Rockwell Automation 1797 User Manual

ControlNet Ex Media

1797-series

Planning and Installation Manual

Important User Information

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (Publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.ab.com/manuals/gi) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc. is prohibited.

Throughout this manual, when necessary we use notes to make you aware of safety considerations.

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you:

• identify a hazard

• avoid a hazard

• recognize the consequence

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that dangerous voltage may be present.

Labels may be located on or inside the equipment (e.g., drive or motor) to alert people that surfaces may be dangerous temperatures.

Preface

Overview of the ControlNet Ex Media System

What’s in This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Common Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 1

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 1-1

Understand the ControlNet Ex Media System . . . . . . . . . . . 1-2

Understand ControlNet Ex Components . . . . . . . . . . . . . . . 1-4

Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Trunk Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Cable Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Trunk Terminator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Tap Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Fiber Repeater Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

ControlNet Ex System Installation Requirements . . . . . . . . . 1-9

Certified Equivalent ControlNet Ex System Components 1-10

UL, cUL I/O Entity Parameters and Requirements . . . . . 1-11

European Community Directive Compliance . . . . . . . . . 1-12

EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Ex Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

What Is Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Plan a ControlNet Ex Media System

Chapter 2

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 2-1

Determine How Many Taps You Need. . . . . . . . . . . . . . . . 2-2

Connect Programming Devices in Safe Areas . . . . . . . . . . . 2-3

Coax Cable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Fiber Media Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Determine Trunk Cable Section Lengths. . . . . . . . . . . . . . . 2-4

Determine Trunk Cable Section Length When You Use a FLEX Ex Redundant ControlNet

Barrier Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Estimate Fiber Media Lengths . . . . . . . . . . . . . . . . . . . . . . 2-7

Determine How Many Trunk Terminators You Need . . . . . 2-7

Determine What Type of Connectors You Need . . . . . . . . . 2-8

Use Redundant Media in a Hazardous Area . . . . . . . . . . . . 2-10

Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Understand Conductor Categories. . . . . . . . . . . . . . . . . 2-13

General Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . 2-14

Ferrite Beads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Required Ferrite Beads. . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Add Ferrite Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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Table of Contents ii

Install a ControlNet Ex Media System

Order Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

General Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Plan a Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Plan Your Network . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

What Is Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Chapter 3

What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 3-1

Install the Trunk Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Wire External to Enclosures . . . . . . . . . . . . . . . . . . . . . 3-1

Wire Inside Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Mount the Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Select Where to Mount the Taps. . . . . . . . . . . . . . . . . . 3-2

Mount the Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Install Fiber Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Installation in Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Electrostatic Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Select a Fiber Repeater Hub Mounting Location . . . . . . 3-8

Mount the Fiber Repeater Hub . . . . . . . . . . . . . . . . . . . 3-9

Connect the Fiber Repeater Hub to a ControlNet

Ex Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Install Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Collect Your Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Strip the Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Test for Electrical Shorts and Continuity Between the

Center Conductor and the Shield . . . . . . . . . . . . . . . . . 3-19

Attach the Connectors to the Cable. . . . . . . . . . . . . . . . 3-20

Test for Electrical Shorts and Continuity Between the

Connector Body and Pin . . . . . . . . . . . . . . . . . . . . . . . 3-24

Connect Cable Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Terminate Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Connect Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Install the 1797-BCNR Module . . . . . . . . . . . . . . . . . . . . . . 3-28

Mounting Dimensions

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Appendix A

What This Appendix Contains . . . . . . . . . . . . . . . . . . . . . . A-1

Tap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Universal Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . A-2

Adjust the Cable Strip Tool

Protect Your System Against Electrostatic Discharge

Index

Table of Contents iii

Appendix B

What This Appendix Contains . . . . . . . . . . . . . . . . . . . . . . B-1

Calibrate the Cutting Blades. . . . . . . . . . . . . . . . . . . . . . . . B-1

Reverse and Replace the Cutting Blades. . . . . . . . . . . . . . . B-3

Change the Memory Blade Holder . . . . . . . . . . . . . . . . . . . B-5

Appendix C

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Table of Contents iv

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Preface

What’s in This Chapter

Use this manual to plan and install a ControlNet Ex media system. This manual describes the required components of an intrinsically-safe cable system and how to plan for and install these required components.

This manual targets the configurion of a ControlNet Ex system. However, since a ControlNet Ex system and a ControlNet system can be linked, it may be necessary to introduce and refer to concepts on the ControlNet side of the network.

Some configurations on a standard ControlNet system may not be possible within a ControlNet Ex configuration. Many of the installation methods and equipment for the ControlNet Ex system is the same as those available for the ControlNet system. However, some differences do exist. As you use this manual, note these differences.

The following tables describe where specific information is found in this manual.

For See Chapter

Help understanding the ControlNet Ex Media System 1 Help planning a ControlNet Ex Media System 2 Installation of a ControlNet Ex Media System 3

For See Appendix

Mounting dimensions (taps, universal mounting bracket, and repeater)

Adjusting the cable strip tool B Protecting your system against electrostatic discharge C

ATTENTION

You must have fundamental knowledge about

electronics and electrical codes to interpret and apply the concepts in this manual.

1 Publication CNET-IN003A-EN-P - January 2006

Preface 2

Abbreviations and Symbols

Common Techniques

The following table explains abbreviations and symbols we use in this manual.

This Means

PVC cable polyvinyl chloride cable FEP cable fluorinated ethylene propylene cable PLC processor Allen-Bradley programmable logic controller

network continues (other nodes not shown)

We use the following conventions throughout this manual:

• bulleted lists indicate information, not procedural steps

• numbered lists indicate sequential step

TIP

This symbol identifies helpful tips.

For More Information

For more information, refer to the following:

• Electronic Data Sheets:

http://www.ab.com/networks/eds/index.html

• RSNetWorx and RSLinx Software Demos and Tutorials

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Chapter

Overview of the ControlNet Ex Media System

What This Chapter Contains

Use this chapter to familiarize yourself with the ControlNet Ex media system. The following table describes what this chapter contains and where to find specific information.

For Information On See Page

Understand the ControlNet Ex Media System 1-2 Understand ControlNet Ex Components 1-4 ControlNet Ex System Installation Requirements 1-9

This system is an intrinsically-safe system specifically designed for use in hazardous areas.

TIP

For information on installation requirements for hazardous areas, refer to NFPA 70 (National Electrical Code NEC), Article 500.

This publication describes how to plan and install a ControlNet Ex media system in a hazardous area. Refer to the following publications for information on how to plan and install a coax and fiber media system in a non-hazardous environment:

• CNET-IN002, ControlNet Coax Media Planning

and Installation Manual

• CNET-IN001, ControlNet Fiber Media Planning

and Installation Manual

ATTENTION

1 Publication CNET-IN003A-EN-P - January 2006

The ControlNet Ex media system cannot be used in a safe environment after it has been exposed to signals from a hazardous area.

1-2 Overview of the ControlNet Ex Media System

Understand the ControlNet Ex Media System

Safe Area

Coax Segment

Network

Trunk Cable

Coax (1786) Fiber Hubs

The ControlNet Ex media system gives you the flexibility to design a communication network for your particular application. To take full advantage of this flexibility, spend sufficient time when you plan how to install your network before you assemble any of the hardware.

For information on installing ControlNet media in a hazardous area, refer to the ControlNet Coax Media Planning and Installation Manual, publication CNET-IN002.

Use the following figures and term definitions to understand the ControlNet Ex media system

Figure 1.1 ControlNet Coax to Fiber system for FLEX Ex

Hazardous Area

Coax Segment

Fiber Segment

Ex (1797) Fiber Hubs

Trunk Cable

Term Means

Network • A collection of connected nodes

• A collection of nodes with unique addresses in the range of 1-99

• The connection paths between any pair of devices may include repeaters and bridges.

Segment • Trunk cable sections connected via taps with terminators at each end and with no

repeaters.

Trunk Cable • The bus or central part of a media system Trunk Cable Section • A length of a cable between any two taps Fiber Repeater Hub • Consists of a fiber repeater and fiber adapter

• The components reconstruct and retransmit all traffic on one fiber or coax segment

side to another coax or fiber segment side.

Tap • The connection between any device and the ControlNet Ex or ControlNet media

system

41326

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Overview of the ControlNet Ex Media System 1-3

Te rm M ean s

Node • Any physical device connecting to the ControlNet Ex or ControlNet media system that

requires a network address to function on the network

• A network may contain a maximum of 99 nodes

• This address must be in the range of 1...99 and be unique to that network.

Trunk Terminator • A 75 Ω resistor mounted in a BNC plug

Tap Terminator • Terminates a tap drop-cable that has yet to be connected to a node with a “dummy”

node

Barrier • Barrier for coax cable provides isolation between safe and hazardous areas

Repeater • A device that connects two or more segments together

You can also use the 1797-BCNR FLEX Ex Redundant ControlNet Barrier Module to interconnect between ControlNet coax and ControlNet Ex networks. This module provides an alternative to installing ControlNet Ex fiber repeater hubs.

Network

Figure 1.2 ControlNet Coax barrier system for FLEX Ex

1797-BCNR

Safe Area

Coax Segment

TT T

Trunk Cable

Refer to Install the 1797-BCNR Module on page 3-28 for more information.

Hazardous Area

Coax Segment

Trunk Cable

41326

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1-4 Overview of the ControlNet Ex Media System

Understand ControlNet Ex Components

The ControlNet Ex media system is comprised of these components:

• Nodes

• Taps

• Trunk cable

• Cable connectors

• Terminators

• Segments

• Fiber repeater hubs (option)

• Tap terminator

• Network

• Insulators

• Coax barrier

For information about purchasi ng t hese components see the Allen-Bradley C ontrolNet Media

Component List, publication AG-PA002.

(option)

Nodes

Nodes are defined as physical devices connected to the ControlNet Ex media system that require a network address to function on the network.

40953

Tap s

Taps connect each node on a network to the coax media system via an integral 1 m (39.6 in.) drop cable.

Drop Cable

1 m (39.6 in.)

40944

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Overview of the ControlNet Ex Media System 1-5

There are four styles of taps available with:

• T or Y placement of BNC connectors

T-tap

Y-tap

40955

• Straight or right-angle connector on the drop media

40956

ATTENTION

Straight

Right-angle

Use only intrinsically-safe taps in a ControlNet Ex media system. Intrinsically-safe taps are marked “ControlNet Ex Tap.”

See page 2-2 for detailed information on taps.

Trunk Cable

The trunk cable is the bus, or central part of the ControlNet Ex

coax media system. The trunk cable may be composed of multiple sections of cable. Quad-shield RG-6 type coax cable can be used to construct trunk cable sections.

ATTENTION

You must use either of these types of ControlNet Ex trunk cable:

• 1797-RG6, Belden 3092A

• Belden 3092A blue quad-shield RG-6 type coax

cable

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1-6 Overview of the ControlNet Ex Media System

Cable Connectors

Use a cable connector (cat. no. 1786-BNC) to attach coax trunk cable sections to the tap’s BNC connector.

Trunk Cable

40957

Optional Connectors

Rockwell Automation also offers optional cable connectors for use in your network configuration. See page 2-8 for available connectors.

Trunk Terminator

A 75 Ω terminator (cat. no. 1797-XT) must be installed on the tap at

each end of a segment.

Trunk Cable

40958

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ATTENTION

Use only intrinsically-safe trunk terminators in a ControlNet Ex media system. Intrinsically-safe trunk terminators are marked “CNet Ex Trk Trm.”

Overview of the ControlNet Ex Media System 1-7

Tap Terminator

A tap terminator (cat. no. 1797-TCAP) is available to terminate unused taps.

Segment

1797-TCAP

Trunk Cable

ATTENTION

Use only intrinsically-safe tap terminators in a

40959

ControlNet Ex media system. Intrinsically-safe tap terminators are marked “CNet Tap Trm.”

Segments

A segment is a collection of coax trunk cable sections, taps, and two terminators.

Segment

Trunk Cable

40959

The total allowable length of a segment depends upon the number of taps in your segment and the coax cable type used.

See page 2-1 for detailed information.

Fiber Repeater Hubs

You can use fiber as the connector from your safe area to your hazardous area. Use fiber repeaters to connect the coax cable to the fiber. Fiber repeater hubs increase the number of taps, extend the total length of your segment, or create a star configuration (go off in multiple directions from one point). The number of fiber repeater

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1-8 Overview of the ControlNet Ex Media System

hubs and cable length total are limited depending on your network topology. You can have a maximum of 5 repeaters in series.

Safe Area

Coax Segment

TTT T

Trunk Cable

Coax (1786) Fiber Hubs

Hazardous Area

Coax Segment

Fiber Segment

Ex (1797) Fiber Hubs

41327

When you insert a fiber repeater hub into your cable system, you create a new segment. The same restrictions on the number of taps and cable length apply to this new segment.

ATTENTION

Use only the intrinsically-safe 1797 version of the fiber repeater hub in the hazardous area.

Network

A ControlNet network is the collection of connected segments, fiber repeater hubs, and nodes.

Insulators

The ControlNet Ex media system must maintain isolation from ground. Many of the connectors have metal parts. These parts must be insulated from ground contact by 500V insulation material. Insulators are provided with ControlNet Ex media system components that require insulation. For example, the ControlNet Ex taps are supplied with an insulator kit.

A large variety of BNC connectors are available for use with the ControlNet Ex media system. As a result, insulators for all types of connectors are not available. In these cases, wrapping the exposed metal with 500V insulation electrical tape is acceptable.

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Overview of the ControlNet Ex Media System 1-9

Two insulator kits are available:

• Catalog number 1797-BOOT provides standard BNC trunk cable

insulators.

• Catalog number 1797-INS provides a variety of the preformed

boots and insulators used with the ControlNet Ex system products.

ControlNet Ex System Installation Requirements

You can connect a maximum of 48 ControlNet Ex taps with a total of 250m of coax cable when using fiber hub architecture. The maximum distance increases to 1000m when you use only 2 taps.

Refer to Determine Trunk Cable Section Lengths on page 2-4 and see the table below for more information.

Catalog Number

1797-RPA ControlNet Ex

1797-RPFM ControlNet Ex

1797-ACNR15 Redundant

1797-BCNR FLEX Ex

1797-TCAP ControlNet Ex

1797-TPx ControlNet Ex

1797-XT ControlNet Ex

Catalog Name Description

Represents one ControlNet Ex Modular Repeater Adapter

Fiber Repeater Module, Medium Distance

Media ControlNet Ex Adapter

Redundant ControlNet Barrier Module

Tap (Dummy) Terminator

Coax Tap

Trunk Terminator

node and must be connected to a

coax trunk cable by

1797-TPx

Allows connection of a maximum

of two devices per 1797-RPA and

is powered directly by 1797-RPA

Represents one ControlNet Ex

node and must be connected to a

coax trunk cable by

1797-TPx -each one with two

redundant output channels that

are connected to different

ControlNet Ex networks (coax

cables and 1797-TPx)

Galvanic isolation barrier for

signal between the non-intrinsic

ControlNet system an

intrinsically-safe ControlNet Ex

system.

Represents one ControlNet Ex

node and is a simple capacitor

(56pF) with a coax connector

Four types of connections

available: S (straight T-tap), R

(right angle T-tap), YS (straight

Y-tap), and YR (right angle Y-tap) -

a maximum of 48 taps can be

connected by coax trunk cable

Simple resistor (75 Ω) with coax

connector that must be on each

end of the ControlNet Ex coax

trunk for termination

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1-10 Overview of the ControlNet Ex Media System

Catalog Number

1786-RG6 Quad-Shield,

1786-BNCP,

-BNCJ, BNCJI

1797-BOOT FLEX Ex Boot

Catalog Name Description

Maximum (functional) length

RG-6 75Ω Coax

Trunk Cable

Standard Coax Trunk Cable BNC Couplers

Insulator Kit

between two 1797-TPx is 3280ft

(1000m) - each 1797-TPx reduces

the (functional) coax cable length

by 16.3 m (53.4 ft)

Standard cable couplers

Replacement insulators

You can install fiber connecting the 1797-RPFM module with any approved associated device throughout the safe location.

All cables and fiber media that are not light blue must be marked as IS using the 1797-EXMK marking kit or other locally approved IS identification or segregation method.

ATTENTION

You must isolate all metallic parts during the installation of the ControlNet Ex system to prevent an earth connection. Use dielectric-strength isolating material. The isolating material must withstand voltages > 500V ac.

Certified Equivalent ControlNet Ex System Components

You may use these items as equivalents for system components.

Component Catalog Number Source

Coax Trunk Cable 1797-RG6 Rockwell Automation

3092IS

3092A with blue jacket Belden Wire & Cable Co.

1 Belden Wire & Cable 1189A may be used, but with functional loss of communication distance

or nodes.

Belden Wire & Cable Co.

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Overview of the ControlNet Ex Media System 1-11

UL, cUL I/O Entity Parameters and Requirements

TIP

For more information on UL and cUL installation requirements, refer to publication 1797-RM001, FLEX Ex System Certification Reference Manual.

Te rm in al s Vt (V) It (mA) Groups C

Male Bus Connector 5.8 400 A-G 3.0 3.0

(µF) La (µH)

The entity concept allows interconnection of intrinsically-safe apparatus with associated apparatus not specifically examined in combination as a system when the approved values of V

of the associated apparatus are less than or equal to V

and I

of the intrinsically-safe apparatus and the approved values of Ca

max

of the associated apparatus are greater than Ci + C

and L

respectively for the intrinsically-safe apparatus.

cable

and I

cable

or V

and

max

and L

Wiring methods must be in accordance with the National Electric Code, ANSI/NFPA 70, Article 504 and 505 or the Canadian Electric Code CSA C22.1, Part 1, Appendix F. For additional information refer to ANSI/ISA RP12.6.

WARNING

Substitution of components may impair the intrinsic

safety of this system.

AVERTISSEMENT: La substitution de composant peut compromettre la securite intrinseque.

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1-12 Overview of the ControlNet Ex Media System

If fiber optic cable is provided with a metal shield, it must be connected to a dedicated intrinsic safety ground in the intrinsically-safe location and isolated in the non-intrinsically-safe location or be connected to a ground in the hazardous location and isolated in the intrinsically-safe location.

The glass fiber must have a minimum diameter of 6µm.

European Community Directive Compliance

The ControlNet Ex System has the CE mark. It is approved for installation within the European Community or EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

The ControlNet Ex System is tested to meet the Council Directive

89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

• EN50081-2 — EMC - Generic Emission Standard, Part 2 -

Industrial Environment

• EN50082-2 — EMC - Generic Immunity Standard, Part 2 -

Industrial Environment

The ControlNet Ex System is intended for use in an industrial environment.

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Overview of the ControlNet Ex Media System 1-13

Ex Directive

The ControlNet Ex System is tested to meet the Council Directive 94/9 EC (ATEX 100a) Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres by applying the following standards:

• EN50014:1992, Electrical Apparatus for Potentially Explosive

Atmospheres

• EN50020:1994, Electrical Apparatus for Potentially Explosive

Atmospheres - Intrinsic Safety “i”

• EN50039:1980, Electrical Apparatus for Potentially Explosive

Atmospheres - Intrinsically-safe Electrical Systems “i”

• pr EN50284:1997, Special requirements for construction, test,

and marking of electrical apparatus of equipment group II, category 1 G

What Is Next?

Now that you have a general understanding of the ControlNet Ex media system, you are ready to go to Chapter 2 to design a ControlNet Ex media system for your specific requirements.

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1-14 Overview of the ControlNet Ex Media System

Notes:

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Plan a ControlNet Ex Media System

Chapter

What This Chapter Contains

Read this chapter to determine your network requirements.

For See Page

Determine How Many Taps You Need 2-2 Connect Programming Devices in Safe Areas 2-3 Coax Cable Type 2-3 Fiber Media Type 2-4 Determine Trunk Cable Section Lengths 2-4 Estimate Fiber Media Lengths 2-7 Determine How Many Trunk Terminators You Need 2-7 Determine What Type of Connectors You Need 2-8 Use Redundant Media in a Hazardous Area 2-10 Application Considerations 2-13 Ferrite Beads 2-15 Order Components 2-17

After reading this chapter, consult engineering drawings of your facility for specific information concerning the best location for installing your network.

TIP

1 Publication CNET-IN003A-EN-P - January 2006

The ControlNet Ex media system is a ground-isolated network. To help prevent accidental grounding:

• Properly select cable, connectors, and

accessories. Local agencies require use of these items for instrinsically safe system certification.

• Use the supplied ight-blue intrinsically-safe

insulators and dust caps to cover exposed metal parts.

• Any accessories should have a dielectric rating of

greater than 500V.

• Use good installation techniques.

• Use blue tape to help prevent metal-to-ground

connections.

2-2 Plan a ControlNet Ex Media System

Determine How Many Taps You Need

The number of taps you need depends on the number of devices you want to connect to the network. You need a tap for each node, repeater, or fiber hub on the network.

If you plan to add nodes later, you should consider ordering and installing the cable and connectors for these additional nodes when you install the initial network. This will minimize disruption to the network during operation.

TIP

A disconnected drop cable can cause noise to enter the network. Because of this, we recommend that you have only one unconnected tap per network for maintenance purposes. Use a tap terminator, catalog number 1797-TCAP, on any unconnected drop cable.

TIP

If you are planning future installation of additional nodes, and can tolerate losing communication for a short time, do not install the tap. Instead, install a BNC bullet connector, catalog number 1786-BNCJ. See page 2-8 for more information on the 1786-BNC bullet connector.

Ex Insulator Kit

With Intrinsically-safe Insulators

30394-M

Each tap kit contains the following pieces:

Tap (1797-TPS, -TPR, -TPYS, -TPYR)

Dust Cap

For noise suppression, ferrite beads are molded on the drop cable.

TIP

BNC Connector Kits

ControlNet Ex

Cable Labels

Screws

Universal Mounting Bracket

41329

We provide the light-blue intrinsically-safe insulators and dust caps to cover exposed metal parts. Use these items for instrinsically safe system certification by local agencies.

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-3

These tap kits are available (dust caps not shown):

Connect Programming Devices in Safe Areas

Straight T-Tap Straight Y-Tap Right-Angle T-tap

1797-TPS

1797-TPYS

Connect programming devices in safe areas to the ControlNet cable system through a 1784-KTCX15 communication card. Use a ControlNet tap to connect the communication card to the network.

Figure 2.1 Use a 1784-KTCX15 Communication Card on Coax Media

Programming Terminal

1784-KTCX15

Right-Angle Y-Tap

1797-TPR 1797-TPYR

Node

41330

Coax Cable Type

41331

You must use 1786-RG6, Belden 3092A, or Belden 3092A blue quadshield RG-6 coax cable as the ControlNet Ex trunk cable.

Publication CNET-IN003A-EN-P - January 2006

2-4 Plan a ControlNet Ex Media System

Fiber Media Type

Determine Trunk Cable Section Lengths

Trunk Terminator With Intrinsically-safe Insulator

Fiber media type specifications are listed below.

• Fiber type 62.5/125

• Connector type ST (plastic or ceramic)

• Operating wavelength 1300 nm

• Optical power budge 13.3 dB

You should install all fiber for your ControlNet Ex cable system in accordance with the regulations contained in applicable country codes, state codes, and applicable municipal codes (for example, National Electric Code). All metal connectors must be insulated from the ground. Use blue ControlNet cable or the ControlNet Ex Cable Marking Kit (1797-EXMK) to mark cable as intrinsically-safe. When you use the 1797-EXMK, be certain to place one marker at every meter of length.

A segment is comprised of several sections of trunk cable separated by taps. The total cable length of a segment is equal to the sum of all of the trunk cable sections, including taps.

Tap TapTap

IS Insulators

Trunk Cable Section

Trunk Terminator With Intrinsically-safe Insulator

30094-m

TIP

When determining the length of trunk cable sections, measure the actual cable path as it is routed in your network. Consider vertical dimensions as well as horizontal dimensions. You should always calculate the three-dimensional routing path distance when determining cable lengths.

Cover all exposed metal on connectors with either the intrinsically-safe insulators or other forms of insulation.

Select the shortest path for routing the cable to minimize the amount of cable you need. The specific details of planning such a cable route depends upon the needs of your network.

The total allowable length of a segment containing standard RG-6 quad-shield cable depends upon the number of taps in your segment. There is no minimum trunk cable section length

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-5

requirement. The maximum allowable total length of a segment is 1,000 m (3,280 ft) with two taps connected. Each additional tap decreases the maximum length of the segment by 16.3 m (53.4 ft). The maximum number of taps allowed on a segment is 48 with a maximum length of 250 m (820 ft).

IMPORTANT

Figure 2.2 ControlNet Single Media Derating Curve

Maximum Allowable Segment Length for FLEX Ex on ControlNet =

1000 m (3280 ft) - 16.3 m (53.4 ft) X [Number of Taps - 2]

EXAMPLE

An allowable total length of RG-6 cable segment in your application can be determined by using the equation below. Each additional tap decreases the maximum length of the segment. The maximum number of taps allowed on a segment is 48. Each additional tap decreases the maximum length of the segment.

The derating curve is applicable only when the cable meets ControlNet attenuation specifications.

)

1000 (3280)

(f m

750 (2460)

t g n e

500 (1640)

t n e

250 (820)

m g e S

32 48

Number of Taps

30014-m

If your segment requires 10 taps, the maximum segment length is:

1000m (3280 ft) - 16.3 m (53.4 ft) x [10 - 2] 1000m (3280 ft) - 130.4 m (427.7 ft)= 869.6 m

(2852.3 ft)

IMPORTANT

This equation applies when the cable does not meet ControlNet attenuation specifications.

Maximum Allowable Segment Length of Cable =

(20.29 db - Number Of Taps in Segment *.32 db)

Cable Attenuation @ 10 MHz per 304 m (1000 ft)

Note: Cable attenuation is defined as the signal loss measured at 10 MHz per 304 m (1000 ft) of cable. Cable attenuation for ControlNet Ex cables is listed in the ControlNet Ex Media Component List, publication AG-PA002.

X 304 m (1000 ft)

Publication CNET-IN003A-EN-P - January 2006

2-6 Plan a ControlNet Ex Media System

EXAMPLE

IMPORTANT

For redundant media, decrease the number of taps by half, as shown in the derating curve.

Figure 2.3 ControlNet Redundant Media Derating Curve

Maximum Allowable Segment Length for FLEX Ex on ControlNet =

1000 m (3280 ft) - 16.3 m (53.4 ft) X [Number of Taps - 2]

If your segment requires 3 taps using 1786-RG6 cable, the maximum segment length is:

([20.29 db - 3*.32 db] / 5.99 db] * 304)

(19.33 db / 5.99 db) * 304 = 982 m (3227 ft)

The total trunk cable length or number of taps can be increased by installing a repeater hub on the segment. This creates another segment.

)

1000 (3280)

(f m

750 (2460)

t g n e

500 (1640)

t n e

250 (820)

m g e S

816 24

Number of Taps

30014-m

Publication CNET-IN003A-EN-P - January 2006

Determine Trunk Cable Section Length When You Use a FLEX Ex Redundant ControlNet Barrier Module

When you use a FLEX Ex Redundant ControlNet Barrier Module (catalog no. 1797-BCNR), the total allowable length of a segment containing standard RG-6 quad-shield cable depends upon the number of taps in your segment. There is no minimum trunk cable section length requirement. The maximum allowable length of a segment that contains a 1797-BCNR module is 500 m. (1640 ft) with two taps connected. Each additional tap decreases the maximum length of the segment according to the derating curve. The maximum number of taps allowed on a segment is 20 with a maximum length of 250 m (820 ft).

500 m (1640 ft)

250 m (820 ft)

Plan a ControlNet Ex Media System 2-7

Segment Length m (ft)

Estimate Fiber Media Lengths

Number of Taps With One FLEX Ex Redundant ControlNet Barrier Module

The maximum length of a fiber media section for the 1797-RPFM module is dependent on the quality of the fiber, number of splices, and the number of connectors. The total attenuation for a cable section must be less than 13.3 dB.

Typically, cable attenuation for a wavelength of 1300 nm is less than

1.5 dB/km.

IMPORTANT

Avoid joining cable with connectors as much as possible. Connectors can cause considerable attenuation and limit the maximum length of your system. Be sure to check the attenuation of each cable sections after the cable is installed.

Determine How Many Trunk Terminators You Need

You must use 75 Ω trunk terminators equipped with intrinsically-safe

insulators (cat. no. 1797-XT) at the end of each segment in the ControlNet Ex cable system.

1797-XT

Intrinsically-safe Insulator

Publication CNET-IN003A-EN-P - January 2006

2-8 Plan a ControlNet Ex Media System

After you have determined the number of segments in your network, multiply this number by two to determine how many terminators you need for your network.

IMPORTANT

To comply with intrinsic safety standards, be sure to cover the exposed metal with the intrinsically-safe insulator provided with each terminator.

Determine What Type of

Use the foll owing table to determine what type of connectors you need.

Connectors You Need

Use This BNC Connector To Cat. No.

cable connector Attach trunk cable sections to a tap’s BNC connector 1786-BNC

Use This Optional BNC Connector To Cat. No.

Bullet (Jack-to-jack) Reserve a space in the trunk cable for future installation of a

tap or to splice a trunk cable

Barrel (Plug-to-plug) Connect two adjacent taps without a trunk cable section

between them

1786-BNCJ

1786-BNCP

Isolated-bulkhead (Jack-to-jack)

Tap Terminator Cap off installed taps that have yet to be connected to a node 1797-TCAP

Right Angle (Jack-to-plug)

Go through grounded panel walls while maintaining the shield isolation of the trunk cable

Provide a 90° bend in your cable (prevent bending your cable

excessively)

See Chapter 3 for the bend radius specification

1786-BNCJI

Refer to the ControlNet Media System Component List, publication AG-PA002 for the part number

Publication CNET-IN003A-EN-P - January 2006

In This Example, ControlNet Ex Cable:

• Enters and exits the panel

enclosure from the side using isolated-bulkhead connectors

• Contains two adjacent

taps connected by a barrel connector

• Reserves one future tap

location with a bullet

Panel Wall

Bullet Connector

Right Angle Connectors

Plan a ControlNet Ex Media System 2-9

Cable Enters and Exits From the Side

Isolated-bulkhead Connectors

Barrel Connector

Taps

20091m

ATTENTION

TIP

Do not let any metallic surfaces on the BNC connectors, plugs, or optional accessories touch grounded metallic surfaces. This contact could cause noise on the network. All exposed metal must be covered with either intrinsically-safe blue insulators or another form of insulation, such as tape with a 500V rating.

If you install a bullet connector for future tap installations, count the bullet as one of the tap allotments on your segment (and decrease the

maximum allowable cable length by 16.3 m [53.5 ft]).

This helps you avoid reconfiguring your network when you install the tap.

Publication CNET-IN003A-EN-P - January 2006

2-10 Plan a ControlNet Ex Media System

Use Redundant Media in a Hazardous Area

Safe Area

1786 Fiber Repeater Hub

B-A

Allen-Bradley

QUALITY

1797 - RPA

Net Ex

Control

Comm

Module

REPEATER ADAPTER

Status

PWR

Coax Trunk Cable A =

Chan 1

+V -V +V -V

Recv Xmit Recv Xmit

You can run a second trunk cable between your ControlNet Ex nodes for redundant media. With redundant media, nodes send signals on two separate segments. The receiving node compares the quality of the two signals and accepts the better signal to permit use of the best signal. This also provides a backup cable should one cable fail.

Trunk cables on a redundant cable network are defined by the segment number and the redundant trunk cable letter.

Actual ControlNet Ex products are labeled with these icons (the shaded icon represent redundant media).

In this figure, the redundant cable trunk cable is trunk cable B.

Hazardous Area

1797 Fiber Repeater Hub

1797 - RPFM

Net Ex

Control

FIBER MODULE MEDIUM RANGE

Chan 2

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

1797 - RPFM

1797 - RPA

Net Ex

Control

Net Ex

Control

FIBER MODULE

REPEATER ADAPTER

MEDIUM RANGE

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

Trunk Cable A =

Coax Trunk Cable B =

1786 Fiber Repeater Hub

B-A

Allen-Bradley

QUALITY

1797 - RPA

Net Ex

Control

Comm

Module

REPEATER ADAPTER

Status

PWR

+V -V +V -V

Recv Xmit Recv Xmit

Trunk Cable B =

1797 Fiber Repeater Hub

Chan 1

Chan 2

B-A

Allen-Bradley

QUALITY

1797 - RPFM

Net Ex

Control

FIBER MODULE

Comm

Module

MEDIUM RANGE

Status

B-A

Allen-Bradley

QUALITY

1797 - RPFM

1797 - RPA

Net Ex

Control

Net Ex

Control

FIBER MODULE

REPEATER ADAPTER

MEDIUM RANGE

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

Node

Observe the following guidelines when planning a redundant media system in a hazardous area.

• Route the two trunk cables (trunk cable A and trunk cable B) differently to reduce the chance of both cables being damaged

at the same time.

• Each node on a redundant-cable network must support

redundant coax connections and be connected to both trunk cables at all times. Any nodes connected to only one side of a redundant-cable network will result in media errors on the unconnected trunk cable.

41346

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-11

• Install the cable system so that the trunk cables at any physical

device location can be easily identified and labeled with the appropriate icon or letter. Each redundant ControlNet Ex device is labeled so you can connect it to the corresponding trunk cable.

• Both trunk cables (trunk cable A and trunk cable B) of a redundant-cable network must have identical configurations.

Each segment must contain the same number of taps, nodes and fiber repeaters. Connect nodes and fiber repeaters in the same relative sequence on both trunk cables.

• Either side of a redundant-cable network may differ in cable

length. The total difference in length between the two trunk cables must not exceed 800 m (2640 ft).

Trunk Cable A =

Trunk Cable B =

Trunk Cable A =

Segment 1

Node

Node Supporting Redundant Media

Hazardous Area

Node

Segment 2

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

B-A

Allen-Bradley

QUALITY

1797 - RPA

Control

Net Ex

Control

Comm

Module

REPEATER ADAPTER

Status

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

1797 - RPA

Net Ex

Control

REPEATER ADAPTER

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

1797 - RPFM

Net Ex

FIBER MODULE MEDIUM RANGE

1797 Fiber Repeater

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

1797 - RPFM

1797 Fiber

Net Ex

Control

FIBER MODULE MEDIUM RANGE

Repeater Hub

B-A

Allen-Bradley

QUALITY

1797 - RPA

Net Ex

Control

REPEATER ADAPTER

PWR

+V -V +V -V

Recv Xmit Recv Xmit

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

Control

FIBER MODULE MEDIUM RANGE

Chan 1

Chan 2

1797 - RPFM

1797 - RPA

Net Ex

Control

Net Ex

Control

FIBER MODULE

REPEATER ADAPTER

MEDIUM RANGE

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

1797 - RPFM

Net Ex

Node

41683

Publication CNET-IN003A-EN-P - January 2006

2-12 Plan a ControlNet Ex Media System

Segment 1

1786 Node

• Avoid connecting a single node’s redundant trunk cable

connections on different segments; this will cause erratic operation.

Hazardous AreaSafe Area 1786 Fiber Repeater Hubs

B-A

Allen-Bradley

QUALITY

Comm

Module Status

Status

B-A

Allen-Bradley

QUALITY

Comm

Module Status

Status

Control

REPEATER ADAPTER

+V -V +V -V

Control

REPEATER ADAPTER

+V -V +V -V

B-A

Allen-Bradley

QUALITY

1797 - RPA

Net Ex

PWR

Chan 1

Chan 2

Recv Xmit Recv Xmit

B-A

Allen-Bradley

QUALITY

1797 - RPA

Net Ex

PWR

Chan 1

Chan 2

Recv Xmit Recv Xmit

1797 Fiber Repeater Hubs

1797 - RPFM

Net Ex

Control

FIBER MODULE MEDIUM RANGE

1797 - RPFM

Net Ex

Control

FIBER MODULE MEDIUM RANGE

B-A

Allen-Bradley

QUALITY

1797 - RPFM

1797 - RPA

Net Ex

Control

Net Ex

Control

FIBER MODULE

Comm

Module

REPEATER ADAPTER

MEDIUM RANGE

Status

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

B-A

Allen-Bradley

QUALITY

1797 - RPFM

1797 - RPA

Net Ex

Control

Net Ex

Control

FIBER MODULE

Comm

Module

REPEATER ADAPTER

MEDIUM RANGE

Status

PWR

Chan 1

Chan 2

+V -V +V -V

Recv Xmit Recv Xmit

1797 Node

Segment 2

41348

A node supporting redundant trunk cable connections will function even if trunk cable A is connected to the B connector on the node and vice-versa. This makes cable fault indications (on the hardware or in software) difficult to interpret and makes locating a bad cable segment very difficult.

ATTENTION

Never connect parts of a ControlNet cable system to those of a ControlNet Ex cable system. The 1786 fiber repeater hub and 1797 fiber repeater hub are used to isolate the two sections of a ControlNet network.

ATTENTION

ControlNet Ex products cannot be used in an intrinsically-safe environment after they have been exposed to non-intrinsically-safe signals.

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-13

Application Considerations

The following guidelines coincide with the guidelines for the installation of electrical equipment to minimize electrical noise inputs to controllers from external sources contained in IEEE standard 518-1982. When planning your cable system keep these installation considerations in mind.

ATTENTION

These guidelines apply only to noise coupling. Intrinsic safety requirements for cable mounting are of the highest priority.

Understand Conductor Categories

Conductors can be divided into three categories.

Category Includes

1 ac power lines

High-power digital ac I/O lines

High-power digital dc I/O lines

Power connections (conductors) from motion drives to motors

2 Analog I/O lines and dc power lines for analog circuits

Low-power digital ac/dc I/O lines

Low-power digital I/O lines

ControlNet Ex communication cables

3 Low-voltage dc power lines

Communication cables to connect between system components within the same enclosure

Publication CNET-IN003A-EN-P - January 2006

2-14 Plan a ControlNet Ex Media System

General Wiring Guidelines

Follow these guidelines with regard to noise coupling. Following intrinsic safety requirements should prevent most or all of these situations from occurring. These guidelines are provided as a general reference for wiring.

• If wiring must cross power feed lines, it should do so at right

angles.

• Route wiring at least 1.5 m (5 ft) from high-voltage enclosures,

or sources of rf/microwave radiation.

• If the conductor is in a metal wireway or conduit, each section

of that wireway or conduit must be bonded to each adjacent section so that it has electrical continuity along its entire length, and must be bonded to the enclosure at the entry point.

For more information on general wiring guidelines, see the

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1.

Wire External to Enclosures

Cables that run outside protective enclosures are relatively long.

To minimize cross-talk from nearby cables, you should maintain maximum separation between the ControlNet Ex cable and other potential noise conductors. Route your cable following these guidelines:

Cable in a Contiguous

Metallic Wireway or Conduit?

Yes 0.08 m (3 in.) Category-1 conductors of less than 20A

No 0.15 m (6 in.) Category-1 conductors of less than 20A

Route Your Cable At Least

0.15 m (6 in.) ac power lines of 20A or more, up to 100 KVA

0.3 m (12 in.) ac power lines greater than 100 KVA

0.3 m (12 in.) ac power lines of 20A or more, up to 100 KVA

0.6 m (24 in.) ac power lines greater than 100 KVA

From Noise Sources of This Strength

Wire Inside Enclosures

Cable sections that run inside protective equipment enclosures are relatively short. As with wiring external to enclosures, you should maintain maximum separation between your ControlNet Ex cable and Category-1 conductors.

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-15

When you run cable inside an enclosure, route conductors external to all raceways in the same enclosure, or in a raceway separate from Category-1 conductors.

Route Your Cable At Least From Noise Sources of This Strength

0.08 m (3 in.) Category 1 conductors of less than 20 A

0.15 m (6 in.) ac power lines of 20A or more, up to 100 KVA

0.6 m (24 in.) ac power lines greater than 100 KVA

Surge Suppression

Transient electromagnetic interference (emi) can be generated whenever inductive loads such as relays, solenoids, motor starters, or motors are operated by hard contacts such as push-button or selector switches. These wiring guidelines assume you guard your system against the effects of transient emi by using surge-suppressors to suppress transient emi at its source.

Inductive loads switched by solid-state output devices alone do not require surge suppression. However, inductive loads of ac output modules that are in series or parallel with hard contacts require surge-suppression to protect the module output circuits as well as to suppress transient emi.

Ferrite Beads

Ferrite beads provide additional suppression of transient emi. Fair-Rite Products Corporation manufactures a ferrite bead

(part number 2643626502) that can be slipped over Category-2 and Category-3 (RG-6 type trunk cable) conductors. You can secure them with heat-shrink tubing or tie-wraps. A cable transient emi induced onto the cable can be suppressed by a ferrite bead located near the end of the cable. The ferrite bead will suppress the emi before it enters the equipment connected to the end of the cable.

Required Ferrite Beads

Five ferrites come with each ControlNet Ex adapter. Four are identical and are for use on the ControlNet Ex trunk cable (two for Segment 1 and two for Segment 2). The fifth ferrite is longer. You use this ferrite on the adapter power cable.

Publication CNET-IN003A-EN-P - January 2006

2-16 Plan a ControlNet Ex Media System

Add Ferrite Beads

Wrap the IS power input cable two turns around the ferrite bead before connecting the terminal block to the adapter.

Five ferrite beads come with the adapter. Four are short and identical. Use these on the ControlNet Ex trunk cable. The fifth, longer ferrite bead is for the adapter power cable.

42206

Add ferrite beads on the ControlNet Ex trunk cable inside the cabinet wherever the trunk cable goes into or out of the cabinet.

Ferrite Beads

30890-M

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-17

Order Components

Now that you are ready to begin ordering components, use these guidelines to help you select components.

General Planning

The ControlNet Ex cable system is isolated from earth and must be protected from inadvertent ground connections.

Plan a Segment

Refer to this list when you plan a segment.

• All connections to the trunk cable require a tap

• Taps may be installed at any location on the trunk cable

• Tap drop-cable length must not be changed

• Maximum number of taps = 48, with 250 m (820 ft) of standard

RG-6 trunk cable

• Maximum trunk cable length of RG-6 trunk cable = 1000 m

(3280 ft), with 2 taps

• 75 Ω trunk terminators are required on both ends

• One tap with an unconnected drop cable may be installed for

maintenance purposes

• Use BNC bullet connectors at future tap locations

• Do not mix redundant and non-redundant nodes

• Use ControlNet Ex tap terminators (1797-TCAP) for all other

unconnected drop cables

• Avoid high noise environments when routing cables

• A supplied ferrite toroid should be used on the ControlNet Ex

trunk as it enters and leaves control cabinets

Publication CNET-IN003A-EN-P - January 2006

2-18 Plan a ControlNet Ex Media System

Plan Your Network

Refer to this list when you plan your network.

• Maximum of 99 nodes (excluding fiber repeater hubs)

• Fiber repeater hubs require a tap but are not counted as nodes

(they are included in the number of devices allowed per segment [48])

• Fiber repeater hubs may be installed at any tap location along a

segment

• There can be only one path between any two points on a

network

• The configuration of both sides of a redundant segment must be

the same

• The total cable difference between the two sides of a redundant

network cannot exceed 800 m (2640 ft)

Order Parts

The following table contains a list of ControlNet Ex Components. Refer to the ControlNet and ControlNet Ex Media System Components List, publication AG-PA002, for a list of other ControlNet parts.

Item Cat. No. Guidelines

Taps Straight T-tap Straight Y-tap Right-angle T-tap

Right-angle Y-tap

Trunk Terminators 1797-XT

Trunk Cable Use the ControlNet Ex Media System

Tap Terminator 1797-TCAP

1797-TPS 1797-TPYS 1797-TPR

1797-TPYR

(quantity of 50)

(quantity of 5)

You need a tap for each connection to the trunk cable (nodes and repeaters).

Each tap kit contains: two BNC connector kits, one dust cap, one universal mounting bracket, ControlNet Ex cable labels and two screws

You need a terminator for each end

of each segment.

Component List, publication AG-PA002,

to order your required length of cable.

Use the dummy load to plug into drop cables that are not attached to a node.

Required Quantity

Number of repeaters x 2

Number of nodes

Number of segments x 2

Follow guidelines on page 2-4

of this document to determine cable length

One for every drop cable that is not attached to a node

Publication CNET-IN003A-EN-P - January 2006

Plan a ControlNet Ex Media System 2-19

Item Cat. No. Guidelines

Coax Tool Kit 1786-CTK Use the tool kit to create your trunk cable

Required Quantity

One

to your specifications.

You will need to double your quantities when ordering components for a redundant cable system.

The connector kit may be shipped with two ferrules. The smaller diameter ferrule should not be used with ControlNet Ex applications.

Publication CNET-IN003A-EN-P - January 2006

2-20 Plan a ControlNet Ex Media System

What Is Next?

After you gather all of the parts for your ControlNet Ex media system, you are ready to go to Chapter 3 to begin the installation of your network.

Publication CNET-IN003A-EN-P - January 2006

Install a ControlNet Ex Media System

Chapter

What This Chapter Contains

Install the Trunk Cable

Follow the instructions in this chapter to install your ControlNet Ex

media system.

For See Page

Install the Trunk Cable 3-1 Mount the Taps 3-2 Specifications 3-6 Install Fiber Hubs 3-6 Install Cable Connectors 3-13 Connect Cable Sections 3-25 Terminate Segments 3-25 Connect Devices 3-27 Install the 1797-BCNR Module 3-28

TIP

When installing your trunk cable, observe your cable supplier’s installation instructions and these guidelines.

You should read Chapter 2, Plan a ControlNet Ex Network, before you install your network.

Wire External to Enclosures

When the RG-6 type coax cable is being pulled through multiple conduit bends, follow these specifications.

For This Coax Cable

PVC 42.75 kg (95 lbs) 76.2 mm (3.0 in.)

1 Publication CNET-IN003A-EN-P - January 2006

The Pull Strength Should Not Exceed

The Bend Radius Should Not Exceed

3-2 Install a ControlNet Ex Media System

Wire Inside Enclosures

When the RG-6 type coax cable is not being pulled through conduit, follow these specifications.

For This Coax Cable The Bend Radius Should Not Exceed

PVC 38.1 mm (1.5 in.) Tap drop-cable 25.4 mm (1.0 in.)

The 1797-EXMK Cable Marking kit is available for clearly marking drop cables and trunk cables as intrinsically-safe.

Mount the Taps

First select where you want to mount the taps, then use this mounting procedure.

Select Where to Mount the Taps

There is no spacing requirement between taps; you can install two adjacent taps if necessary by using a barrel connector (1786-BNCP).

IMPORTANT

Be certain that:

• you choose a convenient location to mount and route the cable.

• the location does not cause any cable bend-radii to exceed the

limits listed on pages 3-1 and 3-2.

If the barrel connector (1786-BNCP) is used, use an intrinsically-safe insulator, the light-blue dust caps we provide, or tape having a 500V insulation rating to cover exposed metal parts. Local agencies require their use for intrinsically-safe certification.

Publication CNET-IN003A-EN-P - January 2006

• you route the cable in accordance with intrinsically-safe cable

routing specifications.

• you do not mount the tap in a position that routes the drop

cable over any ac power terminals on nearby modules.

Install a ControlNet Ex Media System 3-3

ATTENTION

Do not allow any metal portions of the tap, such as the universal mounting bracket screws or connectors, to contact any conductive material. This contact could cause noise on the network.

Also be certain all exposed metal is covered by either the intrinsically-safe insulators or tape having a 500V dielectric rating.

Mount the Taps

You can mount your ControlNet Ex taps (Y-tap and T-tap):

• to a universal mounting bracket, and then mount the tap and

bracket as an assembly.

• through the body holes in the tap using screws, flat washers,

and a tie wrap.

Once you have mounted your taps, you can store or discard any unused universal mounting brackets.

TIP

See Appendix A for universal mounting bracket and tap mounting dimensions.

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3-4 Install a ControlNet Ex Media System

Mount a Tap with a Universal Mounting Bracket

1. Align the universal mounting bracket with the mounting holes

on the tap.

2. Use the screws provided with the tap to attach the tap to the

universal mounting bracket.

Universal Mounting Bracket

Y-Ta p

Universal Mounting Bracket (Provided With Tap)

Use only the screws that are packaged with the tap. They are the proper length and head style.

20084-M

ATTENTION

Dust Cap

T-Ta p

Do not over-tighten the screws. Over-tightening the screws can damage the tap. The applied torque should be 0.2-0.4 Nm (1-2 ft-lbs).

Do not remove the intrinsically-safe dust cap unless the tap drop is connected to a ControlNet Ex product.

20080-M

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Install a ControlNet Ex Media System 3-5

3. Mount the tap and bracket assembly to a DIN rail or another

mounting surface.

DIN Mounting Rail Another Mounting Surface

Universal Mounting Bracket

Use four screws to attach the universal mounting bracket to another mounting surface.

DIN Rail

Suitable Fixture

20081-M

Mount the universal mounting bracket on specified Allen-Bradley mounting rails or #3 style symmetrical DIN rails (35 mm X 7.5 mm [1.38 in. x 0.30 in.])

20082-M

Type of Rail Cat. No. Type of Rail Cat. No.

A-B rail 1492-N1 DIN rail #3 199-DR1

1492-N22 1492-DR5 1492-N44 1492-DR6

1492-DR7

ATTENTION

Use an intrinsically-safe insulator, the light-blue dust caps we provide, or tape having a 500V insulation rating to cover exposed metal parts. Local agencies require their use for intrinsically-safe certification.

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3-6 Install a ControlNet Ex Media System

Mount a Tap Through the Body Holes

TIP

A suitable fixture (mounting surface) can be conductive or grounded because the mounting holes are electrically isolated.

Mount the tap to a suitable fixture by using a tie wrap, or screws and flat washers.

Tie Wrap Screws and Flat Washers

Screws and Flat Washers

41645

Body Holes

ATTENTION

Tie Wra p

You can use a variety of screw types.

Do not over-tighten the screws. Over-tightening the

Body Holes

screws can damage the tap. The applied torque should be 0.2-0.4 Nm (1-2 ft-lbs). Do not use screws larger than #8 in these holes.

(Not Supplied)

41646

Specifications

Install Fiber Hubs

Publication CNET-IN003A-EN-P - January 2006

The following table lists the specifications for the ControlNet Ex taps.

Operating temperature -20 to 70 °C (-4 to 158 °F) Storage temperature -40 to 85 °C (-40 to 185 °F) Relative humidity 5 to 95% noncondensing

Read the following sections before installing a fiber repeater hub.

To Install a Fiber Repeater Hub, You Should See Page

Apply the Installation in Zone 1 and related intrinsically-safe warnings and standards

Select where to mount the fiber repeater hub 3-8 Mount the fiber repeater hub 3-9

3-7

Install a ControlNet Ex Media System 3-7

Installation in Zone 1

The 1797-RPA and 1797-RPFM modules must not be exposed to the environment. You must install these modules in a metal enclosure. This repeater hub has a protection factor of IP20.

Attention: Avoid electrostatic charge.

ATTENTION

These modules cannot be used in a hazardous environment after they have been exposed to non-intrinsically-safe signals.

Electrostatic Charge

Protect the system against electrostatic charge. Post a sign near this module. The sign should read

Attention! Avoid electrostatic charge.

For your convenience, see page C-1 for signs that you can cut out.

European Community Directive Compliance

If this product has the CE mark it is approved for installation within the European Community or EEA regions. It has been designed and tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:

• EN50081-2 EMC — Generic Emission Standard, Part 2 —

Industrial Environment

• EN50082-2 EMC — Generic Immunity Standard, Part 2 —

Industrial Environment

This product is intended for use in an industrial environment.

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3-8 Install a ControlNet Ex Media System

Ex Directive

This product is tested to meet the Council Directive 94/9 EC (ATEX 100a) Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres by applying the following standards:

• EN50014:1992, Electrical Apparatus for Potentially Explosive

Atmospheres

• EN50020:1994, Electrical Apparatus for Potentially Explosive

Atmospheres - Intrinsic Safety “i”

• EN50039:1980, Electrical Apparatus for Potentially Explosive

Atmospheres - Intrinsically-safe Electrical Systems “i”

• pr EN50284:1997, Special requirements for construction, test,

and marking of electrical apparatus of equipment group II, category 1 G

Inputs/Outputs

Do not apply any non-intrinsically-safe signals to the fiber modules.

When you use an intrinsically-safe electrical apparatus according to EN50020, the European directives and regulations must be followed.

Select a Fiber Repeater Hub Mounting Location

The fiber repeater hub should be mounted:

• so that air can flow in and out of the air holes on the top and

bottom of the coax repeater.

For proper ventilation, be certain that there is a minimum of 5.1 cm (2 in.) from surrounding equipment.

• in a NEMA enclosure to provide protection from dust, moisture,

or corrosive atmospheres to a grounded metal plate, if possible.

ATTENTION

Be certain that the adapter and fiber modules are secured together with DIN-rail anchors. Failure to do so may result in the loss of communications or cause damage to the modules.

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Install a ControlNet Ex Media System 3-9

Mount the Fiber Repeater Hub

Follow this procedure to mount the fiber repeater hub.

1. Position the module on a 35 mm x 7.5 mm (1.38 in. x 0.30 in.)

DIN rail (A-B part number 199-DR1) at approximately a 30° angle.

41167

2. Hook the lip on the rear of the adapter onto the top of the DIN

rail, and rotate the module onto the rail.

41166

3. Press the adapter down onto the DIN rail until flush.

The locking tab should snap into position and lock the module to the DIN rail.

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3-10 Install a ControlNet Ex Media System

4. If the adapter does not snap into position, use a screwdriver or

similar device to move the locking tab down while pressing the module flush onto the DIN rail. Release the locking tab to lock the module in place. If necessary, push up on the locking tab to lock.

41168

5. Remove the adapter backplane connector cover.

6. Follow steps 1 through 4 to attach fiber modules to the DIN rail.

7. Once attached to the DIN rail, slide fiber modules to the left to

mate with the adapter.

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41169

IMPORTANT

A DIN-rail end anchor (A-B part number 1492-EA35) must be used on the left side of the adapter and to the right side of the fiber module to keep the units from moving.

8. Be certain the last fiber module has its backplane connector

cover in place.

9. Connect the adapter wiring as shown on page 3-11.

IMPORTANT

You can attach only two media modules to the repeater adapter. If you exceed the module limit, you may cause damage to the adapter or fiber modules and void the intrinsically-safe certification.

Install a ControlNet Ex Media System 3-11

Connect the Fiber Repeater Hub to a ControlNet Ex Network

1. Connect to the ControlNet Ex coax network with the drop line

of the Ex coax tap to the adapter BNC connector.

Intrinsically-safe Insulator

41170

2. Connect the fiber media to the fiber module by attaching the

receive and transmit fibers to either the left or right set of receive and transmit ports.

IMPORTANT

Make note of which fiber is receive and which is transmit. These fibers must be interchanged at the opposite end of the cable.

3. Attach the opposite ends of the cable to the other fiber module.

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

Control

REPEATER ADAPTER

+V -V +V -V

Receive

Transmit

ATTENTION

1797 - RPA

Net Ex

PWR

QUALITY

Recv Xmit Recv Xmit

1797 - RPFM

Net Ex

Control

FIBER MODULE MEDIUM RANGE

Chan 1

Chan 2

B-A

Allen-Bradley

Use the blue intrinsically-safe insulators on all coax

B-A

Allen-Bradley

QUALITY

Comm

Module

Status

1797 - RPA

Net Ex

Control

REPEATER ADAPTER

PWR

+V -V +V -V

B-A

Allen-Bradley

QUALITY

Recv Xmit Recv Xmit

1797 - RPFM

Net Ex

Control

FIBER MODULE MEDIUM RANGE

Chan 1

Chan 2

Tr an sm i t Receive

4131

BNC drop connectors as they are installed.

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3-12 Install a ControlNet Ex Media System

4. Apply +V and -V power from a 1797 power supply to the

adapter through a removable terminal block.

+V -V +V -

V-V+V-V

4129

Screw term inals and sprin g terminals are provided.

5. Strip the +V and -V wires to a length so that no bare conductor

shows after inserting the wires into position.

6. If you are using the spring terminals of the plug, insert a

screwdriver into the slot and carefully pry until the spring clamp opens to accept the wire.

ATTENTION

IMPORTANT

Do not use any unused terminals on this adapter. Using these terminals as supporting terminals can result in damage to the module or unintended operation of your system.

Make certain that you power this adapter with an intrinsically-safe power supply. Do not exceed the values listed in the specifications for this adapter.

Do not remove or replace a module when power is applied. Interruption of the bus can result in unintended operation or machine motion.

Be certain that all fiber modules are attached and secured before you apply intrinsically-safe power to the adapter. Failure to do so may cause damage to the adapter and modules.

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Install a ControlNet Ex Media System 3-13

Install Cable Connectors

Wire Cutters

After you have mounted the taps, you need to attach cable connectors to the ends of your trunk cable sections.

Collect Your Tools

To install the cable connectors, we recommend that you use the tools in the ControlNet Coax Toolkit, catalog number 1786-CTK.

ControlNet Media Component List, Publication AG-PA002

ControlNet Coax Media Planning and Installation Guide, Publication CNET-IN002

Cable Strip Tool With Two Blade Cassettes (One for PVC and One For FEP)

Crimp Tool

Knife

Calibration/Flare Tool

Memory Blade Holder

ATTENTION

Terminators and Extra Connectors

Memory Blade Cartridges (Contains Two Sets of Memory Blades)

41902

Be certain that you calibrate the cable strip tool the first time you use the tool and every time you change the blade for both memory cartridges. Refer to Appendix B for the proper calibration procedure. Due to slight differences between coax cables, you should calibrate the tool when changing:

• part numbers

• from one cable manufacturer to another

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3-14 Install a ControlNet Ex Media System

Strip the Cable

When you cut cable sections, make them long enough to route from one tap to the next with sufficient length so that the bend radius is not less than:

• 76.2 mm (3 in.) for wiring external to enclosures

• 38.1 mm (1.5 in.) for wiring inside enclosures

ATTENTION

Be certain to perform the calibration procedure the first time you use the tool and every time you change the blade or both memory cartridges. Refer to Appendix B for the proper calibration procedure.

1. Verify that you have the proper memory blade holder installed

for the type of cable you are using (PVC-CL2 or FEP-CL2P). If you need to change the memory blade holder, see Appendix B.

Blade Holder

20165

2. Straighten out the end of the cable.

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3. Insert the cable into the cable strip tool’s cutting chamber so that

extra cable, approximately 25.4 mm (1 in.), extends beyond the edge of the tool.

25.4 mm (1 in.) Extra Cable

Cable

20073

Install a ControlNet Ex Media System 3-15

4. Lock the cable into place by moving the chamber-gauge ring

forward until it meets the cable with slight resistance.

20073

This gauge moves two rollers toward the cable and regulates the depth of the cut.

The gauge will click as it moves from one gauge to the next.

5. Hold the cable in one hand, place the index finger of your other

hand inside the chamber-gauge ring and turn the strip tool 360° around the cable. Turn four or five full rotations until the strip tool glides easily around the cable.

IMPORTANT

20074

Repeat steps 4 and 5, moving the chamber-gauge ring forward one notch

for each time you repeat the steps, until you reach the last notch.

Each Time you move the chamber-gauge ring forward a notch, the strip tool makes a deeper cut into the cable.

The last time you repeat steps 4 and 5, apply sufficient pressure on the chamber-gauge ring to be certain the ring has reached the last stage. The chamber gauge reads ‘stop’ for the last repetition.

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3-16 Install a ControlNet Ex Media System

6. After you have moved the chamber gauge ring to the last

position and turned the strip tool the final time: a. Move the chamber-gauge ring backward to release the strip

tool and remove it from the cable.

b. Slip the crimp ferrule onto the cable. Push it back to the

sheath area of the cable to keep it out of the way for the moment.

Crimp Ferrule

41887a

Cable

c. Strip away the appropriate portion of the cable without using

the strip tool.

d. Clean the cable parts that remain from the strip chamber after

each use.

Be sure to strip the cable to expose these layers of the cable:

All Four Shield Layers

Braid/Tape/Braid/Tape

8.3 mm (0.33 in.)

3.7 mm (0.15 in.)

White Foam Electric Or 1st Tape, If Tape Is Bonded

Center Conductor

4.0 mm (0.16 in.)

20076a

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Install a ControlNet Ex Media System 3-17

Be sure to strip the cable to expose these layers of the cable:

All Four Shield Layers

Braid/Tape/Braid/Tape

White Foam Electric Or 1st Tape, If Tape Is Bonded

Center Conductor

4.0 mm (0.16 in.)

20076a

IMPORTANT

8.3 mm (0.33 in.)

3.7 mm (0.15 in.)

If you do not see the three distinct layers of cable or if the outer braid has been scored or cut, snip off the exposed end with the wire cutters and repeat the entire cable-stripping process. It is very important that the outer braid be intact before you crimp the connector.

If You Are Using

FEP cable 7

PVC cable 8

Go To Step

7. If you are using plenum FEP cable, cut off an additional 3.1mm

(approximately 1/8 in.) of the outer sheath with the knife from the toolkit.

All Four Shield Layers

Braid/Tape/Braid/Tape

White Insulation Or 1st Tape

Center Conductor

Sheath

11.44 mm (0.45 in.)

3.7 mm (0.15 in.)

4.0 mm (0.16 in.)

20076a

8. Be certain that the center conductor meausures 4.0 mm (0.16 in.)

in length.

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3-18 Install a ControlNet Ex Media System

Use the imprint guide on the back of the ControlNet tap or the calibration tool to verify this.

Center Conductor

The center conductor should be exactly 4.0 mm (0.16 in.). If the center conductor is too long, cut off the excess with the wire cutter from the cable kit. If it is too short, repeat the entire cable stripping process.

T-Ta p

ATTENTION

PVC Cable Only

Check for any braid stranding that may not have been cut at the proper length. If one strand comes in contact with the center conductor, it could short out the cable. If you find any such strands, cut them to the correct length.

3.7 mm (0.15 in.)

4.0 mm (0.16 in.)

8.3 mm

(0.33 in.)

PVC Cable

PVC/CL2

Calibration/flare Tool

PVC/CL2 FEP/CL2P

FEP/CL2P

Use this end of the calibration tool to verify proper measurements for FEP cable.

4195

Publication CNET-IN003A-EN-P - January 2006

ATTENTION

Check the outer braid of cable for cut or scored braid wire after you strip the cable. If the braid is damaged, cut off the end and strip the cable again. You may need to adjust the appropriate striper blade by backing the set screw out 1/8 of a turn. Do not crimp the BNC to a damaged braid. This type of mistake accounts for most of the connectivity problems that can occur. Precise, clean connections will reduce network errors.

Install a ControlNet Ex Media System 3-19

Test for Electrical Shorts and Continuity Between the Center Conductor and the Shield

1. The NetLinx Media Checker (catalog number 1788-MCHKR) is

the preferred tool for continuity testing. Attach the connector end of the cable to the port on top of the media checker.

Attach the connector end of the cable to the port on top of the media checker.

MediaChecker

1788-MCHKR

SETUP

OFF

ENTER

LENGTH

WIRE MAP

TEST

31195-M

2. As a secondary method, you can also use an ohmmeter or

continuity tester to test for a short between the connector body and pin.

3. Use shorting clips to connect a temporary short between the pin

and connector body at one end of the cable.

Connector Body

20166

4. At the other end of the cable, use the media checker, an

ohmmeter, or continuity tester to test for electrical continuity.

If Resistance Reading Indicates Then

That a short exists Continue to next section

There is no short Use your wire cutters to cut off the

connector, install a new connector and begin testing again

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3-20 Install a ControlNet Ex Media System

IMPORTANT

Replace the trunk cable section if problems persist with the cable after completing these tests.

Attach the Connectors to the Cable

1. Push the calibration/flare tool onto the cable and with a slight

twisting motion (with sufficient inward pressure) to expand the braid.

41888

Push the calibration/flare tool gently and rotate slightly onto the connector while you apply pressure. This will work the base of the connector underneath the wire braid slowly.

4189

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Install a ControlNet Ex Media System 3-21

2. Place the center pin over the center conductor.

Center Conductor

center conductor

41889

Sometimes strands of insulation are left on the center conductor. Be certain that the center

Center Pin

enter pin

conductor is clean before you install the center pin.

IMPORTANT

Be certain that the center pin slips onto the center conductor completely. The back shoulder of the center pin should be up against the white insulation. If it is not, recheck the length of the center conductor.

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3-22 Install a ControlNet Ex Media System

3. With the center pin in place, use the crimp tool to crimp the pin

into place.

The smaller hexagonal crimping notch is for crimping the center pin onto the center connector.

41903

Check for braid strands that could cause a short to center conductor.

4. Slide the ControlNet connector onto the cable.

Braid and Tape Shields

Connector Base

41896

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Install a ControlNet Ex Media System 3-23

5. Slide the crimp ferrule over the three outer shields and

connector base until it meets the shoulder on the connector.

20077e

6. Use the crimp tool to crimp the ferrule. Position the crimp tool

on the ferrule as close as possible to where the connector base and ferrule meet. Press the tool tightly around the ferrule until the crimp tool releases.

The larger hexagonal crimping notch is for crimping the ferrule which holds the connector to the cable.

IMPORTANT

Crimp Ferrule

Many network problems are due to improperly installed connectors. Your connectors should fit tight on the ends of all your cables. Pull the connector to verify that it is attached. If it is loose or comes off, snip off the connector and install a new one. The connector should withstand a minimum 75lbs pull force if properly installed.

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3-24 Install a ControlNet Ex Media System

Test for Electrical Shorts and Continuity Between the Connector Body and Pin

1. Use an ohmmeter or continuity tester to test for a short between

the connector body and pin.

Attach the connector end of the cable to the port on top of the media checker.

MediaChecker

1788-MCHKR

SETUP

OFF

ENTER

LENGTH

WIRE MAP

TEST

31195-M

If Resistance Reading Indicates Then

That a short exists Continue to next section.

There is no short Use your wire cutters to cut off the

connector, install a new connector, and begin testing again.

2. Connect a temporary short between the pin and connector body

at the opposite end of the cable.

Connector Body

41686

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Install a ControlNet Ex Media System 3-25

3. At the same end of the cable tested in step 1, use an ohmmeter

or continuity tester to test for electrical continuity.

Attach the connector end of the cable to the port on top of the media checker.

MediaChecker

1788-MCHKR

SETUP

OFF

If Resistance Reading Indicates Then

That a short exists Continue to next section.

There is no short Use your wire cutters to cut off the

ENTER

LENGTH

WIRE MAP

TEST

31195-M

connector, install a new connector, and begin testing again.

Connect Cable Sections

Terminate Segments

Connect the cable sections to the tap’s BNC connectors and cover all exposed metal with intrinsically-safe insulators.

The taps on the ends of the segment have only one cable connector attached to them. This leaves an open, or unterminated, end on the segment. Signals transmitted along the cable will reflect off these unterminated ends and interfere with transmission.

To eliminate signal reflections from the ends of the segment, you must

attach a 75 Ω trunk terminator (catalog number 1797-XT) to the first

and last taps on the segment. The terms first and last refer to the physical location of the node along the trunk cable.

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3-26 Install a ControlNet Ex Media System

1. Connect one end of the trunk cable section to one of the tap

BNC connectors.

20078

2. Slide the intrinsically-safe blue insulator over the BNC connector

to cover any exposed metal.

3. Install a 75Ω terminator onto the tap’s other BNC connector.

Repeat steps 1 and 2 at the other end of the segment.

1797-XT with intrinsically-safe insulator

ATTENTION

Be certain that the intrinsically-safe insulator covers

20079

all metal parts.

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Install a ControlNet Ex Media System 3-27

Connect Devices

After you terminate your segments, connect your devices.

To Connect a See

Fiber repeater hub Page 3-11 ControlNet Ex adapter Procedure below

1. Remove and save the blue dust cap (on the straight or

right-angle connector).

2. Replace the dust cap with the blue intrinsically-safe insulator

ring.

3. Connect the straight or right-angle connector to your device.

If Your Node Supports Connect the Straight or Right-angle Connector

non-redundant media To the channel A connector on the device (channel B is not

redundant media From trunk cable A to channel A on your device

While both channels are active, we recommend using channel A for non-redundant media.

used)

From trunk cable B to channel B on your device

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3-28 Install a ControlNet Ex Media System

Install the 1797-BCNR Module

Use the 1797-BCNR FLEX Ex ControlNet barrier module in Class I, Divison 2 or Zone 2 safe areas, as shown in the figure.

Figure 3.1 ControlNet Coax to Ex System With 1797-BCNR FLEX Ex ControlNet Barrier Module

Hazardous Area

ControlNet Ex Tap (1797-TPR)

ControlNet Ex Adapter

ControlNet Ex Tap (1797-TPR)

ControlNet A

ControlNet Ex TAP (1797-TPR)

ControlNet B

ControlNet Ex Tap (1797-TPR)

Safe Area

ControlNet Barrier

WARNING

The 1797-BCNR barrier module cannot be used in an intrinsically-safe environment after it has been exposed to non-intrinsically-safe signals.

IMPORTANT

For complete installation instructions and requirements, refer to the FLEX Ex Redundant ControlNet Barrier Module Installation Instructions, publication 1797-5.35.

To install the module:

1. Select the appropriate mounting location.

2. Mount the barrier module on Rockwell Automation part number

199-DR1 DIN rail.

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Install a ControlNet Ex Media System 3-29

3. Ensure the locking tabs snap into place.

IMPORTANT

Connect the ControlNet Ex side of the barrier module to either a 1797-ACNR15 FLEX Ex I/O module or a 1797-TCAP FLEX Ex Safe Tap Dummy Load using only ControlNet Ex Taps (such as 1797-TPR, 1797-TPYR, 1797-TPS, or 1797-TPYS).

4. Remove the insulator boot from the terminals.

5. Connect the trunk cable as shown in the illustration.

ControlNet Trunk Cables

Channel A

Channel B

Out

30502-mdin

a. Connect the ControlNet trunk cable to the Channel A output

connector (1).

b. Connect the redundant ControlNet trunk cable to the Channel

B output connector (2).

c. Connect the ControlNet trunk cable to the Channel A input

connector (3).

d. Connect the redundant ControlNet trunk cable to the Channel

B input connector (4).

6. Install a direct ground wire with a minimum diameter of 4 mm

between terminal 5 and the PA Ground (Equipotential System) in the hazardous area where the ControlNet Ex coax cable is installed.

IMPORTANT

Do not connect terminal 5 or the DIN rail to a standard earth ground connection in the safe area.

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3-30 Install a ControlNet Ex Media System

Notes:

Publication CNET-IN003A-EN-P - January 2006

Mounting Dimensions

Appendix

What This Appendix Contains

Tap Placement

33.02 mm (1.30 in.)

Use these mounting dimensions to mount your taps, universal mounting brackets, and repeaters.

Make copies of these templates as necessary to help you mark placement for your taps.

T-T ap

35.66 mm (1.40 in.)

15.24 mm (0.60 in.)

25.44 mm (1.00 in.)

39.37 mm (1.55 in.)

Y-Tap

30.23 mm (1.19 in.)

15.24 mm

(0.60 in.)

31.37 mm (1.235 in.)

127 mm (5/16 in.) Mounting Holes

20168

1 Publication CNET-IN003A-EN-P - January 2006

20169

A-2 Mounting Dimensions

Universal Mounting Bracket

30.94 mm (1.128 in.)

19.05 mm (0.75 in.)

58.42 mm (2.30 in.)

49.53 mm (1.95 in.)

9.53 mm (0.375 in.)

15.47 mm (0.609 in.)

20170-m

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Adjust the Cable Strip Tool

41892

Appendix

What This Appendix Contains

Calibrate the Cutting Blades

Follow the instructions in this appendix to calibrate the cable strip tool supplied with the ControlNet Coax Toolkit (1786-CTK).

Use the following procedure to calibrate your cable strip tool to cut FEP or PVC cable.

1. Turn the three screws outward to back the blades out. This

prevents the calibration tool from bottoming out.

2. Place the calibration tool into the cable strip tool with the

narrow end installed and facing forward for FEP cable (use the wider end for PVC).

Calibration Tool

PVC

FEP

Adjusting Screws

To Turn The Screw

Increase the cut depth Clockwise

Decrease the cut depth Counterclockwise

2088-m

3. Tighten the chamber gauge ring so that the calibration tool is

locked in place.

4. Continue tightening all the way to the chamber gauge stop.

When aligned properly, the grooves of the calibration tool should align with the blades.

5. Adjust the screws of the memory clip so that the blades just

touch the calibration tool.

ATTENTION

1 Publication CNET-IN003A-EN-P - January 2006

Do not over-tighten the screws of the cable strip tool. The blades should not bend, shift, or penetrate the calibration tool.

B-2 Adjust the Cable Strip Tool

6. Retract the handle of the cable strip tool.

7. Remove the calibration tool from the cable strip tool.

When you have finished, the blade should make a cut of the following dimensions in your cable.

First Cut: All Four Shield Layers-braid/tape/braid/tape

The first cut should cut the outer sheath without cutting the outer wire braid. If the braid is frayed, scored, or cut by the blade, adjust the blade outward slightly to eliminate the fraying.

The first and second cut adjustments need to be precise. Adjustments as small as 1/12 to 1/8 of a turn can make the difference between a perfect and an imperfect cut.

Second Cut: White Insulation Or 1st Tape

The second cut should cut the sheath, three outer shields, and possibly the inner tape shield. The insulation can be scored slightly, but should not have a deep cut.

8.3 mm (0.33 in.)

3.7 mm

4.0 mm

(0.15 in.)

(0.16 in.)

Third Cut: Center Conductor

The third cut should cut all layers of the cable down to the center conductor. This cut should not score the center conductor. If the blade leaves a mark on the conductor, adjust the blade slightly so to eliminate marking the conductor.

30030-m

Publication CNET-IN003A-EN-P - January 2006

ATTENTION

Check the outer braid of cable for cut or scored braid wire after stripping the cable. If the braid is damaged, strip the cable again. If needed, adjust the appropriate striper blade by backing the set screw out 1/8 of a turn. Do not crimp the BNC to a damaged braid. This type of mistake accounts for most of the connectivity problems that occur. Precise, clean connections will reduce network errors.

Adjust the Cable Strip Tool B-3

Reverse and Replace the Cutting Blades

To reverse or change the cutting blades:

1. Use a screwdriver to lift the memory blade holder and swing it

back.

20182-m

2. Slide the memory blade cartridge out of the strip tool.

20183-m

If You Are Go To

Reversing the memory blade cartridge to use the second set of blades

Replacing the memory blade cartridge Step 4

The next step

3. Flip the memory blade cartridge and slide it back into the strip

tool.

Publication CNET-IN003A-EN-P - January 2006

B-4 Adjust the Cable Strip Tool

30031-m

Go to step 5.

4. Align the memory blade cartridge (the side with the raised

notches) to the raised area on the inside of the strip tool and slide the new memory blade cartridge in

Raised Notch

TIP

The blades should be on top as you slide the cartridge in.

Raised Area

30031a-m

5. Swing the memory blade holder closed.

Publication CNET-IN003A-EN-P - January 2006

20069-m

Adjust the Cable Strip Tool B-5

Change the Memory Blade Holder

You received two memory blade holders with your cable strip tool; one is for PVC-CL2 cable, and the other is for plenum FEP-CL2P cable. You need to install the appropriate memory blade holder for the type of cable you are stripping (PVC or FEP).

1. Lift the latches on the memory blade holder and swing it back.

20182-m

2. Snap the memory blade holder off the rod and

remove it from the strip tool.

20070-m

3. Position the appropriate memory blade holder on the rod and

snap the holder into place.

4. Swing the memory blade holder closed.

20069-m

Publication CNET-IN003A-EN-P - January 2006

B-6 Adjust the Cable Strip Tool

Notes:

Publication CNET-IN003A-EN-P - January 2006

Appendix

Protect Your System Against Electrostatic Discharge

Protect the system against electrostatic charge. Post a sign near this module: Attention: Avoid electrostatic charge. For your convenience, we provide some signs you can cut out below.

Post these labels or something similar beside each module to protect the system against electrostatic charge.

Attention: Avoid electrostatic charge.

1 Publication CNET-IN003A-EN-P - January 2006

C-2 Protect Your System Against Electrostatic Discharge

Notes:

Publication CNET-IN003A-EN-P - January 2006

Index

abbreviations and symbols 1-2 about this manual 1-1 application considerations 2-13

barrel connector 2-8 BNC cable connectors 1-6, 2-8

installing 3-13

bridge 1-2 bullet connector 2-2, 2-8

cable connectors 1-6, 2-8

barrel 2-8 bullet 2-8 installing 3-13 isolated bulkhead 2-8 right-angle 2-8

categories of conductors 2-13 coax cable 2-3 Collect Your Tools 3-13 continuity tester 3-19 ControlNet cable system

application considerations cable connector

2-2

bullet

cable connectors 1-6, 2-8

optional 1-6 Coax Toolkit 3-13 component definitions 1-2 connecting cable sections 3-25 connecting devices 3-27 determine

cable needed

number of repeaters 2-8

number of taps 2-2

number of terminators needed 2-7

trunk cable section lengths 2-4

type of cable connectors needed

2-3

2-8

ferrite beads 2-15 installing

cable connectors

trunk cable 3-1 link 2-17 mounting taps 3-2 network 1-2 node 1-4 ordering components 2-17 planning guidelines 2-17

2-13

3-13

redundant media 2-10 repeater 1-2, 1-7, 2-8 segment 1-7, 2-17 stripping trunk cable 3-14 surge suppression 2-15 tap 1-2, 1-4, 2-2, 2-18

mounting dimensions A-1 terminating segments 3-25 terminator 2-18 terminators 1-3, 2-7 testing for electrical continuity 3-19,

3-24

trunk cable 1-2, 1-5, 2-18

testing 3-19, 3-24

wiring 2-14

wiring external to enclosures 2-14

wiring inside enclosures 2-14 trunk cable section 1-2, 1-5, 2-4 wiring guidelines 2-14

ControlNet Coax Toolkit

crimp tool knife 3-17 strip gauge 3-18 strip tool 3-14

3-22

adjusting the cutting blades B-1

changing the memory blade holder

B-5

crimp tool 3-22

FEP cable 1-2 ferrite beads 2-15 flare tool 3-13

installing cable connectors

stripping the cable stripping trunk cable 3-14

isolated bulkhead connector 2-8

3-17

link

planning

2-17

media

redundant

mounting dimensions

tap

2-10

guidelines 2-10

A-1

Publication CNET-IN003A-EN-P - January 2006

2 Index

NetLinx Media Checker 3-19 node 1-4

ohmmeter 3-19 ordering components 2-17

programming terminals

ways to connect to a ControlNet link

publications

1770-4.1 AG-PA002 1-4, 2-8 CNET-IN001 1-1 CNET-IN002 1-1

PVC cable 1-2, 3-1, 3-17

2-14

redundant media 2-10

guidelines 2-10

repeater 1-2, 1-7, 2-8

selecting where to mount 3-8

RG-6 cable 2-3, 3-1 right-angle connector 2-8

2-3

changing the memory blade holder B-5

support

questions or comments about manual

1-2

technical product assistance 1-2

surge suppression 2-15

tap 1-2, 1-4, 2-18

determine number needed 2-2 mounting 3-2

to a universal mounting bracket 3-4

using the body holes 3-6 mounting dimensions A-1 selecting where to mount 3-2

techniques used in the manual 1-2 terminators 1-3, 2-7 trunk cable 1-2, 1-5

bend radius 3-1 installing 3-1 pull strength 3-1 stripping 3-14 terminating 3-25 testing for shorts and continuity 3-19,

3-24

wiring external to enclosures 2-14, 3-1 wiring inside enclosures 2-14, 3-2

trunk cable section 1-2, 1-5, 2-4, 3-25

segment 1-7

planning 2-17 terminating 3-25

strip tool

adjusting the cutting blades

B-1

wiring

external to enclosures inside enclosures 2-14, 3-2

wiring guidelines 2-14

2-14, 3-1

Publication CNET-IN003A-EN-P - January 2006

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Installation Assistance

If you experience a problem with a hardware module within the first 24 hours of installation, please review the information that's contained in this manual. You can also contact a special Customer Support number for initial help in getting your module up and running:

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Publication CNET-IN003A-EN-P - January 2006 5 PN 957208-04

Rockwell Automation 1797 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Preface

What’s in This Chapter

Abbreviations and Symbols

Common Techniques

For More Information

What This Chapter Contains

Understand the ControlNet Ex Media System

Understand ControlNet Ex Components

Nodes

Tap s

Trunk Cable

Cable Connectors

Trunk Terminator

Tap Terminator

Segments

Fiber Repeater Hubs

Network

Insulators

ControlNet Ex System Installation Requirements

Certified Equivalent ControlNet Ex System Components

UL, cUL I/O Entity Parameters and Requirements

European Community Directive Compliance

EMC Directive

Ex Directive

What Is Next?

What This Chapter Contains

Determine How Many Taps You Need

Connect Programming Devices in Safe Areas

Coax Cable Type

Fiber Media Type

Determine Trunk Cable Section Lengths

Determine Trunk Cable Section Length When You Use a FLEX Ex Redundant ControlNet Barrier Module

Estimate Fiber Media Lengths

Determine How Many Trunk Terminators You Need

Use Redundant Media in a Hazardous Area

Application Considerations

Understand Conductor Categories

General Wiring Guidelines

Ferrite Beads

Required Ferrite Beads

Add Ferrite Beads

Order Components

General Planning

Plan a Segment

Plan Your Network

Order Parts

What Is Next?

What This Chapter Contains

Install the Trunk Cable

Wire External to Enclosures

Wire Inside Enclosures

Mount the Taps

Select Where to Mount the Taps

Mount the Taps

Specifications

Install Fiber Hubs

Installation in Zone 1

Electrostatic Charge

Select a Fiber Repeater Hub Mounting Location

Mount the Fiber Repeater Hub

Connect the Fiber Repeater Hub to a ControlNet Ex Network

Install Cable Connectors

Collect Your Tools

Strip the Cable

Test for Electrical Shorts and Continuity Between the Center Conductor and the Shield

Attach the Connectors to the Cable

Test for Electrical Shorts and Continuity Between the Connector Body and Pin

Connect Cable Sections

Terminate Segments

Connect Devices

Install the 1797-BCNR Module

What This Appendix Contains

Tap Placement

Universal Mounting Bracket