................................................................... 2

2.1 Introduction ............................................................................................................................................................................... 2
2.2 Intrinsically safe output ............................................................................................................................................................ 3
2.3 Host port .................................................................................................................................................................................... 3
2.4 24V supply ................................................................................................................................................................................. 4
2.5 Screen terminals ........................................................................................................................................................................ 4
2.6 Status indicators ........................................................................................................................................................................ 4

3 CONNECTING FIELD DEVICES TO A FISCO SUPPLY ..................................................................................... 4

3.1 Introduction ............................................................................................................................................................................... 4
3.2 Output voltage and current ...................................................................................................................................................... 4
3.3 Cable resistance ......................................................................................................................................................................... 5
3.4 Field device, voltage and current ............................................................................................................................................. 5
3.5 Typical calculation for IIC (9121-IS) power supply ............................................................................................................... 6
3.6 Typical calculation for a IIB (9122-IS) power supply ............................................................................................................ 6
3.7 Connecting “Entity certified” field devices ............................................................................................................................. 7
3.8 Connecting Zone 0 field devices ............................................................................................................................................... 8
3.9 Configuration tool ..................................................................................................................................................................... 8

4 COMMISSIONING AND FAULT FINDING ........................................................................................................... 8

4.1 Introduction ............................................................................................................................................................................... 8
4.2 Facilities ..................................................................................................................................................................................... 8
4.3 Resistance checks on cable........................................................................................................................................................ 9
4.4 Specialist test equipment .......................................................................................................................................................... 9
4.5 Procedure................................................................................................................................................................................... 9

5 CABLES AND ACCESSORIES ............................................................................................................................... 11

5.1 Cables ....................................................................................................................................................................................... 11
5.2 Terminators ............................................................................................................................................................................. 11
5.3 Interconnection blocks and enclosures .................................................................................................................................. 11

6 SURGE PROTECTION............................................................................................................................................. 12
6.1 Introduction ............................................................................................................................................................................. 12
6.2 Compatible surge protection devices ..................................................................................................................................... 13
6.3 Protecting the system .............................................................................................................................................................. 13

7 MOUNTING OF FISCO POWER SUPPLIES IN ZONE 2 AND DIVISION 2 ................................................... 15

7.1 General..................................................................................................................................................................................... 15
7.2 Typical installation.................................................................................................................................................................. 15
7.3 Mounting of the units in Zone 2 or Division 2....................................................................................................................... 15
7.4 Maintenance and fault finding ............................................................................................................................................... 16
7.5 Further combinations ............................................................................................................................................................. 16

i
8 CERTIFICATION AND SAFETY DOCUMENTATION OF FISCO SYSTEMS ............................................... 16
8.1 Introduction ............................................................................................................................................................................. 16
8.2 MTL FISCO power supplies .................................................................................................................................................. 16
8.3 MTL terminator ...................................................................................................................................................................... 17
8.4 MTL 24V Zone 2/Division 2 power supply ........................................................................................................................... 17
8.5 Cables ....................................................................................................................................................................................... 17
8.6 Enclosures and glands............................................................................................................................................................. 17
8.7 Simple apparatus..................................................................................................................................................................... 17
8.8 Safety documentation.............................................................................................................................................................. 17
8.9 Safety documentation for a FISCO system ........................................................................................................................... 18

9 APPENDIX I: SIMPLE APPARATUS AND THE ATEX DIRECTIVE ............................................................. 19

9.1 Introduction ............................................................................................................................................................................. 19
9.2 Standards ................................................................................................................................................................................. 19
9.3 Conclusion ............................................................................................................................................................................... 19

10 APPENDIX II: EXTRACT FROM BS EN 50020: 2002 ........................................................................................ 19

ii
1 INTRODUCTION 1.4 Cables
One of the more interesting results of the experimental work was
1.1 About this document that adding standard instrument cable to a power supply reduces
the incendivity of the system rather than increasing it. Previously it
This application note is a practical guide to the selection, was assumed that the cable inductance and/or capacitance stored
installation and maintenance of equipment complying with the energy would be available to supplement the energy available from
Fieldbus Intrinsically Safe Concept (FISCO). The document begins the source of power. The experimental evidence however suggests
with a discussion of the origins of FISCO and an introduction to the that the cable parameters, because of their distributed nature,
main elements that should be considered when assembling FISCO modify the form of the test apparatus spark so as to make it less
systems. Later sections then develop each subject in more detail, incendive and there is also some theoretical analysis to support this
with the intention of providing clear guidance to new and view.
experienced fieldbus users.
However because the experimental work covers only a limited
The document will be updated regularly to reflect changes in practice range of cable parameters, circuit voltage and current, it was
and to incorporate new information as it emerges. Please make sure considered prudent to limit the acceptable cable parameters in a
you have the most recent version by visiting the MTL website FISCO IS circuit to those in Table 2.
www.mtl-fieldbus.com or contacting your local Eaton
representative. (The issue number of this application note is shown Parameter Value
on the top right-hand corner of the Contents page.) We welcome
comments and constructive criticism of the text, which should be Loop resistance 15T/km to 150T/km
directed by email to [email protected]
Loop inductance 0,4mH/km to 1mH/km
The commonly used term ‘H1’ is used in the text to describe the low
Capacitance 45nF/km to 200nF/km
frequency fieldbus (31.25kbits/s) as defined by FOUNDATION
fieldbus. Maximum length of each spur
60m in IIC and IIB
cable
IEC terminology is used throughout the document when referring to
Gas and Apparatus Groups. North American equivalents are as Maximum total cable length 1km in IIC and 5km in IIB
follows: Table 2 - FISCO cable parameters

IEC North America These limits are not restrictive, as a typical fieldbus trunk cable has
parameters of 50T/km, 0,8mH/km and 120nF/km. The length of the
IIC (Hydrogen) Groups A, B trunk is usually determined by the operational requirements. The
IIB (Ethylene) Group C restriction of the length of the spurs can occasionally be irritating
but if necessary this can be ameliorated by the use of additional
Table 1 - Gas group comparison
current limitation.
In the longer term this work on cables may be applied to the design
1.2 Background
of all IS systems. This would require further work to determine the
The increase in the use of fieldbus systems in hazardous areas was limits that are applicable, and consequently for the time being the
given a significant boost by the development of an international (IEC) relaxation is only being applied to fieldbus systems.
standard for intrinsically safe (IS) fieldbus systems. This standard was
based on experimental evidence and theoretical analysis done by the 1.5 Power supplies
German certification body PTB, and became known as the Fieldbus
Intrinsically Safe COncept (FISCO). The first edition of the full The FISCO standard utilises recent work on the ignition capability of
standard (IEC 60079-27) was published in April 2005. constant current power supplies to propose acceptable levels of power
for supplies with a ‘rectangular’ characteristic, as opposed to those with
The document is the first significant attempt to simplify the a falling, resistor-limited characteristic. This permits a greater useable
application and documentation requirements of IS systems in the power for the fieldbus trunk, particularly if the less sensitive gas group
last fifty years. All the standards for explosion protection have IIB (Ethylene) meets the installation requirements.
become steadily more restrictive and more complex with time, and
the FISCO standard is a refreshing departure from this trend.
x
1.3 Principle 300

PTB in collaboration with German industry examined the intrinsically x Safety

safe needs of the 31,25 kbit/s physical layer of fieldbus and
developed an approach applicable to both Profibus-PA and Operational
FOUNDATION fieldbus H1 systems. A PTB report W-53e dated x
August 1994 provided details of the experimental evidence and the
initial thinking on which an IEC document was based. From this x
proposal, the IEC standard has emerged with only very minor
modifications. The result is a comprehensive document, which covers
all aspects of a low frequency fieldbus system allowing a system to be
built with only minimum analysis of the safety requirements and very
simple documentation. The design/manufacture of the apparatus was 16
made slightly more difficult so that the system configuration could be OUTPUT VOLTAGE (V)
made easier. Arguably this has tended to improve safety as the
apparatus is certified, with the manufacturer subjected to surveillance, Figure 1 - Current versus voltage curves for fieldbus power supplies
while system design and installation is less tightly controlled.
The use of active current limitation restricts the categorisation to ‘ib’, but
The initial IS fieldbus proposal was restricted to ‘ia’ IIC sources of it is not usual for a fieldbus trunk to be installed in a Zone 0. Any spur
power, while the FISCO specification permits power supplies to use which is directly associated with a Zone 0 can be further protected
non-linear regulation and the lower apparatus (gas) group IIB. This to achieve ‘ia’ status. The original Foundation Fieldbus requirement
makes considerably more power available to the IS trunk and was for a ‘IIC ia’ power supply, which was very restrictive, as
consequently enables more field devices to be supported on each indicated by the curves for the MTL5053 in Figure 1.
IS trunk.
The available power is always considerably less than that of the
safety description and Figure 1 illustrates the available power
achieved by the MTL FISCO power supplies. The calculation of
how many field devices can be powered from a power supply is a

1
relatively simple application of Ohm’s Law. The user takes into The 5,32W dissipation usually requires some form of power
account the current consumption of each field device, the voltage limitation in each device so as to achieve a T4 temperature
drop in the trunk cable, and the fact that field devices require 9V to classification but there are fairly standard methods of doing this
operate. If the assumption is made that the field devices require without much difficulty. It is possible to utilise devices certified to
20mA and are all at the remote end of the IS trunk, then the the original fieldbus specification by introducing some power
number of devices which can be powered from the MTL IIC power limitation in the spur. This does however require a small
supply is five at the end of a 600m trunk. The corresponding IIB modification to the supporting documentation.
power supply will supply twelve devices at the end of a 300m trunk,
demonstrating the desirability of a IIB gas classification where that
is acceptable. The number of devices connected to a bus is also
1.7 Documentation and inspection
determined by the plant layout, and by consideration of the system A major benefit of the FISCO system is that no detailed analysis is
reliability. The number of devices is usually quite low, five or six, necessary to ensure the safety of the system, and additions do not
with ten being unusual. If the available trunk length is a limitation, require a revaluation of the whole system. The gas group of the
moving the repeater power supply into the field, (which may be a system is determined by the power supply, and the temperature
Zone 2 or Division 2) may provide a solution. classification of each piece of apparatus by its certification (usually
A typical power supply is as illustrated in Figure 2. This power T4).
supply incorporates isolation from its source of power and the host The documentation is only a list of the connected apparatus. This
bus, the necessary terminator, and some diagnostic capability. is normally done electronically and can readily cross-refer to the
These are not FISCO requirements but are operationally desirable. certification documents of the apparatus.
Power In Host Fieldbus
19.2V to 30V A further advantage of this system is that inspection procedure is
_ _ simplified to ensuring that the system is unchanged and
+ + S +
1 2 3 4 5 6 undamaged. Many of the field devices carry a unique identifier and
Host Power part of the inspection procedure can be done automatically as part
14 to 32 Vdc of the ‘asset management’ program. An occasional inspection for
T 30mA
mechanical damage is still necessary, but if the equipment is
unchanged and operational it is unlikely to be unsafe.
Documentation requirements of FISCO systems are described in
more detail in Section 8.

1.8 Conclusion
When a full range of FISCO devices are available it will be possible
T to assemble a system without a detailed analysis and
documentation, confident in the knowledge that it will be safe. It will
7 8 9 SAFE AREA / ZONE 2 / DIV 2 be simpler and possibly safer than the equivalent conventional
_ ZONE 1 / DIV 1 system.
+ S
IS Fieldbus The use of non-linear power supplies enables sufficient field
devices to be connected to a single trunk, particularly if a IIB gas
classification is acceptable.
The FISCO technical specification is the first simplification of
explosion protection standards since the rationalisation of the gas
grouping. “For these small mercies, much thanks”.

2 POWER SUPPLIES

2.1 Introduction
MTL’s FISCO power supplies are designed to meet the
requirements of the International Electrotechnical Commission
(IEC) technical specification IEC 60079-27 and provide power and
the signal repeater function for an intrinsically safe bus designed in
accordance with that specification.
The basic functions of the power supply are illustrated by Figure 3,
which also shows a common but simple application. The power
supply is shown mounted in a safe area. It may be mounted in a
Zone 2 or Division 2 location, as discussed in Section 7 of this
application note.

Figure 2 - FISCO power supply

Refer to Section 2 for a more detailed discussion of power supplies

for FISCO.

1.6 Field devices

The specification of the fieldbus field devices is determined by the
requirement to be compatible with the power supplies and also that
additional devices can be added to a system without having to
reconsider the system safety. All devices have to be certified IIC
and have input parameters of voltage [Ui] 17,5V, current [Ii] 380mA,
power [Pi] 5,32W, capacitance [Ci] 5nF and inductance [Li] 10µH.
Devices may have any temperature classification but the majority
will be T4 (135oC).

2
 May contain
power source HOST Model Apparatus Safety Description Useable Output
and number Class
terminator T Uo Io Po

V mA W V mA

9121-IS IIC 14 180 2,52 12,4 120

L HOST
TRUNK 9122-IS IIB 14,8 359 5,31 13,1 265
N 24V Table 3 - Power supply output characteristics
supply
E
These values are indicated on the curves of Figure 1 and
1 + 2
_ 3 + 4
_ 5S 6 + interconnected by a broken line. The choice of output voltage is
Host Power
14 to 32 Vdc
made so as to maximise the number of field devices that can be
T 30mA
connected to each power supply.
FISCO The use of active semiconductors to limit the current, results in the
POWER
SUPPLY power supplies being restricted to category 'ib’ level of protection in
accordance with the IEC apparatus standard. This restriction was
imposed because of concern about possible transients, and with
T
_
the state of knowledge at the time of the decision it was decided
+ 8 S 9
7
that the risk was not acceptable in Zone 0 locations. In practice the
MTL power supplies have three stages of voltage limit and two
stages of current limit so that they satisfy the US requirements for
SAFE AREA
intrinsically safe apparatus for use in locations which are area
classified by Divisions, including areas of continuous hazard.
ZONE 1 / DIV 1
The bi-directional fieldbus signal has to be developed across the
5 devices (110mA) in IIC IS power supply and be transferred to the host port, which repeats the
TRUNK
signal to the host. This means that the power supply must have low
12 devices (250mA) in IIB impedance at low frequencies to give a constant voltage as a
source of power, and high impedance at the signal frequency of
31,25kbits/sec. This shaped impedance characteristic is achieved
by using an active filter, which must operate without adversely
T affecting the IS characteristics of the power supply.
Figure 3 - Block diagram of simple FISCO system The IS trunk must be correctly terminated at each end and a
The power supply converts a 24V supply to an intrinsically safe permanently connected terminator for this purpose is included in
power supply which feeds the IS trunk. The fieldbus signal, which is the power supply.
superimposed on this voltage, is fed into a repeater for The IS output is separated from the source of power and the
transmission to and from the system host. repeated fieldbus signal so as to satisfy the intrinsic safety
There are two MTL FISCO power supplies: the 9121-IS is suitable requirements of isolation to withstand 250V. This three port
for use where a IIC (hydrogen) apparatus classification is required, isolation simplifies the design of the IS system since it removes the
and the 9122-IS, where a IIB (ethylene) classification is adequate. possibility of interaction between the circuits. A further advantage is
They differ only in output characteristics, the IIB version having that it removes the possibility of interaction between earth faults on
more output power. the different circuits, which are frequently the cause of operational
faults. This type of fault is extremely difficult to diagnose. Normally
Throughout this document the trunk-cable screens are shown the IS fieldbus circuit is operated in a fully floating mode, without
earthed or bonded at a single point. any direct connection to earth. A single earth fault unbalances the
circuit and introduces some noise. In most cases the circuit
• The host-trunk screen would normally be connected to the continues to operate, but it becomes noisy and less reliable.
control system earth, which is shown by the symbol . However the circuit may fail completely. Multiple earth faults on the
same circuit invariably lead to operational failure. From an intrinsic
• The IS-trunk screen would usually be bonded locally to the safety viewpoint there is a requirement that an intrinsically safe
plant structure, where the FISCO power supply is located, and circuit should normally be fully floating or earthed/grounded at one
is shown by the symbol . point, and some codes suggest that isolation should be periodically
This is the usual, but not the only, acceptable practice. The checked. The IS fieldbus circuit is self-checking in respect of
guidance of IEC 60079-14 should be followed at all times. multiple earths and hence an isolation check on a functional
system is not necessary.

2.2 Intrinsically safe output

2.3 Host port
The permitted safety description of FISCO power supplies is
defined in the FISCO specification. Both Foundation Fieldbus H1 The connection for the repeater trunk, which is usually the
and Profibus PA organisations have adopted and utilised the connection for the host trunk, is a normal fieldbus port. The port
specification and the nominated values. The available power is requires 9V and a small quiescent current (less than 4mA) to
always less than that permitted by the safety description. The operate. The bi-directional signal transmitted through the repeater
FISCO specification clarifies the requirements of constant current is reshaped, thus improving the quality of the transmitted signal.
power supplies and this permits higher levels of power than that Since the galvanic isolation from the intrinsically safe supply is
available from a resistive limited source. designed to remain safe when connected to a source with the fault
capability of a 250V mains supply (Um: 250V), there is no
Figure 1 illustrated the available power for the different types of requirement for the host or host trunk to conform to any special
power source. The use of constant current power supplies also requirements. Any conventional arrangement is acceptable, and
means that the power dissipated in the unit is much lower and this avoids the special consideration necessary when lower values
consequently the power supply enclosure can be smaller. (The of Um are used.
MTL supplies occupy only 42mm of DIN rail.)
A major advantage of the three-port isolation of the MTL 9121-IS
The two lower curves relate to the conventional Foundation and 9122-IS power supplies is that both the host trunk and the 24V
Fieldbus source of power (such as the MTL 5053 fieldbus power supply can be operated with small common mode voltages or
supply), and the two higher curves relate to supplies with a referenced to different earths without any significant interaction
rectangular safety characteristic such as the 9121-IS and the 9122- between the ports. Normally these connections are earthed or left
IS MTL power supplies. The safety descriptions and useable output ‘floating’, and any common-mode voltages are small (less than
of the MTL FISCO power supplies are listed in Table 3. 36V). Although the design of the power supplies permits common

3
mode voltages as high as 250V, their use with high voltages in
normal operation introduces a number of practical problems and 2.5 Screen terminals
should be avoided. On those rare occasions where it is
unavoidable, then special consideration needs to be given to Terminals are provided for anchoring the screens/shields of both
personnel safety, for example additional marking would be the trunk cables. These terminals are not electrically connected to
necessary. The presence of high common mode voltages where anything inside the module, and only provide mechanical support.
the power supplies are mounted in Zone 2 or Division 2 requires The recommended practice is to secure a braided screen in a
very special consideration and, although possible, is not ferrule and secure it in the terminal. The drain wire of a wrapped
recommended. screen is normally secured by the terminal and the end of the cable
sleeved to tidy up the exposed wrapping.
The MTL 9121-IS and 9122-IS units contain a power supply which
can be used to power the host trunk. When the host trunk is The screens should be earthed/grounded at one end. Usually the
powered from the host, the supply in the MTL unit is switched out. IS trunk screen should be earthed at the FISCO power supply and
This power supply can provide up to 30mA within the permissible the host trunk screen earthed at the host.
voltage range of 14 to 32V, and provides sufficient power to meet
the requirements of most existing hosts which do not have a power 2.6 Status indicators
supply. It is important that a trunk has only one source of power,
unless specific attention has been given to ensure that an There are four LEDs on the front of the MTL FISCO power
impedance mismatch or undesirable circulating currents cannot supplies, and these can be used to establish the status of a
occur. The normal practice is therefore to use a single source of system. The green LED, marked ‘Pwr’ (power) indicates that the
supply, either the host or the power supply in the MTL unit. voltage across the intrinsically safe trunk output is present, thus
confirming that input power is present and the power supply is
In addition the unit contains a terminator which can be switched in functioning.
to terminate one end of the host trunk. There should only be one
terminator at the end of each trunk. Hence where additional field The red LED marked ‘Fault’ is lit when the current limit on the
devices or multi-dropped FISCO power supplies use the host trunk, intrinsically safe supply is activated. The most probable cause is
only the MTL unit at the end of the trunk should have its terminator either a fault on the cable or attempting to operate too many field
switched in. devices from the IS output. A quick initial check is to unplug the IS
output and the power supply should recover.
The configuration already illustrated in Figure 3 is the usual pattern.
However the host trunk can be used to interconnect other devices, The two yellow LEDs marked Host and IS are both permanently on
including other MTL power supplies. The limitations are usually the if the data chain on their respective trunks is healthy. If there are
amount of data that the host can use, the current available from the data communication errors the LEDs will either turn off or flash
host trunk power supply, and the resistance of the host trunk. In intermittently.
practice the small current required by the host port allows the host
A satisfactory installation should have the green power LED and
trunk to be very long (1,8km) unless field devices which require
the two yellow signal monitors permanently on and the red fault
very high standing currents also use this trunk. This attribute is
LED extinguished. The power supply thus provides a good basis for
useful if the power supply is used as a repeater to extend the
the initial analysis of the status of the system.
effective trunk length.

2.4 24V supply 3 CONNECTING FIELD DEVICES TO A

Since the intrinsically safe output is also galvanically isolated from
FISCO SUPPLY
the 24V connections with the capability to remain safe with a 250V
mains fault, then the unit providing the 24V feed to the FISCO 3.1 Introduction
power supplies can be any type of conventional construction. It is
recognised that the majority of switch mode power supplies This section considers how to design a working system using MTL
generate high voltages as part of their normal function, but these FISCO power supplies. The principal requirement is to ensure that
high voltages have limited potential fault power and apparatus there is an adequate voltage at the field device terminals to ensure
having Um: 250V is considered to be adequately protected against that it will function correctly. The necessary calculation is a simple
faults from this type of power supply. application of Ohm’s law, using the power supply operational output
voltage and output current, the cable resistance, the operating
The IIC FISCO power supply (9121-IS) requires 190mA at 24V and current of the field device and the minimum operating voltage of the
the fully loaded IIB supply (9122-IS) requires 300mA at 24V. The field device. Each of these factors can be considered separately.
FISCO power supplies have steering diodes associated with the
24V terminals so that if duplicate 24V supplies are used then a
common mode failure due to one supply failing does not occur. The 3.2 Output voltage and current
diodes also serve to prevent damage to the FISCO power supply if The minimum useable output voltage and current from the two
the 24V supply is accidentally connected the wrong way round. FISCO power supplies are listed in Table 4.
There are two MTL 24V power supplies suitable for this application.
The MTL 5991 operates over the voltage range 85 to 264Vac and Type number Apparatus class Useable output
supplies a minimum of 1.7A (output current 2A when the supply Volts (V) Current (mA)
voltage is greater than 105V). This is more than adequate for the
majority of safe area applications. Where a higher power is required 9121-IS IIC 12,4 120
or the power supply is to be located in a Zone 2 or Division 2, then 9122-IS IIB 13,1 265
the MTL power supply type 8914-PS-AC should be used. This
works over the same voltage range, provides up to 10A, and is Table 4 - Useable output from FISCO power supplies
approved for Division 2 use by FM and certified as Category 3 The output current determines the maximum number of field
apparatus in Zone 2 in accordance with the ATEX Directive. For devices that can be connected to the power supply even with
more information on these power supplies see their individual data relatively short trunk installations.
sheets available on www.mtl-inst.com.
Note: The output voltage specified is at 25oC, and is used in all
subsequent calculations since it represents a reasonable approach
to the majority of installations. The power supplies have a positive
temperature coefficient of 12mV/oC, which should be considered if
the power supplies are operated at lower temperatures. If the power
supply and fieldbus cable are operated at low temperatures, the
reduced resistance of the cable counteracts the lower output from
the supply.

4
3.3 Cable resistance 1 1 0 0 N– N+

The FISCO technical specification IEC 60079-27 requires that

cables comply with the following parameters:
1.0V
nom.
Parameter Value

Loop resistance 15T/km to 150T/km

Power bias
Loop inductance 0,4mH/km to 1mH/km (9V minimum)

Capacitance 45nF/km to 200nF/km

32µs
Maximum length of each spur
60m in IIC and IIB
cable
Time
Quiescent Active
Maximum total cable length 1km in IIC and 5km in IIB
Table 5 - FISCO cable parameters Figure 4 - Idealised voltage waveform of field device

These requirements must be met but are not usually a significant

limitation as all commonly used instrument cable complies with the
cable parameters specified. (Typically 50 T/km, 0,8 mH/km and
120nF/km). Occasionally the limitation on spur length is a slight 30mA
inconvenience but this can be usually overcome by careful
positioning of the field junction box. 20mA ± 10mA

Existing conventional wiring may be used for fieldbus installations, Typical

10mA quiescent
and frequently proves adequate. Where specialist cable is installed current
it is designed to meet the 100T characteristic impedance
requirement and is usually a screened, balanced, multi-stranded Time
twisted pair. The American version is normally seven strands of 18
Figure 5 - Idealised current waveform of field device
AWG, which has a loop resistance slightly less than 50T/km. The
European version is of similar multi-strand construction, equivalent For the majority of field devices the average current and the
to 1mm in diameter, having a maximum resistance of 44T/km at quiescent current are the same value. However when the quiescent
60oC. For the purpose of the example calculations in this current is below 10 mA the transmitting current is asymmetrical
application note the cable resistance is assumed to be 50T/km about the quiescent current and the average current rises to
since this is a reasonably practical figure. approximately 10mA. This phenomenon is illustrated in Figure 6
and should be taken into account when calculating the viability of a
system utilising low current devices. The increase in current is only
3.4 Field device, voltage and current relevant to the one active device in a system, and can be taken into
All fieldbus devices should operate satisfactorily with an average of account by adding 10mA to the total current consumed by the
9V at their terminals. It is desirable to have a small margin above system.
this, but the example calculations use this minimum figure. + +

The standing current required by field devices varies considerably.

A survey of currently available devices suggests a range from 10 to
Iq Iq
28mA with the majority requiring slightly less than 20mA. The 10mA 10mA
number of devices which can be powered from a given source is
largely determined by the current required and even a small change
can have a significant effect on the length of cable permitted or the
0 Time 0 Time
number of devices which can be connected. Where possible, the Receiving Transmitting Receiving Transmitting
actual current consumption of the field devices in a system should Iq < 1mA Iq = 5mA

be used to determine its acceptability. A figure of 20mA per device

+ +
is used in the illustrative examples since this gives a reasonably
prudent answer.
Iq Iq
If the average current required is reduced from 20mA to 15mA per
device, the number of devices that can be connected to the 9121- 10mA 10mA
IS (IIC) power supply increases from six to eight, and from thirteen
to seventeen for the 9122-IS (IIB) supply. This does not change
the useable trunk length significantly. 0 Time 0 Time
Receiving Transmitting Receiving Transmitting
Iq = 10mA Iq > 15mA
Figure 4 and Figure 5 illustrate the idealised voltage and current
waveforms on the terminals of a field device. It is the average value Figure 6 - Field device current waveforms
of the current drawn that is relevant to the power supply
performance. Similarly it is an average voltage of 9V which is
required at the field device terminals.

5
 The spurs are restricted to 60m by the FISCO standard and hence
3.5 Typical calculation for IIC (9121-IS) power have a resistance of less than 3 ohms and produce a voltage drop
supply of 60mV when carrying 20mA. Except in the cases where the
distribution unit contains voltage-dropping components, the voltage
The information necessary to be able to calculate whether a system drop in the spur can be ignored and hence the system will work if
will operate is the average current drawn by each of the field the trunk is less than 680m long. A similar calculation can be made
devices, and the resistance of the trunk cable. using a different number of field devices, or devices using different
currents. The two criteria to be applied are that the total current
A configuration, which is frequently used and is a simple illustration
drawn must not exceed 120mA and the voltage drop on the trunk
of the necessary calculation to determine operational capability, is
must not exceed 3,4V. For example, the trunk lengths
shown in Figure 7.
corresponding to six and three devices are 560m, and 1130m
HOST
respectively. Assuming that all the devices are at the remote end of
the trunk gives a simple calculation and a pessimistic answer,
T which ensures that the system will work. It is the usual practice to
do this calculation first and only resort to doing the more precise
calculation if the simple calculation gives an unsatisfactory answer.

L HOST There are a large number of variations on the interconnection of

TRUNK field devices to the trunk and the operational requirements can
N 24V
supply always be analysed by the application of Ohm’s law. Figure 8
E illustrates a possible configuration and demonstrates that if some of
1 + 2
_ 3 + 4
_ 5S 6 +
the field devices are moved closer to the power supply then the
permissible length of the trunk increases. If the devices are
IIC FISCO
T
POWER SUPPLY distributed at equal intervals along the trunk, the voltage drop on
9121 - IS each section decreases as the total current carried by that section
12.4 V 120mA of the trunk decreases. The resultant pattern that emerges is
illustrated on the diagram and the total trunk length increases to
750m.
T SAFE AREA
7 + 8 S 9
_ HOST

IS ZONE 1 / DIV 1 T
P I = 100mA TRUNK
680m
34T
3,4 V
I1
(20mA) HOST
L
NODE TRUNK
I5 9V N 24V
I2
supply
E
_ _
I4 T I3 1 + 2 3 + 4 5 S 6 +

T
IIC FISCO
POWER SUPPLY
Figure 7 - IIC FISCO power supply with five field devices at end of 9121 - IS
IS trunk 12,4 V 120mA

Figure 7 illustrates a system with five field devices on spurs at the

remote end of an intrinsically safe trunk. The first requirement is to
T SAFE AREA
ensure that the total current requirement of the field devices is not _
7 + 8 S 9
greater than the output capability of the power supply (120mA). If it
is assumed that each field device requires an average current of 100mA ZONE 1 / DIV 1
250m
20mA then the maximum number of devices that can be powered 12.5T
IS
TRUNK
from the IIC power supply is five as illustrated. The calculation of 1.25 V
the maximum acceptable length of the IS trunk is then as follows:
11,15V
80mA
Acceptable voltage drop in trunk = Supply voltage – Minimum 250m
operating voltage of field devices 12.5T
1.0 V
10.15V
= 12,4V - 9V
40mA
250m
= 3,4V 12.5T
0.5 V
Total current in trunk = Number of field devices x Average current 9.65V
per device
T
= 5 x 20mA
Figure 8 - IIC FISCO power supply with five field devices distributed
= 100mA along length of IS trunk

Maximum resistance of trunk = Acceptable voltage drop ÷ Total

current in trunk 3.6 Typical calculation for a IIB (9122-IS)
power supply
= 3,4 ÷ 0,1
The IIB power supply has minimum output parameters of 13,1V
= 34T and 265mA at 25oC for operational purposes. If the assumptions of
the previous calculations are applied then the maximum number of
Maximum length of trunk = Maximum resistance of trunk
field devices that can be supplied is thirteen. When twelve devices
÷ Resistance per km of trunk
are concentrated at the remote end of the trunk as indicated in
= 34 ÷ 50 Figure 9 then the calculation follows the pattern of Figure 7 and the
available voltage drop on the trunk is 4,1V, and the permitted trunk
= 0,68 km (680m) length is 340m.

6
 HOST HOST

T T

L HOST HOST
TRUNK L
TRUNK
N 24V 24V
supply N
supply
E E
1 + 2
_ 3 + 4
_ 5 S 6 +
1 + 2
_ 3 + 4
_ 5S 6 +
IIB FISCO
T
POWER SUPPLY T
IIB FISCO
9122 - IS POWER SUPPLY
9122 - IS
13,1 V 265mA
13,1 V 265mA

T
SAFE AREA T
7 + 8 S 9
_ SAFE AREA
_
7 + 8 S 9

P I= 240mA ZONE 1 / DIV 1

340m ZONE 1 / DIV 1
17,1T
IS
4,1 V TRUNK 240mA 200m IS
10T 2,4 V TRUNK

NODE
9V 10,7V
20mA

T
120mA 200m
10T 1,2 V

Figure 9 - IIB FISCO power supply with twelve field devices at end of IS
trunk 9,5V
20mA
An increased trunk length becomes available if the number of field T
devices is reduced, and the pattern shown in Table 6 emerges.

Number of field devices Length of IS trunk (m)

Figure 10 - IIB FISCO power supply with twelve field devices split into
4 1025 two nodes on the IS trunk

5 820
3.7 Connecting “Entity certified” field
6 683 devices
7 585
So far, we have considered only FISCO certified field devices. If
8 512 field devices certified to the FF816 Entity physical layer standard
are required to be added to a FISCO segment, power to the device
9 455 will need to be limited. This is to ensure compatibility with the Entity
10 410 certification, which specifies a safety description of 24V, 250mA
and 1.2W. The maximum output power of the 9121-IS and the
11 372 9122-IS (as specified in the safety description) is 2.52W and 5.31W
respectively, so to protect the Entity certified field device, a limiting
12 340
device must be interposed in its connection to the segment.
Table 6 - Relationship between trunk length and number of devices
The 9321-SC and the 9323-SC spur connectors provide this limiting
There are a very large number of possible combinations of field action and should be chosen to suit the gas group(s) involved. Use
devices with the IIB power supply. It is probable that the simple Table 7 to choose the appropriate one. One spur connector is
calculation assuming that the devices are concentrated at the end required for each Entity-certified field device. It would typically be
of the trunk will give a satisfactory answer, which ensures that the mounted inside the junction box that contains the Megablock wiring
system will work. A more detailed calculation taking into account hub. Note that the 9323-SC may be used with the 9121-IS or 9122-
the different voltage drops can be made if this proves to be IS FISCO power supplies.
necessary. Figure 10 illustrates this type of calculation with the
field devices split into two groups of six with one group 200m along Table 7 - Choosing a spur connector for the appropriate gas group
the trunk, and the second group positioned a further 200m along
the trunk. FISCO power supply

The first 200m of the trunk carries the current for all twelve devices Gas group 9121-IS 9122-IS
(240mA through 10T) and drops 2,4V, which gives a minimum IIC / A & B 9321-SC –
voltage of 10,7V at the first node. The second part of the trunk
carries 120mA and drops a further 1,2V giving a minimum voltage IIB / C & D 9323-SC 9323-SC
of 9,5V at the final node. This is adequate and hence the system is
operationally satisfactory.
Figure 11 and Figure 12 illustrate the use of the spur connectors in
the field for the gas group types.

7
 IIB FISCO IIC FISCO
POWER SUPPLY POWER SUPPLY
9122 - IS 9121 - IS
IIC FISCO
POWER SUPPLY SAFE AREA
9121 - IS
T
ZONE 1 , IIB ZONE 1 , IIC
SAFE AREA 12.4 V 120mA
_ DIV 1, Group C or D DIV 1, Group A or B
7 + 8 S 9

ZONE 1 , IIC IS
TRUNK
DIV 1, Group A or B

Entity
cert. device NODE NODE
Spur
connector NODE

9321-SC
T T
T

Spur Spur
Figure 11 - Use of the 9321-SC spur connector in IIC/A,B applications 9322-SC connector connector 9322-SC

ZONE 1 ZONE 1
ZONE 0 ZONE 0
IIB FISCO
POWER SUPPLY
9122 - IS
T Figure 13 - Use of the 9322-SC EEx ia spur connector for Zone 0 field
SAFE AREA
7 + 8 S 9
_ devices
ZONE 1 , IIB
DIV 1, Group C or D
IS 4 COMMISSIONING AND FAULT FINDING
TRUNK

4.1 Introduction
Entity A major advantage of an intrinsically safe system is that it may be
cert. device worked on in a hazardous area without switching it off or obtaining
Spur
connector NODE a gas clearance certificate. Clause 4.6.2 of IEC/EN 60079-17
details the permitted activities. These are the removal and
9323-SC replacing of apparatus and modules and the use of appropriate test
T equipment. This enables the diagnosis of faults and their correction
to be accomplished quite readily.
It is not a practical proposition nor permitted to carry out detailed
fault finding on the apparatus within an intrinsically safe circuit
when it is in or connected to the hazardous area. Major repairs to
Figure 12 - Use of the 9323-SC spur connector in IIB/C,D applications any intrinsically safe apparatus may affect the level of safety
provided and invalidate the certification. In general, only the
Both the 9321-SC and the 9323-SC are designed for DIN rail
manufacturer or his authorised representative should effect repair.
mounting. The 9321 is nominally 64mm square and occupies
18mm of rail length, while the 9323-SC is 105mm wide by 90mm This section assumes that the power supply is mounted in a safe
high and uses 12.6mm of rail length. (non-hazardous) area. When the power supply is used in a Zone 2
or Division 2 location then the procedure is slightly modified. The
3.8 Connecting Zone 0 field devices slightly different requirements are discussed in section 7 of this
application note
Some fieldbus applications have devices located in Zone 0, or have
an electrical connection into Zone 0 that requires EEx ia 4.2 Facilities
certification. The MTL FISCO power supplies may not be
connected directly into Zone 0 because their hazardous area output The MTL FISCO power supplies have system status indicators to
carries Ex ib certification. aid fault diagnosis. A further useful feature is that all the
interconnections are made using plug in terminals, which makes
The 9322-SC spur connector provides an EEx ia protected spur
disconnection and correct reconnection relatively easy. The plugs
from an Ex ib trunk, and can be used with either the 9121-IS or the
are designed to fit securely, and should be removed using a small
9122-IS FISCO power supply. See Figure 13.
screwdriver as a lever as illustrated by Figure 14. (The Zone 2 and
One spur connector is required for each field device in Zone 0. Division 2 standards require the plugs and sockets to have a
considerable extraction force and this is also desirable from an
Note: The 9322-SC must not be confused with a conventional EEx operational reliability viewpoint).
ia barrier, which limits both voltage and current. The 9322-SC limits
the current only, as the voltage is already limited by the 912X-IS A spare set of plugs could be procured for the FISCO power
FISCO power supply. supply, to make testing of the power supply and reconnection of the
existing wiring easier. A single plug with the polarising strips
Like the 9321-SC, the 9322-SC is approximately 64mm square and removed will fit into any of the sockets but this could lead to
uses 18mm of DIN rail length. subsequent misuse and the utilisation of a full set of plugs is the
recommended practice.
3.9 Configuration tool
The Ohm’s Law calculations considered so far in this chapter may
be automated by using a software-based configuration tool. We
have such a tool, which may be downloaded from the
website www.mtl-inst.com. The 9121-IS and 9122-IS
FISCO power supplies are supported, together with the
‘Megablock’ range of wiring hubs and ‘Entity’ and ‘Ex ia’ spur
connectors.
8
 The monitored function is selected by scrolling through using the
‘Mode’ selection button on the front of the device. Although signal
levels greater than 150mV are acceptable, they will be typically in
the range 500 to 900mV.
Note that the FBT-3 monitor draws approximately 10mA from the
bus and could exceed the segment capacity in marginal systems,
possibly resulting in the loss of communication to other devices. A
good practice during the design phase would be to anticipate the
load presented by the monitor.
The FBT-5 fieldbus wiring validator supplies the power and a test
signal so that when used with the FBT-3 the suitability of wiring to
be used in a fieldbus system can be checked. It is unlikely that a
newly installed cable using one of the fieldbus specified cables will
cause any difficulty. However if an existing cable with less well-
defined parameters is to be used, then a check of its transmission
qualities is prudent.

Figure 14 - Disconnection of FISCO power supply terminal block

4.3 Resistance checks on cable

A simple resistance check on each installed cable before
connecting it to equipment is desirable since this can save a
considerable amount of time. This is best carried out using a
certified intrinsically safe tester, since this reduces the possibility of
making an error when testing the cable in the hazardous area.
There are a number of such testers commercially available.
The insulation checks on a screened twisted pair should be
between the wires, from each wire to the screen, and from the
Figure 15 - FBT-3 - Fieldbus monitor
screen to the structure. Values greater than 100kT should be
achieved on a new installation, but the system should operate with
values above 10kT. The insulation test is carried out at a low
voltage but this is satisfactory for this purpose.
In addition, the loop resistance of the cable should be checked by
shorting one end of the pair. The acceptable value is determined by
the value used in the calculation to demonstrate the feasibility of
the intended interconnection of equipment. It should be
remembered that copper has a relatively high temperature
coefficient of resistance (+20% for 25oC rise) if the wiring is to be
subjected to significant changes in ambient temperature.

4.4 Specialist test equipment

None of the currently available specialist test equipment is certified
for connection to the intrinsically safe part of the circuit, without
obtaining a gas clearance certificate. This test equipment can be
used effectively on the safe area side of the power supply and to
apply tests to the intrinsically safe terminals when the intrinsically
safe circuit is disconnected. Figure 16 - FBT-5 - Fieldbus wiring validator

When connected across an active bus, the FBT-3 fieldbus monitor

(Figure 15) checks: 4.5 Procedure
It is not possible to write a fault-finding procedure that is applicable
• the voltage across the bus (>9V).
to all the possible configurations of a FISCO intrinsically safe
• the signal level of the Probe Node frame from the Link Active system. The normal techniques of checking the power supplies and
Scheduler (>150mV). the presence of signals are equally applicable to fieldbus systems
as they are to almost all other systems. This section suggests a
• the number of devices on the network and also any additions possible way of checking some of the functions of the system. The
or removals. host would usually first detect the failure of the system, and in
some cases indicate which of the field devices is defective.
• the signal level and identity of the device with the lowest signal
level (>150mV).
• the average noise level (<75mV).
• the peak noise level (<75mV).
• the signal level of a new devices response (>150mV).

9
 May contain The yellow LED marked ‘Host’ is normally on if the data on the host
power source HOST
and trunk are healthy. If there is a problem then the LED is either
terminator T extinguished or flashes, depending on the nature of the fault. The
FBT-3 can be used to assist in diagnosing the nature of the fault.
The yellow LED, marked IS, monitors the data on the IS trunk in a
HOST
similar manner, being normally on, and flashing or extinguished if
L
TRUNK there is a fault. The FBT-3 should not be used on the IS trunk, even
N 24V
within the safe area, without a gas clearance certificate which
SUPPLY
E covers the whole system.
_
1 + 2
_ 3 + 4 5S 6 + An operational system should have a green LED and two yellow
Host Power
14 to 32 Vdc LEDs permanently on and the red LED off.
T 30mA

If there is reason to believe that the FISCO power supply is

FISCO defective then it can be further tested as follows. Disconnect the IS
POWER
SUPPLY and host trunks and apply the FBT-5 to the host trunk connection
(with the host power supply switched off) and monitor the output on
T
the IS trunk with the FBT-3. In this arrangement, the yellow ‘Host’
7 + 8 S 9
_ LED flashes intermittently, but the FBT-3 functions adequately
indicating that the FISCO power supply is functional. The ability of
the FISCO power supply to communicate in one direction is
checked by this interconnection.
SAFE AREA
Checking the communication from the IS trunk to the host trunk is
ZONE 1 / DIV 1 marginally more difficult. The FBT-5 does not function in the
presence of a second source of power, and consequently cannot
IS
6 devices (120mA) in IIC TRUNK be applied directly to the IS trunk terminals. The interaction
13 devices (265mA) in IIB
between the two sources of power can be removed by coupling the
FBT-5 to the IS trunk terminals via a capacitor and providing a
separate resistive load to the FBT-5. The recommended practice is
to couple the positive output from the FBT-5 to the positive IS trunk
T terminal via a 1µF non-polarised capacitor and load the output
terminals of the FBT-5 with a 1kT resistor. The two negative
Figure 17 - Diagram of simple system terminals should then be directly connected. The FBT-3 should be
The following notes based on the simple system illustrated by connected to the host terminals, with the host power supply
Figure 17 may prove helpful. switched in. If the communication facility of the FISCO power
supply is functioning then this should be confirmed by satisfactory
readings on the FBT-3.
4.5.1 24V supply check
Usually the 24V supply has some indication that it is present. In 4.5.3 Field devices
the specific case of the MTL 5991 and the 8914-PS-AC, both
supplies have LEDs on the top surface of the unit, which indicate The host will normally provide a facility for listing the status of the
that the output power is present. If this indication is absent then the field devices if the fault in the device does not pull down the whole
presence of the mains supply should be checked. If this is network. If the network fails then the problem can usually be
satisfactory then the load on the power supply should be removed isolated by systematically disconnecting sections of the IS trunk.
by unplugging the 24V output terminals. If the LED indication This is readily accomplished when the system uses Relcom
reappears then the power supply is overloaded and the power Megablocks, which use plug in terminals. Where such a connection
supply is probably not at fault. The presence of the 24V supply at has an unused connector, this provides a useful point for
the FISCO power supply input terminals can be checked by using monitoring the trunk voltage.
the FBT-3 in the relevant mode or any other multimeter. The majority of field devices have built in diagnostic tests, which
can be addressed by the host. Consequently their failure can be
4.5.2 FISCO power supply quickly diagnosed and their isolation and removal readily
accomplished. It is advisable to disconnect the field device spur at
The LED indicators on the power supply enable its operation to be the connection block so as to remove the risk of shorting out the IS
readily checked. trunk during the maintenance operation.
The green LED marked ‘Pwr’ is connected across the intrinsically
safe output and should be on at all times, indicating that the dc 4.5.4 IS Trunk
volts are present at the IS trunk terminals. This can be confirmed
by removing the IS trunk plug and measuring the voltage with the If it is thought desirable to measure the voltage and current in the
FBT-3. It is important to disconnect the IS trunk before using the IS trunk or its spurs, or their isolation from ground, this should only
FBT-3, since the FBT-3 is not suitably certified. Measurements on be done using a suitably approved multimeter.
the connected IS trunk can be made using one of the commercially
available certified multimeters. The most common cause of the 4.5.5 Host and host trunk
absence of voltage on the IS trunk is the absence of the 24V supply
to the input. The FBT-3 will usually provide all the information necessary to find
any fault in the host trunk, which is usually only a simple
The red LED marked ‘Fault’ is illuminated when the supply to the IS interconnection. If the host develops a fault then the diagnostic
trunk goes into current limit. If disconnecting the IS trunk plug procedure of the particular host should be followed. The use of the
extinguishes the LED, then the probable causes are a short circuit FBT-3 across the host trunk can yield useful information but the
of the IS trunk or attempting to supply too many field devices. signal and noise level measurements are affected by their transition
Selective disconnection of the field devices usually reveals the through the FISCO power supply and hence should be interpreted
source of the problem. When first switched on the FISCO power with that in mind.
supply may go into current limit as some field devices have a high
starting current, but if no other faults are present the system will
start and the fault indication is removed as the line voltage
recovers.

10
5 CABLES AND ACCESSORIES 5.2.2 The IS field trunk
The FISCO power supplies have a built-in terminator, permanently
5.1 Cables connected at the start of the IS field trunk.

The choice of cables for use with fieldbus signals is not restrictive, The remote end of the IS trunk must also be terminated. A suitable
and frequently existing cables can be used thus reducing terminator is sometimes included in fieldbus wiring hubs (e.g. some
installation costs. Where a ‘gas clearance certificate’ can be Megablock models), otherwise a separate terminator, such as the
obtained the suitability of an existing cable can be checked by FBT1-IS, must be used.
using the combination of the FBT-3 and FBT-5 testers as
The FBT1-IS is certified as Category II 1 in accordance with the
discussed in section 4. There are a number of cables specifically
ATEX 94/9/EC apparatus directive, and as EEx ia IIC T4 apparatus
designed to carry the 31,25 kbit/s signal which usually follow the
in accordance with the CENELEC IS standard EN 50020. The
specification of the cable used in the conformance testing of
terminator has permitted input parameters as required by the
fieldbus circuits. This is a ‘single twisted pair cable meeting the
FISCO standard and hence can be used in any FISCO circuit
following minimum requirements at 25oC.
without any further consideration of the system safety.
• impedance at fr (31.25 kHz) = 100T ± 20% * Note: The terminator is also suitable for use in other fieldbus
• maximum attenuation at 1.25 fr (39 kHz) = 3.0 dB/km circuits, because of its wide range of permitted input parameters.

• maximum capacitive unbalance to shield = 4nF/km, tested The FBT1-IS terminator provides an IP20 level of ingress protection
using a 30m or longer sample and is intended for DIN rail mounting in an enclosure that provides
adequate protection from the surrounding environment.
• maximum d.c. resistance (per conductor) = 24T/km
• maximum propagation delay change 0.25 fr to 1.25 fr 5.3 Interconnection blocks and enclosures
=1.7 µs/km In almost all circumstances it is usual to connect individual
• conductor cross sectional area (wire size) =0,8 mm2 instruments via spurs from the IS trunk, so that a particular
(#18 AWG) instrument can be removed or replaced without interrupting the
operation of the whole system. ‘Daisy-chain’ connections and the
• minimum shield coverage shall be 90% use of more than one wire per terminal are not the recommended
practice for both serviceability and reliability reasons. The Relcom
* fr is the frequency corresponding to the bit rate
IS Megablock uses plug-in terminals which allow the IS trunk to be
The IEC60079-27 standard requires that the IS trunk should have carried through the block and individual instruments to be spur
the cable parameters as already stated in Table 2. A typical connected to the IS trunk. Screws retain the plug-in terminals so as
instrument cable has parameters of 50T/km, 0.8mH/km and to ensure the integrity of the interconnection.
120nF/km and almost all instrument cables fall within the permitted The Relcom Megablocks for applications in which spur short circuit
parameters. protection is not required are FCS-MB2, FCS-MB4, FCS-MB8 and
The use of a screened cable removes the necessity for segregation FCS-MB10-T, which cater for two, four, eight and ten spurs
of the IS trunk from non-IS cables for safety reasons. Normally respectively. The 10-way version also incorporates a permanently
segregation is desirable to ensure that interference problems are connected terminator. These devices are certified as intrinsically
minimised and clear identification of the cables is possible. Where safe EEx ia IIC T4 by LCIE under certificate number
colour is used to identify the cables it should be light blue. However LCIE02ATEX6212X. In each case, the input safety parameters of
the requirement is that the IS cables should be clearly identified, the trunk connection are Ui < 17,5V, I < 380mA, P < 5,32W, Ci = 0
and this is possible using a number of other techniques. and Li = 0, making the Megablocks suitable for use in FISCO
systems. The voltage, current and power values are transferred
directly to the spurs as Uo, Io and Po respectively, because the
5.2 Terminators trunk and spurs are electrically connected in parallel.
A terminator is a well-defined 100T impedance that is placed at the Where spur short circuit protection is required, Megablock types
start and end of a trunk cable. If this is not done the signal may be F245 (4 way), F251 (8 way), F259 (10 way with fixed terminator-
reflected, which reduces the wanted signal and causes unwanted see Figure 18) or F261 (10 way with switched terminator) should be
spurious signals. selected. These include the SpurGuard™ feature, which limits the
current drawn on each spur and therefore prevents a shorted spur
The 9121-IS or 9122-IS FISCO power supplies provide a repeater
from bringing the whole trunk down. A red LED near each spur
function, which has the effect of creating two separate fieldbus connection indicates that a spur is shorted and is in overcurrent
segments: one between the host control system and the FISCO mode. The trunk-to-spur voltage drop is typically 0,1V in ‘untripped’
power supply – the host trunk; and the other between the FISCO
mode; equivalent to a DC resistance of 5T.
power supply and the field end of the intrinsically safe trunk – the IS
field trunk.
Each of these segments must be terminated at both ends.

5.2.1 The Host trunk

Starting at the host end, a termination panel is frequently used, and
this will include a fixed or a switchable terminator, which should be
enabled. If a termination panel is not used, a separate terminator
such as the FBT1-IS should be connected across the fieldbus
wiring, close to the terminals of the host system.
At the other end of the host trunk, the FISCO power supply
incorporates a switchable terminator – this is normally enabled. In
applications where more than one FISCO power supply is
connected in parallel to the host segment (thereby creating multiple
hazardous-area segments), only one of the power supplies has the
host-side terminator enabled. This is illustrated in Figure 26, where
the terminator in the first unit is switched into circuit, while the
terminator in the second is not.

Figure 18 - Megablock F259 IS field termination block

11
Note that the current drawn by a spur in short circuit condition will
be 42mA, so some margin should be included at the design stage
to ensure that the power supply is not taken beyond its current
capacity. It is normal to assume that only one spur will have a short
circuit fault (as it is likely to be quickly rectified before another fault
occurs), so an additional margin of 20-25mA is adequate.
The Megablocks provide the IP 20 ingress protection required by
the intrinsic safety standard. The units are intended for DIN rail
mounting within an enclosure which provides adequate protection
against the environment in which it is mounted.
The principal requirement for mounting any intrinsically safe or
associated apparatus is that the method of mounting should not
allow the method of protection to be invalidated by any foreseeable
contamination, mechanical damage, or unauthorised interference.
Usually the equipment in the safe area is mounted in conventional
cabinets and there is no significant problem. In some
circumstances, there may be a need to consider the temperature
rise within a closely packed cabinet.
Figure 19 – Examples from the MTL Process JB junction box range
Where equipment is mounted in less favourable circumstances, for
example in the field; a higher level of protection is required. When The maximum permitted ambient temperature of the equipment
the enclosure is mounted in the hazardous area, the enclosure determines the maximum external operating temperature. A T4
must meet the requirements of ‘simple apparatus’. The enclosure temperature classification is always achieved if the maximum
materials should comply with the requirements of IEC 60079-0, permitted ambient temperature is not exceeded.
which specifies the ‘General Requirements’ of apparatus used in We have a range of field enclosures (see Figure 19) designed
hazardous areas. For example a plastic enclosure is required to specifically for housing Megablock wiring components. Available in
have anti-static properties and some resistance to solar radiation. stainless or powder-coated steel, or carbon-loaded polyester
Although it is not specifically required, the most convenient way to material, the Process Junction Boxes can accommodate
ensure a satisfactory choice of enclosure in countries that follow Megablocks of different sizes and are available with a choice of
IEC/CENELEC rules is to use an Exe (increased safety) cable gland types. For more information visit www.mtl-ins.com.
component approved enclosure. The installation remains an IS
installation and the enclosure needs to be clearly identified as
containing IS circuits to ensure that maintenance procedures are 6 SURGE PROTECTION
correctly followed. A Division 2 approved enclosure may be
selected in North America. The enclosure should be sufficiently
large so that the contents are easily fitted and wiring can be easily 6.1 Introduction
connected. The space required for the tidy accommodation of wires
This section discusses the protection of a FISCO system against
is usually underestimated and sharp bends in wires are always
electrical surges. Despite the increasing robustness of modern
undesirable but especially at low temperatures. Where the
designs, damaging surges can come from a number of sources, of
enclosure accommodates apparatus with plug in terminals, such as
which the most common is from adjacent lightning strikes. In
the Relcom Megablocks, extra space is required so that the plugs
assessing the necessity for surge protection, it is important to
can readily be removed and the attached cables can flex as the
recognise that fieldbus systems are susceptible to common mode
plug is removed.
failures that can close down the whole system. It is difficult to
Space for the accommodation of glands, which allows them to be summarise the circumstances in which surge suppression
installed, is also required. It is desirable to drill holes to becomes necessary but protection of all inputs to the system from
accommodate all the glands that will be required when all the spare external sources and all wiring runs within the system which are
capacity in the enclosure is utilised. Any holes intended for glands, longer than 50m horizontal or 10m vertical should be considered.
which are not used initially, should be closed using blanking plugs, Lightning and surge protection for fieldbus systems is
which maintain the IP rating of the enclosure. Accommodating the comprehensively discussed in MTL Surge application note TAN
required number of glands frequently decides the size of the 1010 and this should be consulted for a more complete picture. It
enclosure. is important to recognise that surge damage does not always
produce instantaneous failure. The long-term failures (six
The choice of glands is decided by the requirement to be months) that appear intermittently at inconvenient times are
compatible with the cable used, to maintain the ingress protection frequently more expensive and always more difficult to find.
of the enclosure and to comply with the spacing of the gland holes.
Frequently, certified Exe glands are used since these are readily The use of surge protection devices (SPDs) on an intrinsically safe
available and may be a site standard, but certification is not a (IS) circuit results in the circuit being indirectly ‘earthed’ at more
requirement. than one point, which is contrary to the normal practice for IS
circuits. However the use of SPDs is an acceptable practice, which
Consideration should be given to fitting breathing/drain devices to improves safety, and is covered by sections in the IS systems
reduce the possible problems caused by condensation. Whether standard IEC 60079-25 and the code of practice IEC 60079-14.
such devices are fitted is a decision relevant to a particular The MTL Surge application notes TAN 1004 and TAN 1005
installation based on local knowledge, but it should be a conscious consider the interaction between intrinsic safety and surge
decision. protection in more detail.
Elevation of the internal temperature of an enclosure is not a NOTE: The TANs mentioned in this section, other application notes
problem for enclosures containing only interconnection blocks. on surge protection, and relevant data sheets can be obtained on
Enclosures containing power supplies will have an internal line at www.mtlsurge.com or from your local Eaton representative.
temperature rise, which is a function of the contents and layout of
the enclosure. It is difficult to generalise about all the possible
combinations, but allowing for an internal temperature rise of 15oC
is a reasonable estimate for a metal enclosure, which is not tightly
packed. The usual practice of avoiding excessive solar radiation by
shading should be followed, and locating the enclosure so that easy
access for installation and maintenance purposes is desirable.

12
 circuit the device is either ‘nL’ or ‘nA’ as decided by the circuit in
6.2 Compatible surge protection devices which it is used.
Where an SPD is used on an IS fieldbus trunk or spur it must not c) The MA4000 (illustrated in Figure 22), which is the power supply
have significant capacitance or resistance. The use of standard SPD normally used with fieldbus applications. It is a parallel device
SPDs is unlikely to produce acceptable results and may not be that is easy to mount and has the additional advantage of meeting
safe. The capacitance of the SPD must be low (less than 100 pF) the requirements for Zone 2 or Division 2 mounting.
so as not to affect the safety analysis of the system or to attenuate
the fieldbus. The resistance introduced must also be low (less than Full details of these devices are available on their respective data
1T), since a significant resistance would reduce the useable trunk sheets.
length, which is already adversely restricted by the limitation on
available current and energy imposed by the IS requirements. A
resistance of a few ohms can also cause an impedance mismatch.
The two devices commonly used on the fieldbus trunks are:
a) The FP 32 (illustrated in Figure 20), which is a DIN rail mounted
unit and is used as part of the wiring system when an enclosure or
other protection against the environment is present. It is a series
device and introduces a resistance of 0,5T into each lead. This
resistance should theoretically be taken into account when deciding
the available trunk length of a system (trunk cable loop resistance
50T/km), but can usually be ignored. The effective device
capacitance is less than 50 pF and can be ignored from both an
operational and safety viewpoint. The FP32 has provision for
terminating and protecting the cable screen.
Figure 22 - MA4000 Surge Protection Devices
The FP 32 carries EEx ia IIC T4 and EEx ia IIB T3 intrinsic safety
certification for connection into FISCO circuits power by the 9121-
IS or 9122-IS. When used in a Zone 2 type ’n’ circuit the FP32
6.3 Protecting the system
acquires the type of protection of the circuit in which it is used, that No two fieldbus installations will be the same, but the surge
is type ‘nA’ in a non-arcing circuit and type ‘nL’ in an energy-limited protection of any system can be considered by analysing the
circuit. separate sections as illustrated by the simple system of Figure 23.
A systematic progression through the possible sources of
problems, and deciding what precautions (if any) are necessary is a
desirable approach.
DATA HIGHWAY
OTHER
INPUTS

HOST

HOST
L TRUNK
24V
N supply
E
Figure 20 – FP32 Surge Protection Devices
1 + 2
_ 3 + 4
_ 5S 6 +
b) The TP 32 (illustrated in Figure 21), which is mounted in a Host Power
14 to 32 Vdc
T
hexagonal stainless steel enclosure and is designed to be screwed 30mA

into an unused port of a field mounted device. It is a parallel device FISCO

POWER
and introduces no series resistance into the trunk or spur. Its SUPPLY
effective capacitance is less than 50pF and hence is negligible.

T
SAFE AREA
7 + 8 S 9
_

ZONE 1 / DIV 1

200m
IS
TRUNK
10m
10m

200m

10m
10m

T
Figure 21 - TP32 Surge Protection Devices
10m
The TP32 device is certified ia IIC T4 to the CENELEC IS
apparatus standard EN 50020 and meet the requirements of
Category 1 equipment in accordance with the 94/9/EC (ATEX)
Directive. It has negligible inductance and capacitance and Pi =
5,32W. It may therefore be connected into FISCO networks Figure 23 - Typical Fieldbus system
powered by the 9121-IS or 9122-IS. When used in a Zone 2 type ‘n’

13
6.3.1 Host to relocate the junction box so as to avoid the problem. Where this
is not possible, it is better to forget the common protection of the
The host has to be checked to ensure that it is protected from field devices and protect them individually. A TP 32 protecting each
invasion via all its input connections because surges can cause of the three devices becomes the preferred solution. The two
significant damage beyond the immediate interconnecting interface. possibilities are shown in Figure 24.
The mains supply input is frequently subjected to surges either The two devices located midway on the IS trunk are vulnerable to
from adjacent lightning strikes or switching surges from other surges from both directions and the simplest solution is to abandon
equipment connected to the system. Unless the supply is already the possibility of common protection, and to individually protect the
part of a carefully protected supply, the use of a dedicated SPD is field devices using a TP 32.
recommended. If the FISCO power supply is close then sharing the
protected supply is a practical proposition. The MA 4000 is The SPDs associated with field devices are usually bonded to the
normally used as the dedicated protector. adjacent plant structure, which is part of the equipotential plane of
the plant. This prevents local potential differences, which is the
The communications highway above the host controller normally principal cause of damage and provides a path for the surge
requires protection, because it is quite frequently long and may current.
even cross into equipment powered from a different distribution
centre. The type of SPD required varies with the form of the data
being transmitted. 6.3.5 Connecting blocks and terminators
The other data inputs should all be examined to establish whether The IS versions of the Relcom Megablock (FCS-MB4-IS and FCS-
they should be protected. Similarly connections to peripheral MB8-IS) are simple interconnection of terminals and will withstand
equipment should be examined even though they are unlikely to be large surge voltages (in excess of 10kV) both in common and
a source of problems. series mode. The IS terminator is constructed so that it will
withstand a high level of common mode surge voltage pulses and a
The host trunk is not likely to require protection if the FISCO power 600V series mode pulse.
supply is close to the host, which is the usual situation when the
DATA HIGHWAY
two devices are in the safe area. If the FISCO power supply is
OTHER
moved away from the host, or if the host trunk is connected to other INPUTS
fieldbus elements then the host trunk terminals may need HOST
protection. The FP 32 is the preferred SPD for this purpose.
The ‘earthing’ or bonding of the SPDs associated with the host
requires some care so as to maximise the effectiveness of the T

protection. Advice on the best techniques is given in TAN 1003.

L
6.3.2 24V supply HOST
TRUNK
N 24V
supply
The mains supply to the 24V supply requires the same E
consideration as that of the host. If the supply is moved away from 1 + 2
_ 3 + 4
_ 5 S 6 +

the host, and supplied from a field ring main, it will almost certainly T
Host Power
14 to 32 Vdc
30mA
require to be separately protected. The MA 4000 is the usual MA4000
FISCO
solution. POWER
SUPPLY
Normally the 24V supply and the FISCO power supply are mounted
close together so as to avoid having significant voltage drop T

between the two devices and hence surge protection is not 7 + 8 S 9 _

necessary. If the 24V supply is carried a significant distance and/or

used to supply significant power to other apparatus then surge FP32
SAFE AREA
protection may be necessary. However this is not a usual
installation. ZONE 1 / DIV 1

200m

6.3.3 FISCO power supply 10m

TP32 TP32
10m
The host trunk connection would only require protection at the
FISCO power supply end in those less usual circumstances where
IS
the trunk connection to the host also requires protection. It is TRUNK

almost always the case that a cable needs to be protected at both

200m
ends since protecting one end invariably increases the problem at
the other. The process is therefore to decide whether the trunk
connection at the host needs protection. If it does then the
connection at the FISCO power supply also needs to be protected. TP32
The FP 32 is the preferred solution. TP32

The IS trunk connection normally needs protection if it is more than

100m long in the horizontal direction (even 50m should give pause FP32

for thought) or 10m in the vertical direction. This means that almost T
all installations need to be protected. The IS trunk illustrated in T
Figure 23 would require to be protected in almost any location in
the world. The FP32 is the preferred solution.
10m
30m
(vertical)

6.3.4 Field devices

TP32
Where the field devices are spurred off the end of the trunk on
short spurs in the way illustrated by the three devices in Figure 23
then they can all be protected by a single SPD at the point where
Figure 24 - Adequately protected Fieldbus system
the end of the IS trunk enters the junction box. The FP32 mounted
in the junction box provides a solution. The FISCO system rules When used in conjunction with field devices protected as described
only allow spurs of up to 60m in length, and hence long spurs are in the section above the connecting block and terminator are
not a reality. However if even a 60m spur was taken vertically up a directly protected by the shared FP32 or indirectly protected by the
vulnerable structure then a considerable voltage could develop surge protection of the TP32s on the field devices. The number of
between the field device and the junction box. The ideal solution is TP 32s and their relative positions with respect to the junction box

14
affects the protection offered by the TP32. However the residual overheating. Terminal blocks with “knife-edge” disconnects, or a
surge should not damage the Megablock or terminator. plug and socket in the safe area are considered to be adequate.
Although the cable is non-arcing the plug which contains terminals
Figure 24 illustrates comprehensive surge protection of the system 4 and 6 can be disconnected without isolating the circuit because in
shown in Figure 23. It does not address the less frequently required normal operation it will always be carrying a non-incendive current.
protection of the host bus or the separate protection of the mains It should be noted that although the spark created by disconnecting
supply to the 24V supply, since these are straightforward this plug is non-incendive, shorting the host trunk may create an
modifications. The alternative techniques for protecting the three incendive spark. (The plug is constructed so that it is not easily
field devices at the end of the IS trunk are illustrated. short-circuited when it is disconnected). It is therefore not
permissible to disconnect the host bus wiring without first
disconnecting the host trunk in the safe area or isolating the supply.
7 MOUNTING OF FISCO POWER SUPPLIES
IN ZONE 2 AND DIVISION 2 The FISCO power supply requires a 24V supply, which can be
derived from any convenient source. The isolation between the
source of this power and the two fieldbus trunks removes any
7.1 General concern about interaction between the fieldbus system and other
equipment connected to the 24V supply. Figure 25 shows the 24V
There are a number of reasons why it might be thought desirable to
supply being derived from MTL’s 8914-PS-AC power supply, which
mount the FISCO power supplies in a Zone 2 or Division 2 location.
is approved for mounting in Zone 2 and Division 2 locations. The
The most common is so as to use the power supply as a repeater
potential output from the power supply is a nominal 10A and hence
thus extending the length of the trunk. This is usually a practical
the interconnecting wiring (which would normally be within the
solution since Zone 1/Division 1 locations are normally quite small,
same enclosure) is non-arcing, and is required to be secure. If this
and the power supply can be positioned in the larger Zone
wiring is rated at 10A, the current limit in the power supply is
2/Division 2 location so as to take full advantage of the permitted
adequate protection against overheating. The IIC FISCO power
length of the host trunk.
supply requires 190mA at 24V and this value is comfortably less
than the permitted non-incendive value of 234mA. Similarly, a fully
7.2 Typical installation loaded IIB FISCO power supply requires 300mA at 24V and this is
less than the 585mA permitted for a IIB non incendive supply. This
May contain permits the terminal plug on the FISCO power supply carrying the
power source HOST
and/or SAFE AREA 24V supply to be disconnected without isolating that supply.
terminator T
Shorting the wiring from the 24V supply would create an incendive
spark; it is therefore not permissible to disconnect the
interconnecting wiring without first isolating the supply.
MTL8914-PS-AC

HOST
The mains supply can be derived from any convenient source, but
L
TRUNK must comply with Zone 2/Division 2 non-arcing requirements.
N 24V
supply The installation of the intrinsically safe fieldbus trunk follows the
E
usual requirements of such systems. The isolation from the 24V
1 + 2 _ 3 + 4 _ 5S 6 + supply and the host trunk, provided by the FISCO power supply,
Host Power removes any necessity to consider interaction between the
14 to 32 Vdc
T 30mA intrinsically safe and the other circuits.

FISCO The screens of the buses are usually earthed or bonded at one end
POWER as illustrated in Figure 23. The host trunk screen is normally
SUPPLY
earthed at the host to the clean earth busbar. The IS trunk screen
is normally bonded at the FISCO power supply to the structure or
T equipotential system via the enclosure bonding connection.
7 + 8 S 9
_

7.3 Mounting of the units in Zone 2 or

ZONE 2 / DIV 2
Division 2
The fundamental requirement of mounting these units in Zone 2 or
ZONE 1 / DIV 1 Division 2 is that they should be adequately protected from
IS
environmental effects, which can adversely affect their safety.
6 devices (120mA) in IIC TRUNK Among the effects normally considered are protection from
13 devices (265mA) in IIB
weather, contamination by dust or corrosive atmospheres, ambient
temperature, solar radiation, mechanical impact and unauthorised
interference. There is no universal solution applicable to all
locations which is economic and practical, but there are some
T general guidelines which may prove helpful.

Figure 25 - Fieldbus power supply installed in Zone 2 or Division 2

If the location is outdoors in a normal industrial location then the
requirement is an enclosure which has a minimum ingress
Figure 25 illustrates the simplest installation of this power supply in protection rating of IP54, an impact rating of at least 7Nm, and
a Zone 2 or Division 2 location. A host controller is connected to the adequate resistance to corrosion. The usual solution is to use an
non-intrinsically safe side of the power supply. In many Exn or Exe or Division 2 approved enclosure since this provides
circumstances the host would supply power to the bus and contain some assurance of suitability, and avoids having to be concerned
a terminator. In this case the FISCO power supply would have its about the effects of static and provision for bonding etc. If a
terminator switched in and the internal host power supply not reasonable size enclosure is chosen (frequently determined by the
connected. When used in this mode, terminals 4 and 6 only draw a necessity to make provision for adequate glanding and making off
very small current (less than 4mA) and generate a signal current of of the field cables) then a temperature rise within the enclosure of
±10mA. In consequence the length of the host trunk is determined less than 15oC can be expected. With the equipment under
entirely by operational considerations (1,9km for a type A cable). consideration then the temperature limitation under consideration is
The host trunk itself is usually non-arcing because the host the ambient temperature limit of 70oC. This restricts the external
controller is unlikely to have non–incendive approval and hence the ambient temperature of the box to 55oC, which is adequate for
cable must be mechanically protected from damage. The screened most locations provided that direct sunlight is avoided. The
cable normally used for fieldbus trunks satisfies the requirements of temperature rise inside the enclosure is not an entirely negative
non-arcing installations. It is not usual to provide an elaborate feature, since it does tend to prevent condensation while the
means of isolation or fusing for these low power cables because equipment is turned on.
even under fault conditions the cable is not likely to suffer

15
There are situations where these levels of ingress protection are satisfied. The possible permutations are almost infinite, but
not adequate, and the installer should be aware of these. For considering the possibility of a second FISCO power supply as
example in the offshore industry it is usual to specify enclosures suggested in Figure 26 illustrates some of the possibilities.
which will withstand the deluge test. There are also installations
where these levels of protection are not necessary, For example in The second FISCO power supply can share the 24V power supply
some locations in the pharmaceutical industry there are Zone 2 or and be housed in the same enclosure. Either power supply can be
Division 2 areas that are clean and dry with restricted access and a separated from the 24V power supply by unplugging the connector,
standard 19-inch rack would be adequate. The decisive question is, which incorporates terminals 2 and 3, since this carries a non-
“is the enclosure ‘adequate for the purpose’?”, and there is no incendive current. Since the FISCO power supplies require only a
single answer that fits all locations. very small continuous current the length of the host bus is
determined only by operational considerations. The total number of
Temperature classification of this Zone 2/Division 2 installation is field devices connected to both FISCO power supplies must not
not a problem and would possibly justify a T6 (85oC) classification. exceed the capability of the host port. Only one of the two
However since almost all applications only require a T4 (135oC) terminators available at the end of the host bus should be switched
classification the temperature classification is restricted to T4 at into the circuit.
70oC ambient since this is beyond any possible dispute.

8 CERTIFICATION AND SAFETY

7.4 Maintenance and fault finding
DOCUMENTATION OF FISCO SYSTEMS
One of the disadvantages of non-arcing circuits is that usually
working on the circuits without first isolating the circuit is not
permitted. The alternative is to operate under a 'gas free clearance’ 8.1 Introduction
certificate system (which is usually available in most hazardous This section reviews the certification of the MTL FISCO power
locations) when the practices used in safe areas are acceptable. supplies in detail and the certification required of other components
In the particular case of the MTL FISCO power supply the plug-in of the system. A major system simplification embodied in the
terminals on the non-IS side of the unit can be disconnected FISCO technical specification is the simplification of the required
without first isolating the supply, because the current normally documentation. The documentation of a hypothetical system is
carried is non-incendive and the risk of shorting the leads together used to illustrate the relative simplicity of creating the required
is low. This facility used with the status LEDs on the FISCO power documentation.
supply enables almost all of the diagnostic process to be carried The CE mark (which appears on all MTL products) indicates that
out, before the circuit must be isolated. The intrinsically safe trunk the product conforms to all the relevant European Community (EC)
may of course be live-worked without gas clearance. directives, not just the ATEX directive.
Note: The terminal plugs can be withdrawn, but the leads should Copies of all Eaton IS certificates and Category 3 documents
not be removed from the terminals without first isolating the of conformity can be obtained from EatonMTL. Many end-users
system. prefer to store copies of apparatus certificates in some form,
but it is desirable to consider dispensing with these files and
7.5 Further combinations using the web to obtain a current copy of the certificate, when and if
it is needed. The UK notified body, the Electrical Equipment
The host bus can be used to interconnect other fieldbus devices Certification Service (EECS), more commonly known as BASEEFA,
and systems. Theoretically up to 31 devices can be connected to closed down on October 1st 2002. A third UK notified body,
the host bus. In practice the number is restricted by the capability Baseefa (2001) Ltd, has emerged from the closure and Eaton has
of the port on the host controller and is normally restricted to 16. transferred the relevant files to this organisation. This ensures that
The FISCO power supply transfers the field device signals from the the original EECS certificates remain valid and will be administered
intrinsically safe bus to the host bus and consequently it is the total by Baseefa (2001) Ltd in the future.
number of devices connected, either indirectly or directly, to the
port which is relevant.
8.2 MTL FISCO power supplies
May contain HOST
power source SAFE AREA
and/or The 9121-IS power supply IS certification is covered by an EC- type
terminator T
examination certificate issued by EECS. The certificate is
numbered BAS02ATEX7276 and requires that the apparatus be
MTL8914-PS-AC marked  II (2) GD [EEx ib] IIC (-40oC≤Ta≤+70oC). The first part
ZONE 2 / DIV 2
L HOST HOST
of the marking relates to the ATEX directive and indicates that the
N 24V
TRUNK TRUNK
apparatus is safe area mounted ‘associated apparatus’ suitable for
E
supply
Additional connection to Category 2 surface industry equipment in both gas
FISCO or
FNICO supply and dust atmospheres. The CENELEC standards, EN 50020 and
+ _ + _ _ _
1 2 3 4 5S 6 +
Host Power
1
+ 2 3
+ 4 5 S 6 +
Host Power
EN50014, which are used to support the claim of compliance with
14 to 32 Vdc 14 to 32 Vdc
T 30mA T 30mA the ATEX directive, require the remainder of the marking. This
FISCO marking indicates that the apparatus is ‘associated apparatus’
POWER
SUPPLY
suitable for connection to ‘ib’ circuits [normally used in Zone 1
locations] where the hazardous gas is classified IIC (hydrogen) and
T T
the permitted ambient temperature range of the apparatus is as
7 + 8 S 9
_ 7 + 8 S 9 _ indicated.
ZONE 1 / DIV 1 The ATEX Category 3 certification, which justifies the mounting of
IS ZONE1 / DIV 1 (FISCO)
the FISCO power supply in Zone 2, is covered by an
5 devices in IIC TRUNK
ZONE2 / DIV 2 (FNICO) Eaton ‘declaration of conformity’ number
12 devices in IIB MTL02ATEX9121X. This classifies the apparatus as II 3 GD,
which translates as Category 3 apparatus (normally used in Zone
2) for use in surface industry in both gas and dust
T
atmospheres. The marking relating to the CENELEC
Figure 26 - Additional Fieldbus Power Supply Connected certification to the type ‘n’ standard is EEx nA IIC T4. The nA
indicates the non-arcing construction of the power supply and
Figure 26 illustrates the possible interconnection of a second power the nature of the 24V supply and host trunk connections.
supply to the host bus. This power supply could be a FISCO power Normally apparatus classified as ‘nA’ is not gas (apparatus) group
supply or another type of supply suitable for mounting in Zone 2 or sensitive but this apparatus is marked IIC because its IS output is
Division 2 and providing power to Zone 2 or Division 2 field devices. gas group IIC. The T4 temperature classification corresponds to a
In addition any suitably approved field device can be connected to maximum surface temperature of 135oC at the maximum ambient
the host bus provided that the usual operational requirements are temperature of +70oC. This makes it suitable for use in all gases
except carbon disulphide. The letter ‘X’ at the end of the certificate

16
number indicates that its safe use depends on special conditions 8.6 Enclosures and glands
being met, which are that the power supply must be installed in an
enclosure appropriate to the gas or dust environment, and that it Enclosures and glands do not need to be certified when used to
must be protected from large supply transients. protect IS apparatus. The requirement is to be ‘adequate for the
purpose’, which is to protect the apparatus from contamination,
The 9122-IS power supply is certified in the same way as its mechanical damage and unauthorised interference. Frequently,
companion power supply except that it is certified for gas group IIB Ex e component certified enclosures and glands are used so as to
[ethylene] which allows a greater output power, but excludes its use ensure adequate protection. However this is not a requirement.
in association with IIC gases, which comprise hydrogen, acetylene
and carbon disulphide. The corresponding IS certificate number is
BAS02ATEX7277 and the Category 3 document number is 8.7 Simple apparatus
MTL02ATEX9122.
The requirements of simple apparatus and its position under the
The FISCO power supplies are also approved by FM Approvals ATEX Directive are discussed in Appendix I. In the particular case
Corporation (FM), under Project ID 30125710, as intrinsically safe of FISCO systems, the total capacitance and inductance in the
to the FM standards, which are normally accepted in North America apparatus should not be greater than 5nF and 10µH separately.
and elsewhere. The certification covers the use of the power
supplies connected to hazardous areas that are classified in Zones
(the IEC approach) as well as in those classified in Divisions (the
8.8 Safety documentation
more usual US approach). The power supplies are suitable for use One of the merits of the FISCO system is the reduction of the
in circuits which enter Division 1 because they meet the safety documentation required. Because there is no necessity to
requirement for Division 1 associated apparatus. However the carry out the compatibility tests and calculate the permitted cable
certification for use in installations that are classified using the parameters of the system in the same way as an entity concept
Zone system is ‘ib’ and this restricts the connected circuits to Zone system, the documentation can be reduced to a single table.
1 locations unless additional precautions are taken. This is because
the IEC standard does not permit active current limiting circuits in This is best illustrated by the example overleaf, which describes the
‘ia’ systems. ‘typical installation’ in Figure 27.

The FM approval also covers the mounting of the power supplies in

HOST
Class I, Division 2 or Zone 2 providing that the usual installation
requirements are met. T

The approval for the 9121-IS supply covers the use with Class I,
Groups A,B,C,D T4 gases and IIC T4 gases and the 9122-IS
supply is restricted to Groups C and D T4 and IIB T4 gases. The
intrinsically safe output from both power supplies is approved by L HOST
TRUNK
FM for use in Class II, Groups E (metal dusts), F (carbonaceous N 24V
dusts), G (grain/other dusts) and Class III (fibers) in Division I SUPPLY
E
locations. All the other requirements are the same as for the EECS
certification. 1 2 3 4 5 6
_ _
+ + S +
T 1
Where a FISCO power supply is used in association with dust
atmospheres, the 9122-IS supply should normally be used, since it IIC FISCO
POWER SUPPLY
provides additional power, but is still acceptably safe. 9121-IS
12,4 V 120 mA
8.3 MTL terminator T
_
+ S
7 8 9
The IS certification of the MTL fieldbus terminator type FBT1-IS
covered by an EC- type examination certificate issued by Baseefa SAFE AREA
(2001) Ltd. The certificate number is Baseefa02ATEX0042 and
requires that the apparatus be marked  II 1 G EEx ia IIC T4 ZONE 1 / DIV 1
(-40oC≤Ta≤+70oC). The FBT1-IS has input parameters: IS
TRUNK
Ui = 17,5V Ii = 380mA Pi = 5,32W
Ci = 0 Li = 0
and may therefore be used in FISCO systems powered by the RELCOM 7
9121-IS or 9122-IS. 5

8.4 MTL 24V Zone 2/Division 2 power supply 6 2 8

The 8914-PS-AC power supply is certified as Category 3G in

accordance with EN50021: 1999 and designated EEx nA II T4 by T 3
TÜV under certificate number TÜV01ATEX1774X, it may therefore
be located in Zone 2 hazardous areas. It is also certified by
4 ENCLOSURE
Factory Mutual Research Co. (FM) as Class No. 3600/3611 for use
in Class I, Division 2, Groups ABCD hazardous locations. Figure 27 - Typical installation

A table is a possible solution, as shown. The table could also

8.5 Cables indicate the position of the equipment, but this is frequently done
Cables are not required to be certified by the ATEX directive or by elsewhere. Details of choice of glands, installation of cables etc are
the IEC/CENELEC code of practice. They should comply with the usually covered by plant standards of the particular end-user.
requirements of the FISCO technical report. The majority of The safety description document would normally be signed and
instrument cables fall well within the specified limits. Satisfactory dated by the person preparing the document and checked, signed
evidence of compliance may be obtained from the cable and dated by a second person. Both signatories would be required
manufacturer, or by testing a sample (at least 10m long) with a to be trained and competent in this particular area of expertise.
bridge using a frequency of 10kHz.
Note: The system temperature range is determined by the cable
specification and the ‘ib’ classification by the classification of the
FISCO power supply.

17
8.9 Safety documentation for a FISCO system
System title Typical Installation

Conclusion
This safety document demonstrates that the FISCO system described satisfies the requirements of a IIC ib intrinsically safe system in
which the field devices mounted in the hazardous area all have a T4 temperature classification and can be used in the ambient temperature
range of –30oC to +60oC.

Remarks
This document only considers in detail the IS power supply and the IS circuit. The apparatus connected to the safe area terminals of the
FISCO power supply complies with the Um: 250V requirement of that power supply and does not need to be further considered.
The cable used for the IS trunk and spurs is UNITRONIC BUS PA blue, type 2020234 T and has parameters compatible with the FISCO
requirements, and has a useable temperature range of –30oC to +60oC.

Equipment used

Item Description Manufacturer Type Number Classification Certificate Number Temperature Range
No.

1 FISCO supply Eaton 9121-IS EEx [ib] IIC FISCO BAS02ATEX7276 -40oC to +70oC

2 Wiring hub Relcom F245 Simple Apparatus -45oC to +70oC

Megablock

3 Terminator Eaton FBT1-IS EEx ia IIC T4 FISCO Baseefa02ATEX0042 -40oC to +70oC

4 Enclosure Tincan 333OS Simple Apparatus -40oC to +70oC

5 Temperature Hot 999C EEx ia IIC T4 FISCO ZZZ02ATEX 0001 -40oC to +70oC
Transmitter

6 Pressure Bars 888P EEx ia IIC T4 FISCO YYY02ATEX0002 -40oC to +70oC

Transmitter

7 Flow Transmitter Wave H2O EEx ia IIC T4 FISCO XXX01ATEX0003 -40oC to +70oC

8 Valve positioner Fixit V55 EEx ia IIC T4 FISCO WWWATEX0005 -35oC to +65oC

Document compiled by Document checked by

Jack Horner B.Sc C.Eng Tom Piper M.Sc. M.B.A
st
April 1 2002 11th Sept 2002

18
 9.3 Conclusion
9 APPENDIX I: SIMPLE APPARATUS AND
The continued use of simple apparatus in intrinsically safe circuits
THE ATEX DIRECTIVE is compatible with both ATEX directives and the relevant Brussels’s
directorate has confirmed this. The accepted current practice
9.1 Introduction remains unchanged

Simple apparatus has been in use as a valuable part of intrinsically Note: The USA still uses the older definition of simple apparatus
safe systems for at least forty years, and the use of this apparatus with the ‘1,2V, 100mA, 25mW and 20µJ’ limitations. This makes
has to be reassessed with the introduction of the two ATEX very little practical difference but has to be taken into account if a
directives. The situation was explored in November 2000 at a system for world-wide use is being designed.
meeting of the CENELEC sub-committee SC31-3 and the relevant
technical advisor to the Brussels Directorate (Noel O’Riordan) and
a statement which amplified the guidance given to the same 10 APPENDIX II: EXTRACT FROM BS EN
committee in October 1999 was agreed. These two statements 50020: 2002
remain the accepted interpretation of the directive.
5.4 Simple apparatus
The original guidance was:
The following apparatus shall be considered to be simple
"Simple apparatus" will use the phrase from the directive "is not apparatus:
capable of causing an explosion through its own potential
source of ignition" thus indicating but not stating that a) Passive components, for example switches, junction boxes,
certification to the ATEX Directive is not required. That simple resistors and simple semiconductor devices
apparatus need not be marked in accordance with Clause 27 of
b) Sources of stores energy with well-defined parameters,
EN 50014: 1997 will be stated."
for example capacitors or inductors, whose values shall be
The final agreed interpretation was: considered when determining the overall safety of the
system;
"Simple apparatus is considered not to require certification by a
notified body .The responsibility for compliance with the c) Sources of generated energy, for example thermocouples
relevant parts of the standard rests with the persons claiming and photocells, which do not generate more than 1,5V,
compliance, who may be a manufacturer or user. Certification 100mA and 25mW. Any inductance or capacitance present in
to the ATEX Directive is not required because of the low levels these sources of energy shall be considered as in b).
of energy, which are added to the intrinsically safe circuit by
Simple apparatus shall conform to all relevant requirements of this
this apparatus. Simple apparatus is required to be clearly
standard but is not considered to contain a potential source of
identified when it is installed.
ignition capable of causing an explosion and need not be marked in
The intention is that simple apparatus is confined to pieces of accordance with clause 12. In particular, the following aspects shall
apparatus which are fundamentally simple. Their safety should always be considered:
be readily verifiable by visual inspection and reference to
a) Simple apparatus shall not achieve safety by the inclusion of
available data by a competent engineer.
voltage and/or current-limiting and/or suppression devices;
Where a manufacturer considers that certification by a notified
b) Simple apparatus shall not contain any means of increasing
body is desirable then this is permitted. In these circumstances,
the available voltage or current, for example circuits for the
the apparatus shall be certified in the same manner as more
generation of ancillary power supplies;
complex apparatus in accordance with EN 50020 and the ESRs
of the ATEX Directive and be marked accordingly." c) Where it is necessary that the simple apparatus maintains
the integrity of the isolation from earth of the intrinsically safe
The intention of these two statements has been carried through into
circuit, it shall be capable of withstanding the test voltage to
the apparatus and system standards, and are the accepted
earth in accordance with 6.4.12. Its terminals shall conform to
interpretation of the ATEX directive on this subject.
6.3.1;

9.2 Standards d) Non-metallic enclosures and enclosures containing light

metals when located in the hazardous area shall conform to
The most recent apparatus standard is the CENELEC standard 7.3 and 8.1 of EN 50014;
EN50020: 2002, which details the requirements of simple
apparatus in clause 5.4. This clause is reproduced in full in e) when simple apparatus is located in the hazardous area, it
Appendix II but the complete standard needs to be consulted for shall be temperature classified. When used in an intrinsically
comprehensive understanding because of the numerous cross safe circuit within their normal rating and at a maximum
references. The only difference from the IEC requirement in ambient temperature of 40oC, switches, plugs, sockets and
IEC60079-11 is that the clause requiring compliance with the terminals can be allocated a T6 temperature classification for
Category 1 standards has been added. Group II applications. Other types of simple apparatus shall
be temperature classified in accordance with clauses 4 and 6
The new IEC/ CENELEC standard IEC 60079-25 was published of this standard;
early in 2005; the system standard is not directly relevant to the
ATEX apparatus directive, but is utilised when producing f) Where simple apparatus is to be located such that Category
documentation for the risk analysis required by the user directive. 1 G or M1 equipment is normally required, then the apparatus
The system standard does not make any specific reference to the shall also comply with the additional requirements of EN
inclusion of simple apparatus but it is necessary to include the 50284 or EN 50303 as applicable.
known inductive and capacitive parameters (as indicated in clause g) Where simple apparatus forms a part of an apparatus
5.4b) of EN 50020) in the assessment of the system. In the specific containing other electrical circuits, then the combination of
case of a FISCO system, the simple apparatus should have an apparatus shall be considered as a whole.
inductance not greater than 10mH and a capacitance not greater
than 5nF, and can then be regarded in the same way as any field NOTE Sensors, which utilise catalytic reaction or other electro-
device. The 1.5V, 100mA and 25mW limitation is normally chemical mechanisms, are not normally simple apparatus.
considered to apply to the total capability of all the simple Specialist advice on their application should be sought.
apparatus within a single system. Apparatus conforming to these
limitations can be added to an intrinsically safe system without the
necessity to reconfirm the safety analysis of the system. The
system standard does confirm the requirement to clearly identify
the simple apparatus and suggests that the minimum requirement
is 'a traceable plant identification label'.

19
AUSTRALIA NORWAY
MTL Instruments Pty Ltd, Norex AS
10 Kent Road, Mascot, New South Wales, 2020, Australia Fekjan 7c, Postboks 147,
Tel: +61 1300 308 374 Fax: +61 1300 308 463 N-1378 Nesbru, Norway
E-mail: [email protected] Tel: +47 66 77 43 80 Fax: +47 66 84 55 33
E-mail: [email protected]
BeNeLux
MTL Instruments BV RUSSIA
Ambacht 6, 5301 KW Zaltbommel Cooper Industries Russia LLC
The Netherlands Elektrozavodskaya Str 33
Tel: +31 (0)418 570290 Fax: +31 (0)418 541044 Building 4
E-mail: [email protected] Moscow 107076, Russia
Tel: +7 (495) 981 3770 Fax: +7 (495) 981 3771
CHINA E-mail: [email protected]
Cooper Electric (Shanghai) Co. Ltd
955 Shengli Road, Heqing Industrial Park SINGAPORE
Pudong New Area, Shanghai 201201 Cooper Crouse-Hinds Pte Ltd
Tel: +86 21 2899 3817 Fax: +86 21 2899 3992 No 2 Serangoon North Avenue 5, #06-01 Fu Yu Building
E-mail: [email protected] Singapore 554911
Tel: +65 6 645 9864 / 5 Fax: +65 6 487 7997
FRANCE E-mail: [email protected]
MTL Instruments sarl,
7 rue des Rosiéristes, 69410 Champagne au Mont d’Or SOUTH KOREA
France Cooper Crouse-Hinds Korea
Tel: +33 (0)4 37 46 16 53 Fax: +33 (0)4 37 46 17 20 7F. Parkland Building 237-11 Nonhyun-dong Gangnam-gu,
E-mail: [email protected] Seoul 135-546, South Korea.
Tel: +82 6380 4805 Fax: +82 6380 4839
GERMANY E-mail: [email protected]
MTL Instruments GmbH,
Heinrich-Hertz-Str. 12, 50170 Kerpen, Germany UNITED ARAB EMIRATES
Tel: +49 (0)22 73 98 12 - 0 Fax: +49 (0)22 73 98 12 - 2 00 Cooper Industries/Eaton Corporation
E-mail: [email protected] Office 205/206, 2nd Floor SJ Towers, off. Old Airport Road,
Abu Dhabi, United Arab Emirates
INDIA Tel: +971 2 44 66 840 Fax: +971 2 44 66 841
MTL India, E-mail: [email protected]
No.36, Nehru Street, Off Old Mahabalipuram Road
Sholinganallur, Chennai - 600 119, India UNITED KINGDOM
Tel: +91 (0) 44 24501660 /24501857 Fax: +91 (0) 44 24501463 Eaton Electric Ltd,
E-mail: [email protected] Great Marlings, Butterfield, Luton
Beds LU2 8DL
ITALY Tel: +44 (0)1582 723633 Fax: +44 (0)1582 422283
MTL Italia srl, E-mail: [email protected]
Via San Bovio, 3, 20090 Segrate, Milano, Italy
Tel: +39 02 959501 Fax: +39 02 95950759 AMERICAS
E-mail: [email protected] Cooper Crouse-Hinds MTL Inc.
3413 N. Sam Houston Parkway W.
JAPAN Suite 200, Houston TX 77086, USA
Cooper Crouse-Hinds Japan KK, Tel: +1 281-571-8065 Fax: +1 281-571-8069
MT Building 3F, 2-7-5 Shiba Daimon, Minato-ku, E-mail: [email protected]
Tokyo, Japan 105-0012
Tel: +81 (0)3 6430 3128 Fax: +81 (0)3 6430 3129
E-mail: [email protected]

Eaton Electric Limited, EUROPE (EMEA): The given data is only intended as a product
+44 (0)1582 723633 description and should not be regarded as a legal
Great Marlings, Butterfield, Luton
warranty of properties or guarantee. In the interest
Beds, LU2 8DL, UK. [email protected]
of further technical developments, we reserve the
Tel: + 44 (0)1582 723633 Fax: + 44 (0)1582 422283 right to make design changes.
THE AMERICAS:
E-mail: [email protected]
+1 800 835 7075
www.mtl-inst.com
[email protected]
© 2016 Eaton
All Rights Reserved ASIA-PACIFIC:
Publication No. AN9026 Rev 4 221016 +65 6 645 9888
October 2016 [email protected]