Fisher ControlWave Intrinsically Safe Proximity Sensor Interface Board Manuals & Guides

Part Number D301439X012

January 2016

ControlWave Intrinsically Safe Proximity Sensor INTF. Board (for ControlWave EFM/GFC/GFC Correctors)

Remote Automation Solutions

ControlWave ISProx Board

Page

Revision

All pages

January-2016

All pages

July-2007

All pages

March-2007

Initial release

October-2006

Revision Tracking Sheet

January 2016

This manual may be revised periodically to incorporate new or updated information. The revision date of each page appears at the bottom of the page opposite the page number. A change in revision date to any page also changes the date of the manual that appears on the front cover. Listed below is the revision date of each page (if applicable):

ii Revised January-2016

ControlWave ISProx Board

Chapter 1 – Overview

1.1 Introduction

Remote Automation Solution’s ControlWave Series Intrinsically Safe Proximity Sensor Interface board (or the “ISProx board”) provides an intrinsically safe interface to one or two industry-standard variable impedance proximity sensors (see Specifications & Entity Parameters) (NAMUR Gap Sensors). The module also conditions and converts these signals to Open Drain outputs (DOs), which in turn drive ControlWave EFM/GFC/Corrector digital inputs (DIs) or counter inputs (HSCs). ISProx boards are snap-track mounted and are designed for installation and operation within an area requiring either Class I, Div. 2 (Groups A, B, C and D) or Class I, Div. 1 (Groups C & D) certified equipment.

ISProx boards provide the following features:

 ISProx boards are intrinsically safe (IS) and may be used as barrier

between an IS device and a nonhazardous installation.

 Five (5) terminal blocks provide field device wiring flexibility and

convenience: o Terminal block P1 accommodates 6 - 24 Vdc bulk input power

input.

o Terminal blocks P2 and P3 provide open drain outputs (DOs)

(converted from the proximity sensor inputs) which are wired to ControlWave EFM/GFC/GFC Corrector digital inputs (DIs) or counter inputs (HSC).

o Two Input Sensor terminal blocks (P4 & P5) provide an IS

interface to two inductive proximity sensors (two-wire) (with entity parameters matching those of the ISProx).

 Snap-track mounting accommodated.  Small size minimizes panel space requirements.

ControlWave ISProx Board

1.2 ISProx Component Identification

This section discusses components of the ISProx board with which you should be familiar. These components include terminal blocks P1 through P5 and fuse XF1.

 Terminal Blocks

ISProx boards have five terminal blocks which accommodate up to #16 AWG size wire. Tables 1-1 through 1-5 provide terminal block designation and connections.

Revised January-2016 Introduction 1

ControlWave ISProx Board

PIN #

NAME

DESCRIPTION

NOTES

Table 1-1. Bulk Input Power Connector P1

P1

SIGNAL

VDD +6 to +24 Vdc bulk power Bulk Input +6 to +9 (Vdc) for I.S.

1

GND Power Common PCB Common Ground

2

2 Introduction Revised January-2016

Figure 1-1. ControlWave ISProx Board Views & Component Identification Diagram

ControlWave ISProx Board

PIN #

NAME

DESCRIPTION

NOTES

PIN #

NAME

DESCRIPTION

NOTES

PIN #

NAME

DESCRIPTION

NOTES

PIN #

NAME

DESCRIPTION

NOTES

Table 1-2. Converted Prox. Signal Open Drain Digital Output Connector P2

P2

SIGNAL

DO1 Channel 1 Open Drain DO Derived from Prox. Sensor 1

1

GND Circuit Ground

2

Table 1-3. Converted Prox. Signal Open Drain Digital Output Connector P3

P3

SIGNAL

DO2 Channel 2 Open Drain DO Derived from Prox. Sensor 2

1

GND Circuit Ground

2

Table 1-4. Proximity Sensor Input Interface Connector P4

P4

SIGNAL

IN1 Channel 1 Prox. Sensor + Input Input from Inductive Sensor #1

1

GND Power Common PCB Common Ground

2

Table 1-5. Proximity Sensor Input Interface Connector P5

P5

SIGNAL

IN2 Channel 2 Prox. Sensor + Input Input from Inductive Sensor #2

1

GND Power Common PCB Common Ground

2

 Fuse XF1

The XF1 fuse (0.125A fast blow 2 x 7 mm) provides protection for the ISProx and associated field I/O. If an abnormal condition occurs in the ISProx circuitry, the XF1 blows and all current stops flowing. The ISProx also protects against field wiring short circuits.

Revised January-2016 Introduction 3

ControlWave ISProx Board

[This page is intentionally left blank.]

4 Introduction Revised January-2016

A

2.300

1.9 25

3.28

2.7

.410

Note 1: All Dimensions are in I nc hes.

Note 3: Printed Circuit Board (PCB) is

0.0 62” (Thick)

Note 2: Board Mounting Holes (A) are: (.151” Min.) (.161 ” Ma x.)

INTRINSI CALLY

SAFE

PROXIMITY

(ISProx)

SENSOR Board

P5

_

+

P4

_

+

XF1

A

P2

1

2

_

+

P1

P3

1

2

Chapter 2 – Installation

This chapter explains how to install ISProx boards into the ControlWave.

2.1 ISProx Mounting

ISProx Boards are either snap-track mounted (on edge) to the fabrication panel within a ControlWave EFM/GFC Plus housing or panel-mounted and glued to the inside of a ControlWave Corrector Instrument front cover. Figure 2-1 provides ISProx PCB dimensions and Figure 2-2 shows a snap-track mounted unit.

ControlWave ISProx Board

Figure 2-1. ControlWave ISProx Dimensions

Revised January-2016 Installation 5

ContolWave ISProx Board

Figure 2-2. Example of Snap Track Mounted ISProx Board

(Shown mounted to the ControlWave EFM or GFC Plus Fabrication Panel)

2.2 ISProx Sensor Board Wiring

Terminal Blocks are equipped with compression-type terminals that accept a #16 AWG size wire. To make a connection, insert the wire’s bared end (1/4” max.) into the clamp beneath the screw and then tighten the screw. ISProx terminal blocks function as follows:

 P1: Interface for ISProx PCB’s bulk input power

o P1-1 (VDD): +6 to +24 Vdc Bulk Power Input for Div. 2

Barrier Operation) (+6 to +9 Vdc for IS area)

o P1-2 (GND): 6-24V Power Common/Return)

 P2:Interface for Open Drain DO #1 (Converted from Proximity

Sensors)

o P2-1 (DO1): Channel 1 Open Drain Digital Output o P2-2 (GND): Circuit Ground

Note: Use in conjunction with ground from P1-2, P4-2, or P5-2.

 P3: Interface for Open Drain DO #2 (Converted from Proximity

Sensors)

o P3-1 (DO2): Channel 2 Open Drain Digital Output o P3-2 (GND):Circuit Ground

Note: Use in conjunction with ground from P1-2, P4-2, or P5-2.

 P4: Interface for Input from Proximity Sensor #1

o P4-1 (IN1): Input from Channel 1 Proximity Sensor o P4-2 (GND): Channel 1 Proximity Sensor Common

Ground/Return

6 Installation Revised January-2016

 P5: Interface for Input from Proximity Sensor #2

o P5-1 (IN2): Input from Channel 2 Proximity Sensor o P5-2 (GND): Channel 2 Proximity Sensor Common

Ground/Return

2.2.1 Field I/O Wiring

Figure 2-3 illustrates the two primary ISProx wirings.

ControlWave ISProx Board

Figure 2-3. ISProx Wiring Diagram

ISProx wiring requirements depend on the following considerations:

 ISProx Site Environment

o ISProx boards are suitable for installation where equipment must

be certified for operation in either Nonincendive - Class I, Division 2 (Groups A, B, C & D) or Intrinsically Safe - Class I, Division 1 (Groups C & D) environments.

 Proximity Sensor Site Environment and ISProx Board Input

o ISProx boards can be interfaced to inductive proximity sensors

that match the ISProx Entity Parameters. These Proximity Sensors may be installed and operating in a non-hazardous

Revised January-2016 Installation 7

ContolWave ISProx Board

(unregulated) area or either Nonincendive - Class I, Division 2 (Groups A, B, C & D) or Intrinsically Safe - Class I, Division 1 (Groups C & D) environments.

 ISProx Board Output Interface

o ISProx boards functionally interface the output of a proximity

sensor to one or two ControlWave EFM/GFC/Corrector digital inputs (DIs) or counter inputs (HSC). ISProx functionally provides one of the following I/O interfaces: o Intrinsically Safe Barrier installation and interface (Class I,

Div. 1) between a proximity sensor (in an Intrinsically Safe area) and DI/HSC associated with a ControlWave EFM/GFC/Corrector that is situated in either a Nonhazardous or Nonincendive (Class I, Div.2) environment (see Figure 2.3A).

o Intrinsically Safe barrier interface between a proximity

sensor (in an Intrinsically Safe area) and DI/HSC associated with a ControlWave EFM/GFC/Corrector that is situated in an Intrinsically Safe (Class I, Div. 1) environment (see Figure 2.3B).

o Nonhazardous or Nonincendive (Class I, Div.2) installation

and Nonincendive barrier interface between a proximity sensor (in a Nonhazardous or Nonincendive area) and DI/HSC associated with a ControlWave EFM/GFC/Corrector that is situated in either a Nonhazardous or Nonincendive (Class I, Div.2) environment (see Figure 2.3A).

8 Installation Revised January-2016

Chapter 3 – Specifications

This chapter details the specifications for the ISProx board.

3.1 Operating Specifications

Function: In addition to being intrinsically safe, ISProx can serve as an intrinsically safe barrier between up to two IS devices and up to two ControlWave EFM/GFC/Corrector Digital Inputs (DIs) or Counter Inputs (HSCs) in a Div. 2 installation.

Power Requirements:

 Div. II Applications

6Vdc to 24Vdc @ 3.5mA (average current) including prox. sensors

 Div. I IS Applications

6Vdc to 9Vdc @ 3.5mA (average current) including proximity sensors

Fusing: Field Replaceable 0.125A Fast Blow (2 x 7 mm) Fuse

ControlWave ISProx Board

Surge Susceptibility: Field connected circuits are designed to meet the requirements of IEC 1000-4-5 Class 3 Environment for surge withstanding capability

Terminations: Fixed, maximum wire size is 16 gauge

3.2 Environmental Specifications

Temperature:

 Operating Range: -40° to +85°C (-40° to 185°F)

 Storage Range: -40°to +100°C (-40° to 212°F)

Relative Humidity: 15% to 95% (Non-condensing)

Vibration: 1g for 10-500 Hz on any axis per SAMA PMC-31-1 without damage or impairment.

RFI Susceptibility: 3V/meter – 150 kHz to 80 MHz

3.3 Connectors

Terminal Block P1:

For Division II installations, 2-Pin P1 terminal block accommodates input power from a bulk DC (+6 to +24V). For Division I installations, 2-pin P1 terminal block accommodates input power from a bulk DC (+6 V DC to +9V DC).

Terminal Blocks P2 & P3:

2-Pin P2 & P3 terminal blocks provide open drain digital outputs (DO1 & DO2) that are derived from the Proximity Sensor inputs (IN1 & IN2).

Revised January-2016 Specifications 9

ControlWave ISProx Board

3.4 Part Numbers

3.5 Dimensions

Terminal Block P4:

2-Pin P4 terminal block accommodates interfaces to the input from proximity sensor #1 (IN1).

Terminal Block P5:

2-Pin P5 terminal block accommodates interfaces to the input from proximity sensor #2 (IN2).

400113-01-5 ISProx Board

Dimensions are provided in Figure 1-2.

10 Specifications Revised January-2016

Appendix A – Control Drawings

ANYSIMPLE APPARATUS OR APPROVED DEVICE WITH ENTITY CONCEPT PARAMETERS AS FOLLOWS:

P4

P1

P2

ISPROX

PAR T NO.

400113-01-5

P5

P3

8

Voc OR Vt < 6.51V

Isc OR It < 25mA

Ca Ccable + Ci>

La Lcable + Li

>

7

9

+

-

2

HAZARDOUS (CLASSIFIED) LOCATION

CLASS I, DIVISION 1

GROUPS A, B, C AND D

NON-HAZARDOUS LOCATION OR

HAZARDOUS (CLASSIFIED) LOCATION

CLASS I, DIVISION 2

GROUPS A, B, C AND D

1

2

3

4

2

1

2

1

2

LOAD PARAMETER

TERMINALS

Voc (V )

Isc (mA)

Ca

:

F

( )

AB/C/D

La (mH)

P4

P5

6.51

25

2/7/18

30/120/270

1. WHERE MULTIPLE CIRCUITS EXTEND FROM THE SAME PIECE OF

2. BARRIERS MAY BE IN A DIVISION 2 OR ZONE 2 LOCATION IF SO

3. BARRIER OUTPUT CURRENT MUST BE LIMITED BY A RESISTOR SUCH

Barrier Control

ControlWave ISProx Board

NOTES:

INTRINSICALLY SAFE EQUIPMENT, THEY MUST BE INSTALLED IN SEPARATE CABLES OR IN ONE CABLE HAVING SUITABLE INSULATION. REFER TO INSTRUMENTATION, SYSTEMS AND AUTOMATION SOCIETY (ISA) RECOMMENDED PRACTICE ISA RP12.6 FOR INSTALLING INTRINSICALLY SAFE EQUIPMENT.

APPROVED.

THAT THE OUTPUT VOLTAGE – CURRENT PLOT IS A STRAIGHT LINE DRAWN BETWEEN OPEN CIRCUIT VOLTAGE AND SHORT CIRCUIT CURRENT.

Revised January-2016 Control Drawings A-1

ControlWave ISProx Board

4. SELECTED BARRIERS MUST BE THIRD PARTY APPROVED AS PROVIDING

5. CAPACITANCE AND INDUCTANCE OF THE FIELD WIRING FROM THE

I.S. EQUIPMENT

BARRIER

V max

>

Voc (OR Vt)

I max

>

Isc (OR It)

P max

>

Po

Ci + Ccable

<

Ca

Li + Lcable

<

La

IF Po OF THE BARRIER IS NOT KNOWN, IT MAY BE CALCULATED USING

6. BARRIERS MUST BE INSTALLED IN ACCORDANCE WITH BARRIER

7

INSTALLATION MUST BE IN ACCORDANCE WITH NEC (NFPA 70, ARTICLE

8

SIMPLE APPARATUS IS DEFINED AS A DEVICE THAT WILL NEITHER

9

BARRIERS SHALL NOT BE CONNECTED TO ANY DEVICE THAT USES OR

INTRINSICALLY SAFE CIRCUITS FOR THE APPLICATION, AND HAVE Voc or Vt NOT EXCEEDING Vmax or Uo NOT EXCEEDING Ui, Isc OR It NOT EXCEEDING Imax OR Io NOT EXCEEDING Ii, AND THE Po OF THE BARRIER MUST BE LESS THAN OR EQUAL TO THE Pmax OR Pi OF THE INTRINSICALLYSAFE EQUIPMENT, AS SHOWN IN TABLE 1.

INTRINSICALLY SAFE EQUIPMENT TO THE BARRIER SHOULD BE CALCULATED AND SHOULD BE INCLUDED IN THE SYSTEM CALCULATIONS AS SHOWN IN TABLE 1. CABLE CAPACITANCE (Ccable) PLUS INTRINSICALLY SAFE EQUIPMENT CAPACITANCE (Ci) MUST BE LESS THAN THE MARKED CAPACITANCE (Ca OR Co) SHOWN ON ANY BARRIER USED. THE SAME APPLIES FOR THE INDUCTANCE (Lc, Li, AND La OR Lo RESPECTIVELY). WHERE THE CABLE CAPACITANCE AND INDUCTANCE PER FOOT ARE NOT KNOWN, THE FOLLOWING VALUES SHALL BE USED: Cc=60 pF/ft., Lc=0.2 µH/ft.

TABLE 1:

THE FORMULA: Po = (Voc * Isc) / 4 = (Uo – Io) / 4

MANUFACTURER’S CONTROL DRAWING AND ARTICLE 504 OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70, FOR INSTALLATION IN THE UNITED STATES, OR SECTION 18 OF THE CANADIAN ELECTRICAL CODE FOR INSTALLATIONS IN CANADA.

504) AND ANSI / ISA-RP12.6.

GENERATE NOR STORE MORE THAN 1.2V, 0.1A, 20uJ OR 25 mW.

GENERATES IN EXCESS OF 24 VDC UNLESS IT IS ADEQUATELY ISOLATED FROM THE BARRIER.

A-2 Control Drawings Revised January-2016

IS Control

ANYSIMPLE APPARATUS OR APPROVED DEVICE WITH ENTITY CONCEPT PARAMETERS AS DEFINED IN TABLE 2

P4

P1

P2

ISPROX

PART NO.

400113-01-5

P5

P3

8

7

+

-

2

1

2

3

4

2

1

2

1

2

ANY THIRD PARTY

LISTED DEVICE

WITH ENTITY

CONCEPT

PARAMETERS AS

DEFINED IN

TABLE 3

LOAD PARAMETER

TERMINALS

Voc (V)

Isc (m A)

Ca

:

F

( )

AB/C/D

La (mH)

P4

P5

6.51

6.512525

2/7/18

30/120/270

TABLE 2

HAZARDOUS (CLASSIFIED) LOCATION C LASS I, DIVISION 1 GROUPS A, B, C AND D

LOAD PARAMETER

TERMINALS

Vmax (V)

Imax (mA)

Ci

:

F

( )

Li ( m H)

P1

P2

P3

TABLE 3

8

125

15

1.63

0

1. WHERE MULTIPLE CIRCUITS EXTEND FROM THE SAME PIECE OF

2. BARRIERS MAY BE IN A DIVISION 2 OR ZONE 2 LOCATION IF SO APPROVED.

ControlWave ISProx Board

NOTES:

INTRINSICALLY SAFE EQUIPMENT, THEY MUST BE INSTALLED IN SEPARATE CABLES OR IN ONE CABLE HAVING SUITABLE INSULATION. REFER TO INSTRUMENTATION, SYSTEMS AND AUTOMATIION SOCIETY (ISA) RECOMMENDED PRACTICE ISA RP12.6 FOR INSTALLING INTRINSICALLY SAFE EQUIPMENT.

Revised January-2016 Control Drawings A-3

ControlWave ISProx Board

3. BARRIER OUTPUT CURRENT MUST BE LIMITED BY A RESISTOR SUCH THAT

4. SELECTED BARRIERS MUST BE THIRD PARTY APPROVED AS PROVIDING

5. CAPACITANCE AND INDUCTANCE OF THE FIELD WIRING FROM THE

I.S. EQUIPMENT

BARRIER

V max

>

Voc (OR Vt)

I max

>

Isc (OR It)

P max

>

Po

Ci + Ccable

<

Ca

Li + Lcable

<

La

IF Po OF THE BARRIER IS NOT KNOWN, IT MAY BE CALCULATED USING THE

6. BARRIERS MUST BE INSTALLED IN ACCORDANCE WITH BARRIER

7

INSTALLATION MUST BE IN ACCORDANCE WITH NEC (NFPA 70, ARTICLE 504)

8

SIMPLE APPARATUS IS DEFINED AS A DEVICE THAT WILL NEITHER

THE OUTPUT VOLTAGE – CURRENT PLOT IS A STRAIGHT LINE DRAWN BETWEEN OPEN CIRCUIT VOLTAGE AND SHORT CIRCUIT CURRENT.

INTRINSICALLY SAFE CIRCUITS FOR THE APPLICATION, AND HAVE Voc or Vt NOT EXCEEDING Vmax or Uo NOT EXCEEDING Ui, Isc OR It NOT EXCEEDING Imax OR Io NOT EXCEEDING Ii, AND THE Po OF THE BARRIER MUST BE LESS THAN OR EQUAL TO THE Pmax OR Pi OF THE INTRINSICALLYSAFE EQUIPMENT, AS SHOWN IN TABLE 1.

INTRINSICALLY SAFE EQUIPMENT TO THE BARRIER SHOULD BE CALCULATED AND SHOULD BE INCLUDED IN THE SYSTEM CALCULATIONS AS SHOWN IN TABLE 1. CABLE CAPACITANCE (Ccable) PLUS INTRINSICALLY SAFE EQUIPMENT CAPACITANCE (Ci) MUST BE LESS THAN THE MARKED CAPACITANCE (Ca OR Co) SHOWN ON ANY BARRIER USED. THE SAME APPLIES FOR THE INDUCTANCE (Lc, Li, AND La OR Lo RESPECTIVELY). WHERE THE CABLE CAPACITANCE AND INDUCTANCE PER FOOT ARE NOT KNOWN, THE FOLLOWING VALUES SHALL BE USED: Cc=60 pF/ft., Lc==0.2 µH/ft.

TABLE 1:

FORMULA: Po = (Voc * Isc) / 4 = (Uo – Io) / 4

MANUFACTURER’S CONTROL DRAWING AND ARTICLE 504 OF THE NATIONAL ELECTRICAL CODE, ANSI/NFPA 70, FOR INSTALLATION IN THE UNITED STATES, OR SECTION 18 OF THE CANADIAN ELECTRICAL CODE FOR INSTALLATIONS IN CANADA.

AND ANSI / ISA-RP12.6.

GENERATE NOR STORE MORE THAN 1.2V, 0.1A, 20uJ OR 25 mW.

A-4 Control Drawings Revised January-2016

ControlWave ISProx Board

Emerson Process Management

www.EmersonProcess.com/Remote

SS FOR A PARTICULAR PURPOSE WITH

anies in the Emerson Process Management

business unit of Emerson Electric Co. Emerson Process Management, Emerson and the Emerson

Remote Automation Solutions product remains solely with the purchaser and end-user.

Europe:

Emerson Process Management

www.EmersonProcess.com/Remote

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Emerson Process Management

www.EmersonProcess.com/Remote

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Emerson Process Management

www.EmersonProcess.com/Remote

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Emerson Process Management

www.EmersonProcess.com/Remote

For customer service and technical support, visit www.emersonprocess.com/remote/support

Headquarters:

Remote Automation Solutions 6005 Rogerdale Road Houston, TX 77072 U.S.A. T +1 281 879 2699 | F +1 281 988 4445

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Remote Automation Solutions, a business unit of Emerson Process Management, shall not be liable for technical or editorial errors in this manual or omissions from this manual. REMOTE AUTOMATION SOLUTIONS MAKES NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNE RESPECT TO THIS MANUAL AND, IN NO EVENT SHALL REMOTE AUTOMATION SOLUTIONS BE LIABLE FOR ANY INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, LOSS OF PRODUCTION, LOSS OF PROFITS, LOSS OF REVENUE OR USE AND COSTS INCURRED INCLUDING WITHOUT LIMITATION FOR CAPITAL, FUEL AND POWER, AND CLAIMS OF THIRD PARTIES.

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The contents of this publication are presented for informational purposes only. While every effort has been made to ensure informational accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. Remote Automation Solutions reserves the right to modify or improve the designs or specifications of such products at any time without notice. All sales are governed by Remote Automation Solutions’ terms and conditions which are available upon request. Remote Automation Solutions does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any

Remote Automation Solutions

Fisher ControlWave Intrinsically Safe Proximity Sensor Interface Board Manuals & Guides

Specifications and Main Features

Frequently Asked Questions

User Manual

Revision Tracking Sheet

Contents

Chapter 1 – Overview

1.1 Introduction

1.2 ISProx Component Identification

Chapter 2 – Installation

2.1 ISProx Mounting

2.2 ISProx Sensor Board Wiring

2.2.1 Field I/O Wiring

Chapter 3 – Specifications

3.1 Operating Specifications

3.2 Environmental Specifications

3.3 Connectors

3.4 Part Numbers

3.5 Dimensions

Appendix A – Control Drawings