GE Intelligent Platforms. Wellhead RTU Solutions

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1 GE Intelligent Platforms Wellhead RTU Solutions

3 Wellhead RTU Solutions Table of Contents Brochures.Page 3 Presentations..Page 21 Datasheets...Page 35 Parts List.Page 175

5 Brochures

7 GE Intelligent Platforms PAC8000 RTU

A ruggedized, reliable RTU PAC8000 Remote Terminal Unit (RTU) thrives in the desert heat of the Arabian Peninsula and the arctic cold of Siberian oil fields delivering quality, reliability and safety

With increasing pressure to improve operational performance, meet environmental specifications and overcome rising energy costs, oil and gas operations must efficiently and securely monitor and

8 A ruggedized, reliable RTU PAC8000 Remote Terminal Unit (RTU) thrives in the desert heat of the Arabian Peninsula and the arctic cold of Siberian oil fields delivering quality, reliability and safety for your success. With increasing pressure to improve operational performance, meet environmental specifications and overcome rising energy costs, oil and gas operations must efficiently and securely monitor and control entire processes across local and remote locations. You need a partner that understands your business and can deliver the expertise and capabilities to drive results. The PAC8000 RTU solution from GE Intelligent Platforms enables you to easily monitor, diagnose and maintain your utility assets even in the most hazardous environments. Access to timely and accurate mission-critical information from fixed assets such as oil and gas wells, compressor stations, pipelines, fluid storage tanks and utility meters, can eliminate critical gaps in your oil and gas operations, resulting in higher productivity and long-term growth. Benefits Designed by experienced process engineers, PAC8000 RTU is simple to use and delivers significant cost savings and value: Tough environmental specifications from 40 to +70 degrees Celsius continuous operation; 10 years of service in Class G3 corrosive environments Inherent reliability - redundant CPU, power supplies, communications Easy maintainability - hot replacement and automatic configuration Integrated intrinsic safety (optional) Integrate optionally with SafetyNet TUV certified to SIL 2 Scalability from 8 to 1024 I/O Extensive diagnostics for remote health monitoring Minimum cost field mounting Low cost of ownership PAC8000 RTU

Ensuring continuous operations In the unlikely event of failure, PAC8000 RTU maintains your operations with robust redundancy capabilities and flexible communications options.

9 Ensuring continuous operations In the unlikely event of failure, PAC8000 RTU maintains your operations with robust redundancy capabilities and flexible communications options. Firmware updates In keeping with its ability to maintain operations on a continuous basis, a redundant PAC8000 RTU can receive a firmware upgrade. Controller redundancy Redundant controllers can be used for critical applications whereby the redundant controller pair operates in parallel, checking status multiple times through the processing loop and enabling the backup controller to continuously monitor the health of the Master controller. It ensures a rapid and bumpless transfer to the standby controller. Network redundancy PAC8000 RTU has two high-speed Ethernet ports to provide communication security. Each port can be connected to an independent LAN, which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communication. Communication protocols DNP3 over Ethernet Modbus TCP over Ethernet Modbus RTU Serial Each controller has two serial ports that can be configured as a Modbus Master to control and obtain information from Modbus Slaves. The serial ports can also be configured as a Modbus Slave, accepting write commands from Modbus Master devices and providing information on its data registers. Executable programs The control programs are held in nonvolatile memory and can be restored automatically after power cycling of the controller. A new control program can be downloaded to a controller while the existing program is still operating. When the download is complete, the controller will automatically switch to the new control program without interruption to the operation of the plant. Failsafe and automatic cold start The RTU supports fault tolerant communications to the Control Room SCADA; however, in the unlikely event that the communications are lost, the RTU can either continue to operate autonomously or adopt a user-defined safe state. If the RTU continues to operate, data will be logged for transmission once communications have been restored. In the event of power loss, it will perform a cold restart, which restores the program(s) and assumes a predefined status. Controllers can also be configured to perform a warm start if RTU power is temporarily lost during a brownout.

10 Powerful features With PAC8000 RTU, you can meet demanding oil and gas applications while gaining a sustainable competitive advantage. PAC8000 RTU in your system PAC8000 RTU is designed for use in the harshest environments, operating over a temperature range of -40ºC to +70ºC, and it is resistant to 30g shock, 5g vibration and G3 corrosive environments. Each PAC8000 RTU controller node can address up to 64 I/O modules, which, depending upon the number of channels per module, can provide up to 1024 I/O points at a single node! A node can consist of a mixture of analog and discrete modules providing maximum flexibility to system designers. HART passthrough PAC8000 RTU can pass smart HART information from field devices to a distant PC workstation, allowing you to readily interface to asset management software applications to remotely manage the HART information contained in your HART-based field instruments. Hazardous area operation PAC8000 RTU is designed to operate in Class I, Division 2 and Zone 2 hazardous areas and can control I/O modules that have field wiring extending into the more hazardous Division 1, Zone 1 and Zone 0 areas. I/O modules I/O modules transfer signals to and from field instruments. Input modules receive signals from transmitters and sensors and convert them into a digital form for presentation to the controller, while output modules receive commands from the controller and transfer them to actuators. There are a wide range of modules, including types for low-level instrumentation, AC mains and intrinsically safe signals. I/O modules typically have 4, 8 or 16 field channels. A small footprint with a packing density of 3-6mm per channel allows for installations where space is a premium. Field terminals Field terminals provide the interface between the I/O modules and the field wiring, including fusing and loop-disconnect as options. A mechanical keying system prevents an I/O module from being inadvertently connected to the wrong type of field terminal. Mounting onto the module carrier, one to each I/O module, field terminals are clamped firmly by the I/O module to form an electrical and mechanical assembly of high integrity and may be replaced in service without removing carriers or disturbing the operation of other modules.

Carriers Carriers form the RTU s physical and electrical backbone by providing a mounting to support and interconnect the controller, power supplies, I/O modules and field terminals, and carry the

They provide termination points for the LAN and field wiring cable shields and can also distribute bussed field power to the I/O modules; I/O module carriers are available to support four or eight

Power supplies can be optionally redundant and any failures are flagged.

11 Carriers Carriers form the RTU s physical and electrical backbone by providing a mounting to support and interconnect the controller, power supplies, I/O modules and field terminals, and carry the address, data and power lines of the internal Railbus. They provide termination points for the LAN and field wiring cable shields and can also distribute bussed field power to the I/O modules; I/O module carriers are available to support four or eight I/O modules. System power supplies System power supplies are available for the node to convert local AC or DC supplies to power the node and provide field power for I/O modules. Power supplies can be optionally redundant and any failures are flagged. GE s innovative bussed field power scheme for distributing field power avoids complex wiring at the field terminal and minimizes the carrier wiring. Affordable intrinsic safety Our expertise is built into the front end of IS I/O modules for direct connection to hazardous area field wiring. This means no external barriers or isolators, no additional wiring and no extra cost. All you pay for is the integrated IS I/O module. Integrated power supplies Power for IS I/O modules is derived from integrated, modular power supply units, which can each supply between 8 and 20 I/O modules, depending on the I/O type and mix. Optional power supply redundancy is supported by means of an additional, redundant supply unit connected in an n+1 arrangement. In applications with mixed IS and non-is field wiring, the full facilities of the bussed field power regime are retained for the non-is part of the system. In nodes populated only with IS I/O modules, a separate system power supply module provides power for the Bus Interface Module and node services with redundancy capabilities. Versatility and tough design to meet your process I/O needs Oil and gas PAC8000 RTU is designed for the most remote places where oil and gas are found, and its wide temperature range means that it can be mounted outdoors on the plant anywhere in the world. Using redundant power supplies and network cables can increase system availability in these conditions further. Natural gas pipelines When I/O is installed in remote locations, it needs to be reliable and simple to maintain. PAC8000 RTU s I/O modules can be hotswapped on a live system. The configuration is backed up locally so no re-configuration is necessary even if several modules are removed and replaced at the same time. For more information about how PAC8000 RTU can deliver results for your business, visit

12 PAC8000 RTU At the heart of PAC8000 RTU is a powerful, robust controller for advanced control strategies. Controllers Controls up to 64 sixteen-channel modules Redundant controllers with dual redundant Ethernet connections Wide range of protocols including Modbus over Ethernet Regulatory and IEC software execute concurrently providing both process and discrete control On-line configuration and reconfiguration I/O Modules Wide range of I/O for virtually any process signal, including HART Smart analog, thermocouple, RTD, potentiometer, high-speed counter, frequency and quadrature Suitable for safe-area, non-incendive and intrinsically safe applications Remote configuration and interrogation of smart devices Packing density: 3-6mm per channel Live hot swapping Keying stops modules from being fitted in the wrong position Isolation between I/O bus and field wiring Diagnostic services for each channel

Power Supplies (not shown) AC power or 24V dc input versions Supplies power for I/O and controllers Redundant power supply options Bus Interface Modules (not shown) Connects up to 32 sixteen-channel

13 Power Supplies (not shown) AC power or 24V dc input versions Supplies power for I/O and controllers Redundant power supply options Bus Interface Modules (not shown) Connects up to 32 sixteen-channel modules Carriers Tough polycarbonate base protects against shock and vibration Choice of four module, eight module and Node Services versions Cable ground and shield terminals along front edge Reliable no active components so there is nothing to fail Replacement modules are configured automatically, so maintenance is simplicity itself Field Terminals Unique, removable terminals for fast wiring and field replacement Optional fuses and disconnects no interposing terminals required Direct termination for field wiring Field power routed to terminals no daisy chaining at the field terminals Integral tagging system

14 GE Intelligent Platforms Contact Information Americas: or Global regional phone numbers are listed by location on our web site at GE Intelligent Platforms, Inc. All rights reserved. *Trademark of GE Intelligent Platforms, Inc. All other brands or names are property of their respective holders GFA-1149B

15 GE Intelligent Platforms PAC8000 SafetyNet SIL 2 Functional Safety System

A cost-effective functional safety system GE Intelligent Platforms, through its acquisition of MTL Open System Technologies, has established itself as a leading supplier of process I/O and safety

16 A cost-effective functional safety system GE Intelligent Platforms, through its acquisition of MTL Open System Technologies, has established itself as a leading supplier of process I/O and safety products. One of the key technologies that GE now offers is PAC8000 SafetyNet a costeffective functional safety system that meets the safety needs of today s Emergency Shut Down, Fire & Gas and Burner Management applications. Certified as suitable for use in SIL 2 safety functions by TÜV Rheinland, PAC8000 SafetyNet incorporates the latest design techniques to achieve compliance with IEC and IEC PAC8000 SafetyNet is rugged, reliable and open, and has been used worldwide in many different process applications, including power generation, gas plants, chemical and petrochemical industries, pipelines and in all sectors of the oil and gas industries. SafetyNet can handle the harshest environments and has received Lloyd s Register approval for marine, offshore and industrial use in Lloyd s environmental categories ENV1, ENV2 and ENV3. With this environmental capability, SafetyNet can be remote mounted in the world s toughest environments for Alaskan pipelines, Saharan well heads and deep sea FPSOs. SafetyNet s rugged open control platform incorporates Modbus TCP with built-in Fault Tolerant Ethernet (FTE) for redundant communications, providing simple but secure connections to a wide range of standard software and hardware packages. This offers users flexible migration paths that connect to yesterday s legacy control systems, interface with the most up-to-date instruments and software, and look forward to the products that aren t even developed yet. PAC8000 SafetyNet

A new approach to functional safety SafetyNet was specifically developed to work with IEC 61508, and to meet the needs of the majority of safety requirements SIL 2.

17 A new approach to functional safety SafetyNet was specifically developed to work with IEC 61508, and to meet the needs of the majority of safety requirements SIL 2. IEC defines a new approach to safety, described as a structured, practical, realistic, understandable and defensible approach for selecting a safety system for any given hazard. Users must specify more capable safety systems to protect against more dangerous hazards. They must consider the entire safety function lifecycle when they analyze the nature of the hazard and the means to protect against it. And when this analysis results in a high risk process Safety Integrity Level (SIL) 3 or greater, many users will attempt to redesign that process to reduce its risk. Manufacturers of safety products must design safety into their products considering software and other systematic faults as well as random hardware failures. SafetyNet was specifically developed to work with this new approach, and to meet the needs of the majority of safety requirements SIL 2. Not overspecified. Not under-specified. It s as it should be fit for purpose. The SafetyNet solution provides PCS Nitrogen Geismar an OPEN, user-friendly, adaptable, trustworthy, and cost-effective safety platform. Kirk Hadeed, Process Control Engineer PCS Nitrogen

A compact, elegant and cost-effective solution for risk reduction SafetyNet provides a high level of internal and automatic diagnostics achieving SIL 2 without redundant I/O modules or controllers.

18 A compact, elegant and cost-effective solution for risk reduction SafetyNet provides a high level of internal and automatic diagnostics achieving SIL 2 without redundant I/O modules or controllers. An increased level of safety is achieved either by adding redundancy or increasing diagnostic coverage, or both. Traditionally, the focus was on redundancy, but SafetyNet takes a different path. Comprehensive internal diagnostics mean that redundancy is not needed to meet SIL 2 giving you a compact and cost-effective safety solution. The diagnostic testing carried out by PAC8000 SafetyNet is integrated into the product. So you ll find the safety manual simple and straightforward. And when the time comes to make changes, you can focus on the application you won t need to manage changes to the diagnostics too. Optional Redundancy for Availability Though SafetyNet doesn t need redundancy to be safe, it does offer redundancy for increased availability in critical applications. Redundant LANs, power supplies and controllers can all be specified if required. And this is redundancy for continuous processes truly bumpless transfer, alarming of failed components, automatic re-routing of communication paths. It s everything you need to keep your process running continuously. Connect SafetyNet to Your Existing Control System SafetyNet s use of open standards allows for an easy integration of safety instrumented systems with your existing Process Control system. Modbus TCP provides an excellent mechanism for high data transfer rates in real time from SafetyNet to an existing Process Automation System. For those with older legacy systems that don t offer Ethernet connections, the widely used Modbus serial protocol may be an alternative. PAC8000 SafetyNet

SafetyNet Offers Numerous Key Benefits: Increased Availability SafetyNet offers redundant controllers, power supplies and local area networks to increase availability of the SIL 2 safety function and

Safety Certified Peer-to-Peer Communication SafetyNet P2P, a robust and secure Ethernet protocol, meets the needs of SIL 2 safety functions where inputs and outputs are connected to different nodes.

Need to modify an application program or download new firmware? You can do this without stopping the process.

19 SafetyNet Offers Numerous Key Benefits: Increased Availability SafetyNet offers redundant controllers, power supplies and local area networks to increase availability of the SIL 2 safety function and to reduce the rate of nuisance trips. Safety Certified Peer-to-Peer Communication SafetyNet P2P, a robust and secure Ethernet protocol, meets the needs of SIL 2 safety functions where inputs and outputs are connected to different nodes. Live Maintenance Controllers and I/O modules are designed to be live maintained. With care, you can even replace components live in a Div 2 / Zone 2 hazardous area. Need to modify an application program or download new firmware? You can do this without stopping the process. HART Capability Smart HART field instrumentation has enabled new control and asset maintenance programs, and SafetyNet gives access to these powerful tools. Normally Energized and De-energized SafetyNet digital output channels are certified for both normally energized and normally de-energized applications, and can be configured channel by channel. Safety Manual The SafetyNet Safety Manual is simple and straightforward as it should be. Rapid Application Development SIL 2 safety applications are developed in the SafetyNet Workbench, using Structured Text (ST), Ladder Diagram (LD), and Function Block Diagram (FBD). Security and Access Control The SafetyNet security measures include Password protected user accounts, a Trusted Host table of authorized computers, a Key Switch Tag that blocks and permits access to changes and overrides, and a Controller Password to prevent unauthorized access. Validation and Verification Software The SafetyNet Workbench provides tools to test and monitor any changes to the application program. SafetyNet Logic Static Analysis Tool The Static Analysis Tool detects structural errors in control strategies, minimizing application issues, reducing the risk of error and cutting software development time. SafetyNet Logic Differences Utility The Workbench s Differences Utility can be used to compare a new control strategy with earlier versions and significantly reduce reviews and safety application testing. Change Control Log The Workbench maintains a Change Control Log that records all changes to SafetyNet Controllers and modules. Maintenance Override Capability SafetyNet s Maintenance Override temporarily suppresses the normal operation of a safety function for maintenance and may also be used to force a system to shut down, or restart the safety system after a shutdown. Common Platform for Process Control and Process Safety With SafetyNet, you can combine process control and functional safety in a single platform. SafetyNet s Static Analyzer tools can be used to identify all instances of process control data in the safety controller, helping the safety engineer ensure that the use of process data in the controller does not impact the safety function.

20 PAC8000 SafetyNet Platform Power Supplies (not shown) VAC and 24Vdc power supplies Supplies power for I/O and controllers Redundant power supply options Mounting options simplify panel design Power supply monitor alerts controller when a power supply fails PAC8000 SafetyNet Controllers SIL 2 certified with a single controller Redundant controllers increase system availability Field mountable safety control system Controls up to 64 eight-channel modules SafetyNet P2P for certified peer-to-peer communications On-line reconfiguration PAC8000 SafetyNet I/O Modules Analog input modules offer HART capability Discrete modules individual channels can be configured as inputs or outputs Integrated HART support enables remote configuration and interrogation of smart devices Mix SafetyNet and Process I/O modules on the same carrier LEDs indicate channel and module status Live hot swapping Keying stops modules from being inserted in the wrong position Isolation between I/O bus and field wiring

21 Environment Mounts in and connects to Div.2 / Zone 2 hazardous areas Operating temperature ranges 40 C to + 70 C Resistant to corrosive gasses and salt mist Robust operating shock and vibration specifications Carriers DIN rail or surface mounting Carries communications between I/O modules and controllers and distributes System and Bussed Field Power Choice of 4-module and 8-module carriers Cable ground and shield terminals along front edge Replacement modules are configured automatically, so maintenance is simplicity itself Field power can be supplied through connectors on the back of the carrier Field Terminals Unique, removable terminals for fast wiring and field replacement Modules can be replaced without disturbing field wiring Optional fuses and disconnects no interposing terminals required Field power routed to terminals no daisy chaining at the field terminals Integral tagging system

22 GE Intelligent Platforms Contact Information Americas: or Global regional phone numbers are listed by location on our web site at GE Intelligent Platforms, Inc. All rights reserved. *Trademark of GE Intelligent Platforms, Inc. All other brands or names are property of their respective holders M GFA-1124B

23 Presentations

25 Wellhead RTU Overview

26 Introduction

provides the structural and pressure-containing interface for the drilling and production equipment.

27 What is a Wellhead? Wellhead is a general term used to describe the component at the surface of an oil or gas well that provides the structural and pressure-containing interface for the drilling and production equipment. Christmas Tree is an assembly of control valves, pressure gauges and chokes assembled at the top of a well to control flow of oil and/or gas after well has been drilled and completed.

increasing the amount of crude oil that can be extracted from an

Using EOR, 30-60 %, or more, of the reservoir's original oil can be

28 What is Enhanced Oil Recovery (EOR)? Enhanced Oil Recovery (EOR) is a generic term for techniques for increasing the amount of crude oil that can be extracted from an oil field. Using EOR, %, or more, of the reservoir's original oil can be extracted compared with 20-40% using primary and secondary recovery. Three common EOR types: Steam Injection ( cyclic & flooding) Chemical Injection Gas Injection

29 Increased Uptime What if... Reduced Operation, Maintenance Costs We could solve the toughest problems? Safe, Secure, and Reliable Operations 5 / GE Title or job number / 2/8/2011

30 What Wellhead RTU Solution

31 Wellhead RTU Today s Solution Onshore Production & Injection Wells 1. Wellhead Monitoring 2. Wellhead Control 3. Wellhead ESD 4. Wellhead SCADA Batteries Local Panel 8888 Controller Comms - Redundant Ethernet and/or Serial Solar Power Regulation Solar Panel Increased Safety and Reliability: Ethernet Switch Increased Uptime via Hardened Environmental Specs Integrated Safety & Control Enhanced Productivity: Radio Radio Antenna Fibre Optic Accelerate Wellhead Solution Development, Deployment by 50-80% via Control Appliance Appstore SCADA Field Devices - Temp Transmitters - Pressure Transmitters - DP Transmitters - Vortex Flow Meters - Coriolis Flow Meters - Gas Chromatographs Differentiate Wellhead RTU Solution Decreased Project Costs: Reduce Solar Panel, Battery Installation Costs by 8% Radio Antenna Wellhead RTU Solutions For Proficy Process Systems 2.0

32 PAC8000 RTU A Robust RTU Solution Which Includes: Integrated RTU, Control, Safety, & SCADA Hardened Environmental Specs Scalable Low Power Consumption

PAC8000 RTU Key Features Current Features PAC8000 RTU Rugged Environmental Specs (-40 to 70 deg C, 95% RH, G3 Corrosion, 5G Vibration, 30G Shock) Scalable, Modular Design Integrated SIL2 PACSystems

33 PAC8000 RTU Key Features Current Features PAC8000 RTU Rugged Environmental Specs (-40 to 70 deg C, 95% RH, G3 Corrosion, 5G Vibration, 30G Shock) Scalable, Modular Design Integrated SIL2 PACSystems SafetyNet Integrated Intrinsic Safety 8000 IS Modules/FTAS Redundancy Controller, Power, LAN Lower Power Consumption IEC Programming (LD, ST, IL, SFC, FBD, FC) Integrated HART Pass-Thru Protocols Modbus, DNP3.0 Ethernet Hot Swappable Module Replacement Comprehensive Diagnostics ``` NVM Program and Data Storage Robust Module Selection 8000 I/O Modules On-Line System Downloads Access Protection (Passwords) Hi/Lo/Hold Options for Outputs, Enables Failsafe Configurable Filtering for Inputs Robust Technology From a Name You Can Trust Rugged and Reliable -40 to +70 Deg C Operating Temperatures ISA G3 Corrosion Resistance 30G Shock, 5G Vibration Lower Power Consumption Scalable Architecture DNP3.0 Ethernet Protocol Wellhead RTU Solution GE Provides a Robust, Integrated Wellhead Solution That Delivers Lowest Total Cost of Ownership Delivering You Improved Safety Increased Reliability Reduced Operation & Maintenance Costs

34 Customer Wins

On-Shore Oil Production Major NOC in Abu Dhabi Customer s Challenge Remote Field Mount in Extreme Environment Conditions SIL2 Rated Controllers with Reduced Power Consumption High Reliability &

35 On-Shore Oil Production Major NOC in Abu Dhabi Customer s Challenge Remote Field Mount in Extreme Environment Conditions SIL2 Rated Controllers with Reduced Power Consumption High Reliability & Uptime for Continuous Operations in Oil Fields Reduce Cost by Integrated Control & Safety, Small Footprint, Lower Opex GE Solution PAC8000 SafetyNet, Redundant PAC8000 I/O CIMPLICITY HMI/SCADA Customer Benefits Reduced Power Consumption, Lower Capex ~10% Reduced Field Trips by ~ 25% Safe, Secure Oil Field Operations System Access Via the Web Easy Connectivity with Third-Party Systems 11 / GE Title or job number / 2/8/2011

36 EOR Chemical Injection, Saudi Arabia Customer s Challenge Remote Field Mount in Extreme Environment Conditions Low Power Consumption High Reliability & Uptime for Continuous Operations in Oil Fields Reduce TCO Due to Small Footprint, Lower Opex GE Solution PAC8000 Logic Controller PAC8000 I/O CIMPLICITY HMI/SCADA Customer Benefits Reduced Power Consumption, Lower Capex ~10% Reduced Field Trips by ~ 25% Safe, Secure Oil Field Operations System Access Via the Web Easy Connectivity with Third-Party Systems 12 / GE Title or job number / 2/8/2011

37 Datasheets

39 PAC8000 RTU Controller PAC8000 RTU Controller 8521-RT-DE The PAC8000 RTU was designed from the ground up for the extreme and rugged environments found in today s most remote process applications. It provides the reliability and uptime you demand to keep your operations running and your business producing. Its open design allows you to interface it with any HMI/SCADA packages such as ifix, CIMPLICITY, or third party packages. When combined with Proficy Process Systems, it enhances and extends the capabilities of this advanced DCS. Applications The PAC8000 RTU Controller is ideal for all types of RTU applications, including those found in the following industries: Oil & Gas Pipelines, Power Generation, Electrical Distribution, and Water and Wastewater. The Controller platform The PAC8000 RTU Controller executes your control strategies and manages all control activities for the I/O modules. It provides a tight control loop response, quickly giving a control output in response to input data. It also incorporates a rigorous redundancy model, HART and Foundation Fieldbus capability, and a fault tolerant Ethernet implementation to manage communications on the control network and deliver reliable operation Process I/O is a field-mounted distributed I/O system that provides an intelligent interface between field-mounted instrumentation and the PAC8000 RTU Controller Process I/O interfaces to virtually all process signals providing a complete solution for your I/O needs. The complete platform has an environmental specification capable of surviving conditions out in the field. It is built for harsh environments, being shock and vibration resistant, operating over the industrial 40 C to +70 C temperature range that is typically associated with field transmitters, and meeting ISA's stringent G3 corrosion resistance requirements. The Controller and I/O components can all be mounted directly in Division 2/Zone 2 hazardous areas and, when required, can provide a cost effective intrinsic safety solution without the need for external barriers. With the PAC8000 RTU Controller and its I/O mounted in the field, the only wiring back to a control room is the high-speed control network. High Availability - Redundancy Maximize up-time by incorporating redundant controllers, power supplies and network connections. 'Hot swap' modules, without affecting operation or re-configuring, even in hazardous areas. Redundant controllers can be used for critical applications. The master/standby pair operate in a rendezvous redundancy mode with frequent status checks to assure a rapid and bumpless transfer to the standby if required. The PAC8000 RTU Controller redundancy model supports on-line configuration and online firmware changes, where any updates are shared between controllers in real-time, resulting in an easy to use redundant system. The PAC8000 RTU Controller also supports LAN redundancy. A fully redundant local area network (LAN) can be provided where each controller has two independent Ethernet ports connected to two separate independent networks. The controllers monitor the networks' health and will switch between networks when they detect a problem. Redundant power supplies are available to provide power for critical applications that must not shut down if a power supply malfunctions. Reduced termination costs Field wiring goes directly to the I/O terminals in the local field enclosure no additional cross wiring is required. Integrated Intrinsically Safe (IS) capability mixed with general-purpose signals, together with integral tagging and fusing options, dramatically reduce engineering and design costs. Flexible system design Combine analog and discrete modules for maximum flexibility and use of space. IEC programming The RTU Controller takes advantage of Windows based object-oriented technology, graphical user interfaces, and easy to learn software solutions to reduce engineering time. Controller Applications are developed in the PAC8000 RTU Workbench, which fully supports the five IEC automation languages: Ladder Diagram (LD), Sequential Function Chart (SFC), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), plus Flow Chart and is used to develop, download, simulate, debug, monitor, and edit application programs. It lets you mix programming languages in the same project. Its true Windows interface will guide you through development of your project and use of a simulator will allow you to test your programs before startup. Completed applications are then downloaded to the controller. On-line changes The PAC8000 RTU Controller allows online configuration changes during testing, startup, and maintenance phases. This significantly accelerates system start-up and reduces operation downtime. Communication Protocols The PAC8000 RTU Controller supports DNP3 over Ethernet, Modbus TCP/IP, Modbus RTU, and HART Passthrough. The DNP3 Ethernet implementation supports the select-before-operate (SBO), communication sequence for control operation as well as the Store & Forward & report by exception (RBE). GE Intelligent Platforms Global Regional phone numbers are available on our website

PAC8000 RTU Controller PAC8000 RTU Controller IEC 61131-3 language support redundancy with bumpless transfer dual-redundant high-speed Ethernet connections field mountable in harsh process

40 PAC8000 RTU Controller PAC8000 RTU Controller IEC language support redundancy with bumpless transfer dual-redundant high-speed Ethernet connections field mountable in harsh process environments low power consumption on-line configuration and reconfiguration HART pass-through of process and status variables integrated general-purpose and IS signals DNP 3.0 Ethernet Support with NVM Store & Forward Controller redundancy Redundant controllers can be used for critical applications. The redundant controller pair operates in parallel, checking status multiple times through the processing loop enabling the backup controller to continuously monitor the health of the master controller, assuring a rapid and bumpless transfer to the standby controller. Network redundancy In addition to controller redundancy, the PAC8000 RTU Controller has two high-speed Ethernet ports to provide security of communication. Each port can be connected to an independent LAN, which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communication. Executable control programs The control programs are held in non-volatile memory to enable them to be restored automatically after power cycling of the controller. When redundant controllers are used, both controllers execute the program in lock step redundancy for a bumpless transition to the standby in case of a fault being detected on the master. This allows the standby unit to take over from the master during any point in the execution cycle with no interruption in the control program. Remote Modbus Devices The PAC8000 RTU Controller communicates via Modbus TCP over Ethernet and can operate in either Modbus Master or Modbus Slave mode to communicate with remote Modbus devices. Each controller also has 2 serial ports that can be configured as a Modbus Master to control and obtain information from Modbus Slaves and other serial devices, such as weigh scales, barcode readers, etc. The serial ports can also be configured as a Modbus Slave, accepting write commands from Modbus Master devices and providing information on its data registers. Failsafe and automatic cold start In the event of complete loss of communication the controller will adopt a user-defined failsafe mode and similarly instruct the I/O to take up user-defined failsafe values. In the event of power loss the PAC8000 RTU Controller will perform a cold restart, which restores the program(s) and assumes a predefined status. DNP3 over Ethernet DNP is implemented up to Level 3 and supports the select-beforeexecute (SBE) and communication sequence for control operation as well as the Store & Forward. I/O module configuration The PAC8000 RTU Controller receives full details of all the I/O modules under its control and stores the information in non-volatile memory. At start-up the controller downloads to the modules their 8521-RT-DE configuration details, which also include the failsafe states they should adopt in the event of communication failure. Firmware updates In keeping with its ability to maintain operations on a continuous basis, a redundant PAC8000 RTU Controller is also capable of receiving a firmware upgrade. In a manner similar to that used for strategy updates, a controller can receive an update to its firmware while in the field. When the upgrade has been confirmed as successful, the controller can be returned to full operation as a master or as a protective standby. HART passthrough The PAC8000 RTU Controller has the ability to pass smart HART information from field devices to a separate PC workstation, which allows you to readily interface to asset management software applications, to remotely manage the HART information contained in your HART -based field instruments. The PAC8000 RTU Controller works with a variety of asset management packages,. Environmental stability Like all of the 8000 series equipment, the PAC8000 RTU Controller is designed for use in harsh environments. It operates over a temperature range of 40 C to +70 C and is resistant to shock, vibration and corrosive environments. Hazardous area operation The PAC8000 RTU Controller is designed also to operate in Class I, Division 2 and Zone 2 hazardous areas and can connect directly to field devices in the more hazardous Division 1, Zone 1 and Zone 0 areas. Grows as your needs grow The system is scalable to your needs. You can add modular I/O to your system as your needs increase. Redundant controllers can be added without the need to power off your system - the backup controller powers up automatically and is seamlessly brought online. Maximum number of nodes Multiple PAC8000 controller nodes can reside on the same network. However, too many nodes can degrade performance, so GE recommends placing no more than 25 nodes on the same subnet of a network. Each network can contain up to 255 such subnets. GE Intelligent Platforms Global Regional phone numbers are available on our website

PAC8000 RTU Controller PAC8000 RTU Controller 8521-RT-DE 8000 Process I/O hardware Overview 8000 Process I/O is a completely modular I/O solution for both general purpose and hazardous area

I/O Modules I/O modules transfer signals to and from field instruments.

41 PAC8000 RTU Controller PAC8000 RTU Controller 8521-RT-DE 8000 Process I/O hardware Overview 8000 Process I/O is a completely modular I/O solution for both general purpose and hazardous area applications. It is based on a carrier system that supports a range of modules and offers a wide variety of I/O functions, including AC mains and intrinsic safety signals, even within the same node. I/O Modules I/O modules transfer signals to and from field instruments. Input modules receive signals from transmitters and sensors and convert them into a digital form for presentation to the Controller. Output modules receive commands from the Controller and transfer them available, including types for low-level instrumentation, AC mains and intrinsically safe signals, I/O modules typically have 4, 8 or 16 field channels. Field terminals Field terminals provide the interface between the I/O modules and the field wiring. They include fusing and loopdisconnect as options. A mechanical keying system prevents an I/O module from being connected to the wrong type of field terminal. Field terminals mount onto the module carrier, one to each I/O module. They are clamped firmly by the I/O module to form an electrical and mechanical assembly of high integrity. They may be replaced in service without removing carriers or disturbing the operation of other modules. Carriers Carriers form 8000's physical and electrical backbone by providing a mounting to support and interconnect the controller, power supplies, I/O modules and field terminals, and carry the address, data and power lines of the internal Railbus. They provide termination points for the LAN and field wiring cable shields and can also distribute bussed field power to the I/O modules. I/O module carriers are available to support four or eight I/O modules. System power supplies System power supplies are available for the node to convert local AC or DC supplies to power the node or provide field power for I/O modules. 8000's innovative Bussed Field Power scheme for distributing field power avoids complex wiring at the field terminal and minimizes the carrier wiring. 'HART-ability' The use of 'smart' instruments on process plants is growing but this investment is not always fully exploited. Whether it is for a new installation, or the upgrade of an existing one, GE has solutions that provide the connections between the HART field instruments, the control systems and the process automation maintenance software. Specifically, the 8000 Process I/O system has been designed to be transparent to HART signals, thus allowing the host control software and any HART field instruments to communicate directly with each other. In addition, 8000 s HART connection system provides on-line access from a PC to the HART field devices for monitoring device performance. HART devices may be selected for regular status monitoring and alerts can be issued if the status changes. The benefits from this approach are: reduced commissioning time and cost reduced process downtime through status monitoring power loop maintenance costs by using field device diagnostics Process I/O in your system Each PAC8000RTU node can address up to 64 I/O modules which, depending upon the number of channels per module, can provide up to 1024 I/O points at a single node! A node can consist of a mixture of analog and discrete modules and this gives maximum flexibility to the system designer. Full HART pass-through is provided - the 8000 appears "transparent", allowing the inquiring "agent" to access the HART capabilities of field instruments. GE recommends placing no more than 25 nodes on the subnet of a network. Redundancy options 8000 Process I/O has been designed to increase availability and minimize downtime. Redundant controllers, LAN Channels and power supplies can be specified as options to increase system availability. Possible down-time is further reduced by ensuring that the system components using active circuitry can be removed and replaced quickly and easily. Even the field terminals can be replaced without interrupting the operation of adjacent I/O modules. Carriers have no active circuitry and are unlikely to need replacement. Hazardous area applications The 8000 Process I/O is a truly field mountable system even in areas where flammable gases are present. It is available in versions to suit different area classification schemes: a) Equipment and field wiring located in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas. b) Equipment mounted in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas, with field wiring located in Division 1 hazardous locations or Zone 0 hazardous areas. GE Intelligent Platforms Global Regional phone numbers are available on our website

PAC8000 RTU Controller PAC8000 RTU Controller A control node Many industry applications do not present an explosion risk from gas or dust hazards.

42 PAC8000 RTU Controller PAC8000 RTU Controller A control node Many industry applications do not present an explosion risk from gas or dust hazards. In others, the environment may be classified as a Zone 2 or Division 2 hazardous area, where flammable material is expected to occur only in abnormal conditions. For both of these the 2/2 system provides effective distributed I/O for process control supports a full range of I/O module types covering inputs and outputs for both analog and discrete circuits. The node can be mounted out on the plant in a suitable enclosure that is capable of providing protection against the environment. The diagram shows a node containing the basic components: one (or two) PAC8000 RTU Controllers, I/O modules on their carriers linked by carrierextenders and an extension cable with intrinsic safety field wiring The 8000 Process I/O System is also capable of supporting I/O modules with intrinsic safety (IS) field wiring, for connection to certified or 'simple apparatus' field devices in Division 1 or Zone 0 hazardous areas. A range of I/O module types with IS field circuits for industry-standard DI, DO, AI, AO and pulse applications is supported. Integrated power supplies Power for IS I/O modules is derived from integrated, modular power supply units. Each power unit is capable of supplying between eight and twenty I/O modules, depending on the I/O type and mix. Optional power supply redundancy is supported by means of an additional, redundant supply unit connected in a 'n+1' arrangement. In applications with mixed IS and non-is field wiring, the full facilities of the 'Bussed Field Power' regime are retained for the non-is part of the system. In nodes populated only with IS I/O modules, a separate system power supply module provides power for the Bus Interface Module and 'node services'. Redundancy of this supply is also supported. PAC8000 RTU Controller The mission of GE is to design, manufacture and distribute modular, open hardware and software technology-based components for use in the most demanding real-time system applications. These fieldproven components can be snapped together to create sophisticated control systems. Controller Specification Clock Speed: 266 MHz, 16 MB Ram, 1MB NV Ram, 8 MB Flash LAN INTERFACE Transmission medium...100basetx or 10BaseT Ethernet Transmission protocol...dnp and Modbus over high-speed Ethernet Transmission rates Mbits/s LAN connector type (x2)...rj 45 (8-pin) LAN isolation (dielectric withstand) V Action on software malfunction... Halt CPU / Reset CPU Max. nodes on a subnet of a network...25 Max. subnets on a network RT-DE SERIAL INTERFACES (COM 1 & COM 2) Transmission rates kbits/s (async.) Transmission standard......rs485 half-duplex COM 1 connector (on carrier) pin D-type connector (F) COM 2 connector (on controller)...9-pin D-type connector (M) POWER SUPPLIES Voltage V dc Current A ( typ.) A (max.) HAZARDOUS AREA APPROVALS Location of equipment... Zone 2, IIC T4 hazardous area...or Class 1, Div 2, Groups A, B, C, D T4 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No.213 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n. UL Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements, 2nd Edition See System Specification Guide for other parameters MECHANICAL Module dimensions (w) x 232 (l) x 138 (h) mm Weight (approx.) kg Modbus is a trademark of Schneider Automation Inc HART is a registered trademark of the HART Communication Foundation GE Intelligent Platforms Global Regional phone numbers are available on our website

PAC8000 SafetyNet SIL2 certified 1oo1D (single Controller with diagnostics) Process Control & Safety Functions from a single platform Mix standard and SafetyNet Modules on the same nod Single

43 PAC8000 SafetyNet SIL2 certified 1oo1D (single Controller with diagnostics) Process Control & Safety Functions from a single platform Mix standard and SafetyNet Modules on the same nod Single programming environment for Process, Logic and Safety Applications On-line changes supported Mounts in harsh and hazardous Environments The PAC8000 SafetyNet System is a new addition to the GE s product family. Sharing the same fundamental platform as the PAC8000 controllers, a new SafetyNet Controller, a new Earth Line Fault Detect (ELFD) Controller Carrier and two new SafetyNet IO Modules have been developed and certified. The SafetyNet System uses the same field terminals, I/O Module Carriers and Power Supplies as the Process Control products. Configuration and application design is carried out using software tools specifically safety applications -but within a common programming environment. Certified according to IEC as a "Programmable Electronic Safety System", PAC8000 SafetyNet is suitable for use in safety-related applications up to Safety Integrity Level (SIL) 2. As part of the family of open system components designed for the process automation market, it can be closely integrated with the Proficy Process Control System or used as a standalone safety system working alongside any Process Control solution. The system will also operate "openly" with your choice of HMI - whatever package you use. Emergency Shutdown, Fire & Gas and Burner Management application requirements are all met, with certification to IEC for process industries and NFPA 85 for burner management systems. Designed for SIL 2, the SafetyNet System has been specifically developed for safety applications, with features that ensure safety designed in to the product, with a simple and straightforward Safety Manual. The net result is a product that is easy to program, configure and use. The modular approach provides cost effective solutions to safety applications with limited I/O counts per node. And since each SafetyNet node can accommodate up to 64 I/O modules, (each of 8 channels), the requirements of safety systems with high I/O counts are also met. Using a 1 out of 1 with diagnostics structure(1oo1d), a single controller, input module and output module (together with the necessary field terminals, carriers and power supplies and a suitable sensor and final element) meet all the requirements of a SIL 2 safety function. Redundant controllers can be used to improve availability for the SIL 2 safety function - with entirely bumpless transfer. Further availability enhancements can be made by the use of redundant, fault tolerant Ethernet communications and redundant power supplies. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:1

44 PAC8000 SafetyNet General The PAC8000 SafetyNet System is a "Programmable Electronic Safety System", certified according to IEC as suitable for use in safety related applications up to Safety Integrity Level 2. The system is suitable for use in emergency shutdown, fire & gas and burner management applications. New additions to the family The PAC8000 SafetyNet System uses the same basic structure as the PAC8000 controllers, but in addition incorporates specifically developed components. These are: SafetyNet Controllers (8851-LC-MT) Dedicated Controller Carriers for Earth Leakage Fault Detection (8751- CA-NS) SafetyNet IO Modules -Analog Input with HART (8810-HI-TX) and Discrete IO (8811-IO-DC) Workbench software tools for use with the SafetyNet System (8841-LC- MT) Open communications PAC8000 products are open. SafetyNet nodes communicate with one another, with standard PAC8000 nodes, historian and asset management packages and with HMI packages over a fault tolerant Ethernet LAN, running at up to 100 Mbit/s. Peer to peer communication SafetyNet Controllers can communicate with one another via Ethernet using SafetyNet P2P - which has been certified as suitable for use in SIL 2 applications. Robust checks and controls on access and data corruption ensure the safety of communication and allow safety functions for which the inputs and outputs are widely separated to be easily implemented - both in terms of the software programming and in the hardware design. Mixing safe and standard Standard IO Modules can be mounted on SafetyNet Nodes - together with SafetyNet IO Modules - without affecting the node's functional safety performance. Only standard applications can read data from standard Modules, but both standard and SafetyNet applications are allowed to write to standard modules. This flexibility can simplify hardware design, where the physical constraints of the particular locality demand such an approach. Serial interfaces The Open approach extends to Modbus serial interface products - which can be connected to any node (SafetyNet or standard) by an RS485 connection. As with data from standard IO Modules, this data can be read by standard Controllers, but not by SafetyNet Controllers. Both standard and SafetyNet Controllers can write to such devices. Comprehensive programming tools The SafetyNet System is programmed using the Workbench software package in common with the PAC8000 Process GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Control Products. In addition to providing the options of programming the required safety function in one of three IEC languages (Ladder Diagram, Function Block Diagram and Structured Text) the package also provides many useful tools to assist in testing and commissioning. Restricted access Access to modify safety-related parameters within the configuration and application program must be restricted to authorized personnel. The SafetyNet system provides a number of layers and methods of providing this protection. Only users with "Safety Responsibility" can access the safety-related aspects of the Workbench. Only computers that the SafetyNet Controller identifies as "trusted hosts" can download new parameters. A download can only take place when an "over-ride keyswitch" is set to the required position. And, if required, each SafetyNet Controller can be protected by its own password - without which access to the safety parameters is denied. Maintaining field instruments Maintenance over-rides can be implemented from operator workstations in full compliance with the guidelines from TUV. Users define - as part of the safety application - the actions to be taken to maintain a particular instrument and the SafetyNet System then implements these pre-defined actions. HART capability The SafetyNet System allows full access to HART field devices for Emerson's AMS maintenance software. (The first release of SafetyNet will not have full HART capability, contact GE for further information). Earth leakage detection Earth leakage fault detection may be implemented using the 8751-CA-NS Controller Carrier in conjunction with an input channel from an 8811-IO- DC Discrete I/O Module. If ELFD is not required, SafetyNet Controllers can be mounted on 8750-CA-NS Controller Carriers. On-line changes Where allowed by local practices and following adequate testing and approval - new safety programs and configuration can be downloaded online and in real time. In some situations, this may be possible without interrupting the operation of the safety function. Page:2

PAC8000 SafetyNet Harsh and Hazardous Environments The SafetyNet System is as rugged as the other PAC8000 Controller and 8000 Process I/O Components: -40ºC to +70ºC operating ambient temperature;

45 PAC8000 SafetyNet Harsh and Hazardous Environments The SafetyNet System is as rugged as the other PAC8000 Controller and 8000 Process I/O Components: -40ºC to +70ºC operating ambient temperature; Zone 2 or Class 1 Division 2 hazardous area mounting; G3 corrosion resistance; and enhanced shock and vibration capability. The system will operate in the PAC8000 extreme environments found in process industries, allowing remote mounting and a truly distributed architecture in even the most demanding situations. Event Logging and Sequence of Events Recording The SafetyNet System has the same Event Logging and Sequence of Events (SOE) recording capability as the PAC8000 Controllers. Data received from SafetyNet Modules is timestamped by the SafetyNet Controller with a resolution of better than 200ms (this is dependent on the execution cycle - small nodes will deliver better resolution). Data from dedicated (non- SIL) SOE modules is time-stamped with a resolution of less than 0.25ms between different channels of the same SOE module and less than 1ms between channels from different SOE modules. The SafetyNet Controller can record up to 8000 events before its event data buffer begins to be overwritten by new data. Reduced cabling and termination costs In common with the PAC8000 Controllers, the SafetyNet System offers users the opportunity to significantly reduce their spending on wiring and termination costs. Moving control and safety hardware out of the control room and on to the plant gives significant savings. The Field Terminal design allows users to avoid unnecessary spend on marshalling cabinets, cross wiring and marshalling terminals. Integral tagging and fusing further simplifies cabinet design and installation. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:3

PAC8000 SafetyNet Figure 1 typical PAC8000 SafetyNet System layout PAC8000 SafetyNet on your plant Figure 1 shows a typical layout of

SafetyNet node layout and powering Figure 2 shows a typical layout of a SafetyNet node, with Controllers, IO Modules, Field

46 PAC8000 SafetyNet Figure 1 typical PAC8000 SafetyNet System layout PAC8000 SafetyNet on your plant Figure 1 shows a typical layout of a PAC8000 SafetyNet System, together with a PAC8000 Controller, an OPC Server, an HMI and asset management and historian packages all connected together via an Ethernet LAN. Also shown is the PAC8000 Workbench - the dedicated tool for programming and configuring PAC8000 SafetyNet and PAC8000 Controller. SafetyNet node layout and powering Figure 2 shows a typical layout of a SafetyNet node, with Controllers, IO Modules, Field Terminals, and Carriers. The power connections that need to be made are also shown. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:4

PAC8000 SafetyNet Fault Tolerant Redundant LAN The availability of Ethernet connections - between SafetyNet and standard Controllers, historian and asset management packages and HMI stations - has a

To maximise availability of the Ethernet LAN, PAC8000 SafetyNet Systems feature Fault Tolerant Ethernet ports that monitor the integrity of their local network and automatically switch to an

47 PAC8000 SafetyNet Fault Tolerant Redundant LAN The availability of Ethernet connections - between SafetyNet and standard Controllers, historian and asset management packages and HMI stations - has a significant impact on the effectiveness and availability of both safety and control functions. To maximise availability of the Ethernet LAN, PAC8000 SafetyNet Systems feature Fault Tolerant Ethernet ports that monitor the integrity of their local network and automatically switch to an alternate path if the existing path becomes unavailable. If suitable Ethernet switches are used - such as Moxa Industrial Ethernet Switches - they too will monitor their local network and switch to an alternative path when this is required. Monitoring the local network paths even when they are not being used - allows the system to report the loss of any failed paths so that appropriate maintenance can be carried out. Moxa Industrial Ethernet Switches The Moxa Ethernet Switch range is specifically designed for use in Industrial applications that require high availability in harsh environments, with a broad operating temperature range (-40ºC to +75ºC, except EDS-205: -10ºC to +60ºC) and hazardous area mounting capability (Class 1, Div 2 or Zone 2). Two alternative topologies are shown in figures 1 and 2. Which topology is preferred will depend on the physical layout of the entities on the LAN and local preferences. Figure 1 shows a redundant Ethernet LAN, with intra-lan link while figure 2 shows a single "Turbo Ring" that provides an alternate means of ensuring Ethernet availability - implemented in the Moxa EDS405 5-port switch. If any part of the Turbo Ring fails, communication is re-routed automatically within 300ms. Further improvements to availability can be achieved by putting in place a second identical, "Turbo Ring" which should be connected to the first ring by a single intra-lan link. This link would normally be mounted in the control room. The Moxa switches are available with either all copper or a combination of copper and fibre ports. For media conversion between fibre and copper the MOXA IMC-101 can be used. All the Moxa products (except the EDS-205) have dual power supply inputs and a relay output for user configurable fault reporting. Figure 1 - redundant Ethernet LAN with intra-lan link Figure 2 - Turbo Ring Ethernet LAN GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:5

PAC8000 SafetyNet General The 8851-LC-MT SafetyNet Controller stores and runs the SafetyNet application program which is downloaded from the Workbench.

48 PAC8000 SafetyNet General The 8851-LC-MT SafetyNet Controller stores and runs the SafetyNet application program which is downloaded from the Workbench. It manages a number of communication paths: with the IO Modules mounted on the local node via the internal Railbus; with other entities on the Ethernet LAN (other PAC8000 nodes, PCs running the Workbench programming tools, HMI, historian packages and asset management tools) and with remote mounted serial devices. The SafetyNet Controller also manages the implementation of the redundancy strategy either as master or standby. Certification The SafetyNet Controller is certified for use in safety-related applications up to and including SIL 2. The SafetyNet Controller achieves this Safety Integrity Level with a 1oo1D architecture (i.e. it operates in "simplex" mode, with correct operation ensured by comprehensive internal diagnostics). In such applications the SafetyNet Controller is used in conjunction with the 8811-IO-DC SafetyNet Digital Input/Output Module and the 8810-HI-TX SafetyNet Analog Input Module with HART*. The SafetyNet Controller is mounted on its dedicated Carrier 8751-CA-NS. *First release of SafetyNet will not have full HART capability. Safe by design The SafetyNet Controller has been designed specifically for safety-related applications and is certified on the basis of the excellence of its design. It does not depend for its certification on "proven in use" data. Diagnostics If the SafetyNet Controller's internal diagnostics detect a fault that would prevent the SafetyNet System from carrying out its safety function, then it will initiate a controlled shutdown. A controlled shutdown has two objectives - firstly, to ensure that the SafetyNet System enters its failsafe mode; and secondly, to record sufficient data to allow the reason for the shutdown to be determined. If a SafetyNet Controller enters a controlled shutdown, then all communication with IO Modules is stopped and - when the programmed time delay for each IO module has elapsed - they will enter their safe states. System size The SafetyNet Controller can interface with up to 64 locally mounted, 8-channel IO Modules - giving a total capacity of over 500 channels per node. The Ethernet LAN is capable of supporting over 200 nodes, giving a maximum theoretical capacity of over channels! HART pass-through SafetyNet Controllers can be configured to allow transparent access to the process variables and status information provided by HART field instruments. HART data cannot be used within the SafetyNet application (as - for example - it does not employ sufficiently rigorous data error detection algorithms), but communication with such devices can be achieved by using a "passthrough" command which does not involve, nor interfere with, the safety application. (The first release of SafetyNet will not have full HART capability, contact GE for further information). Live maintenance Once the Ethernet LANs are isolated, SafetyNet Controllers can be removed and replaced - with the local power supplies still connected - even in Division 1, Class 2 or Zone 2 hazardous areas. Redundant Controllers SafetyNet Controllers can be used in a master - standby redundant configuration to improve the availability of the safety function, but this is not required for safety. Redundancy is implemented by simply inserting the new Controller in to the free slot on the Controller Carrier. The SafetyNet system will automatically upload the required SafetyNet application to the new Controller and initiate the redundancy algorithms. Switching between redundant Controllers on detection of a fault is automatic and bumpless. The standby Controller continually performs the same processing, on the same data and at the same time as the Master and the results are routinely cross-checked. This ensures that the Standby is always ready to take over control from the Master. The redundancy strategy employed is known as "rendezvous redundancy". The "Change State" button on the Controller Carrier is used to switch a master to being the standby in a redundant pair, to switch a standby offline and to instruct an offline standby Controller to synchronise itself with the Controller and to enter standby. If a SafetyNet Controller has entered the Failsafe state, it can be brought out of this state by use of the Change State button. Serial communications Each SafetyNet Controller provides two serial ports - one of which is physically connected via the Controller Carrier, the other directly on the Controller itself. The two ports can be configured to be entirely independent, or can be made to work redundantly, either as redundant connections to the same serial link or as redundant connections to redundant links. When redundant ports of a single Controller are configured as Modbus masters, redundancy issues are handled automatically by the SafetyNet Controller deciding when to switch to the standby port, alarming failures in the standby). When redundant ports of a single Controller are configured as Modbus slaves and multi-dropped on a single serial link, the SafetyNet Controller will again manage the redundancy (deciding which port respond to the Modbus master and alarming a fault in the standby port). When redundant Controllers are used, this adds additional availability to the arrangements above. It is not possible to use the ports on the standby Controller as additional serial connections. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:6

49 PAC8000 SafetyNet SafetyNet Controller 8851-LC-MT Certified for use in SIL 2 safety applications, according to IEC Comprehensive internal diagnostics provide basis for safety architecture 1oo1D Optional redundancy with bumpless transfer for increased availability Dual redundant high speed fault tolerant Ethernet LAN Two connections to serial devices On-line configuration and re-configuration Communicates with up to 64 I/O modules Communicates on peer-to-peer basis with other SafetyNet and standard Controllers Can write to standard output modules without compromising safety function Live maintainable and hot-swappable - even in Class 1, Div 2 or Zone 2 hazardous areas HART pass-through of process and status variables Event logging up to 8000 events 12Vdc Controller power required from 8913-PS-AC CONTROLLER SPECIFICATION See also System Specification LAN INTERFACE Transmission medium...100basetx or 10BaseT Ethernet Transmission protocol...safetynet P2P* Transmission rates Mbits/s LAN connector type (x2)...rj 45 (8-pin) LAN isolation (dielectric withstand) V Action on software malfunction...halt CPU / Reset CPU * SafetyNet P2P is a modified form of Modbus certified as suitable for use in SIL 2 safety related applications that require peer-to-peer communication. SERIAL INTERFACES (COM 1 & COM 2) Transmission rates kbits/s (async.) Transmission standard...rs485 half-duplex COM 1 connector (on carrier)...9-pin D-type connector (F) COM 2 connector (on controller)...9-pin D-type connector (M) HAZARDOUS AREA SPECIFICATION Protection Technique...EEx nl IIC T4 Location (FM and CSA)...Class 1, Div.2, Grps A,B,C,D T4 POWER SUPPLIES Controller Power Voltage...12V dc (from 8913-PS-AC) Controller Power Supply...0.4A (typical), 0.5A (max.) System Power Supply...15mA (max.) MECHANICAL Module dimensions...69 (w) x 232 (l) x 138 (h) mm Weight (approx.) kg GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:7

50 PAC8000 SafetyNet LED's The SafetyNet Controller has a number of LED s that indicate the status and mode of operation of the Controller. The table below explains what they refer to and describes their operation: Note: the information here given here is simplified. Additional combinations of LED states are used to provide further indication of the status of the SafetyNet Controllers. Full details are found in the relevant instruction manuals. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:8

51 PAC8000 SafetyNet Workbench for SafetyNet Overview PAC8000 Workbench The PAC8000 Workbench is the engineering and documentation tool for the PAC8000 Controllers and SafetyNet Systems. The Workbench is used to perform the following tasks: Configure IO Channel and Module parameters Configure Controller and network parameters Input and manage the IO tag database Engineer and document the control or safety application Generate wizards to simplify HMI design Simulate and test control and safety applications Generate reports to assist in Factory and Site Acceptance Testing SafetyNet Workbench The SafetyNet Workbench (8841-LC-MT) has all the features of the standard Workbench, but additionally includes the special tools required for safety applications. Safety programming languages The Workbench provides three IEC61131 programming languages that can be used to write safety-related application programs: Ladder logic (LD) Function Block Diagram (FBD) Structured Text (ST) Configuration Mode and Safety Responsibility Changes to safety-related parameters are carried out with the SafetyNet Controller in Configuration Mode. Access to this mode is restricted to personnel with Safety Responsibility and its use is constrained by a number of further layers of protection for downloading parameters to SafetyNet Controllers. The SafetyNet system defines 6 password protected levels of access authority with only the 3 highest levels being granted Safety Responsibility. Trusted Hosts To prevent access to SafetyNet Controllers by non-approved instances of the Workbench, remote Modbus devices, asset management packages and HMI, only those that the SafetyNet Controller identifies as Trusted Hosts can download new parameters. Each Trusted Host is recognised by its IP and MAC addresses (remote Modbus devices are recognised by the serial port to which they are connected). For each Trusted Host a number of other restrictions can be defined: Modbus write not allowed Workbench write not allowed HART pass-through not allowed Key Switch Protection When a SafetyNet Controller is added to the Workbench the user is given the option of selecting a tag to act as a Key Switch. This can be used by an Operator to lock the SafetyNet System so that Configuration Mode cannot be entered without their awareness or permission. The Key Switch can be a physical switch, driven from an HMI screen or it can be an output from the SafetyNet application. Controller Passwords When a SafetyNet Controller is added to the Workbench the user is given the option to use a Controller Password. If this option is selected, it is subsequently impossible to enter Configuration Mode without the Controller Password. On-line download Users with safety responsibility can download new parameters to a SafetyNet Controller, from a Trusted Host, to a Controller whose Key Switch is set to permit new downloads and where the particular SafetyNet Controller s Password is known. New parameter download is carried out as a background task over a number of cycles to ensure that the fault reaction and response times are not compromised. Once download is complete and the new parameters have passed the checking and security tests, the new parameters will be automatically adopted. Where redundant SafetyNet Controllers are used, the stand-by Controller will also be automatically updated. Note: on-line download should only be used where there are adequate procedures for approving the changes that have been made and testing them prior to download. Static Analysis Tool Any safety-related application program must be developed by suitably qualified personnel and must be subject to careful scrutiny to ensure safety, but the Workbench provides an additional safety test. The Static Analysis Tool checks for illegal constructs within the safety program prior to download. Differences Utility Once a new SafetyNet application is successfully compiled, it can be downloaded to a SafetyNet Controller. On download, two text reports are generated: a Download Report and a Master Tag Xref. These can be used for comparison with other downloads using the Differences Utility. Download backup A time stamped backup of each safety application is automatically created following a successful download. Changes between versions can be viewed and backups can be used either as a start point for developing new safety applications or to restore an earlier version. Change Control Log The Workbench maintains a Change Control Log that records - for example - when: IO Modules are added, deleted or moved Tags are added to, removed from, or moved within an IO Module IO Configuration parameters are saved Controller IP addresses or node numbers are entered or modified External node numbers are entered or modified Serial communications parameters are entered or modified A successful download is made A Strategy is removed The Controller password is changed GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:9

52 PAC8000 SafetyNet SafetyNet IO Modules Overview General SafetyNet IO Modules interface to safety system field wiring via Field Terminals. The IO Modules and the Field Terminals mount on Carriers that provide mechanical support, but also connect the internal communication bus and power supply connections to the Modules. The IO Modules are certified as suitable for use in SIL 2 safety-related applications. Certification The SafetyNet IO Modules are certified for use in safety-related applications up to and including SIL 2. The SafetyNet System achieves this certification with a 1oo1D architecture. The SafetyNet IO Modules have been designed specifically for safety-related applications and are certified on the basis of the excellence of their design. The certification does not depend on proven in use data. Diagnostics The IO Modules perform comprehensive internal diagnostic tests as an essential part of ensuring that the IO can carry out the required safety function. If the SafetyNet IO Module s internal diagnostics detect a fault that would prevent the SafetyNet System from carrying out its safety function, then it will initiate a controlled shutdown. A controlled shutdown has two objectives firstly, to ensure that the IO Module enters its failsafe mode; and secondly, to record sufficient data to allow the reason for the shutdown to be determined. If a SafetyNet Module enters a controlled shutdown, then all IO channels are deactivated: input channels are not scanned; and output channels are de-energised. Bussed Field Power The Bussed Field Power (BFP) connectors on the rear of IO Module Carriers provide the power connections for field instruments wired to the IO Modules. For the SafetyNet System, BFP must be 24V dc and supplied by MTL s 8914-PS-AC units. These power supplies may be used in redundant pairs, if required. Live maintenance SafetyNet IO Modules can be removed and replaced in a Class 1, Division 2 or Zone 2 hazardous area - once the relevant Bussed Field Power (BFP) connection has been isolated using an appropriate hazardous area switch (such as the MTL951). Removing and replacing the Modules does not interrupt the operation of the other parts of the node. If a Module is replaced by another Module of identically the same type, then no intervention is required for the System to begin operating normally once the Bussed Field Power is restored. Line fault monitoring In addition to the comprehensive internal diagnostics the SafetyNet IO Modules can monitor field wiring for line faults. Event logging Data from SafetyNet IO Modules can be time stamped and stored by the SafetyNet Controller before being downloaded to the PAC8000 SOE Data Retrieval Client or a 3 rd party historian package. SafetyNet IO Module data is time stamped with a resolution of better than 200ms. Failsafe Mode IO Modules will enter Failsafe Mode from the Running State either due to loss of communications with the Controller or because the module has received an instruction from the Controller to enter the Failsafe State. In this state: The Red Fault LED is lit The IO Module is flagged as unhealthy to the Controller All Railbus Write requests are rejected, except instructions to Reset or to exit the Failsafe State Inputs and HART data are read Outputs are de-energised Background diagnostics continue and if a failure is detected, the module will enter Controlled Shutdown Controlled Shutdown A Controlled Shutdown is carried out if a fault is detected in the Module. In this state it can communicate the reason for shutdown. LED s A number of LED s are provided on each IO Module to provide visual indication of the status of the Module, its channels and its power supply. Module Fault LED (red) On - Failsafe Off - Normal operation Flashing (equal:mark space ratio) Cold start in process, will flash until communication is established with SafetyNet Controller. Blinking (On for a short period, then On for a longer period morse code a ) Fault state after controlled shutdown Module Power LED (green) On - Power OK Off - BFP or Railbus Power Failure Module Channel LED s (yellow) See Individual Module Specifications. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:10

PAC8000 SafetyNet SafetyNet Analog IO Module Overview General The SafetyNet Analog Input Module with HART provides the interface to 8 channels of 4-20 ma input signals.

In such applications the module is used with the 8851-LC-MT SafetyNet Controller and 8811-IO-DC SafetyNet Discrete Input/Output Module.

53 PAC8000 SafetyNet SafetyNet Analog IO Module Overview General The SafetyNet Analog Input Module with HART provides the interface to 8 channels of 4-20 ma input signals. The SafetyNet Analogue Input Module is certified for use in safetyrelated applications up to SIL 2. In such applications the module is used with the 8851-LC-MT SafetyNet Controller and 8811-IO-DC SafetyNet Discrete Input/Output Module. Diagnostics The SafetyNet Analogue Input Module carries out a number of diagnostic checks to confirm the accuracy of the measurement reported and the correct operation of the module. In addition to the primary measurement, a second diagnostic measurement is made using different internal circuitry. The two values are then compared. The primary measurement is reported as faulty if it differs from the diagnostic measurement value by more than 2%. Further tests are carried out on internal supply and references voltages. If a particular channel fails a test, then that channel is made inactive. If the failed test indicates that the Module is not working correctly, it will enter Controlled Shutdown. Live maintenance The field wiring connections to the SafetyNet Analogue Input Module are classified as non-incendive and can therefore be live worked in a Class 1, Division 2 or Zone 2 hazardous area. (Note the Bussed Field Power connection must be isolated before the module is removed or replaced). Input sampling and filtering Each input channel is sampled once every 25ms and is filtered by 1st order hardware and software filters. The software filter can be disabled or set to a number of different values according to the filtering requirements of each channel. HART capability The HART capabilities of the Analogue Input Module allow acquisition of secondary variables which can be used by a standard (but not SafetyNet) application program. The Module also allows Emerson s AMS package to communicate with any HART field device transparently, using HART pass-through. (The first release of SafetyNet will not have full HART capability, contact GE for further information). LED s For the operation of the Power and Fault LED s see IO Module Overview. Module Channel LED s (yellow) On Channel in range (4-20mA) Off Channel inactive Flashing (equal:mark space ratio) Any of the following, with an active channel: line fault (indicated by the input measurement being outside the 4-20mA range), loss of HART signal, Hi-Hi or Lo- Lo alarm. Alarms, Deadband, Dead Zone The Analogue Input Module has a number of configurable parameters for managing setting and clearing alarms and triggering the reporting of a new input value. Hi, Hi-Hi, Lo and Lo-Lo alarms can be configured together with a Deadband through which the input must move before the alarm is cleared. The relationship between these parameters is shown in the diagram below. A Dead Zone can also be configured, which is the value by which an input measurement must change before it is reported as a new value. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:11

PAC8000 SafetyNet SafetyNet Analogue Input Module 4-20 ma with HART 8810-HI-TX 8 single ended 4-20mA input channels Certified for use in SIL 2 safety applications Non-incendive field circuits 2-, 3-

channels...8, single-ended Nominal signal range (span)...4 to 20mA Full signal range...0.25 to 24mA Line fault detection Short circuit current...> 23.5mA Open circuit current...< 0.

54 PAC8000 SafetyNet SafetyNet Analogue Input Module 4-20 ma with HART 8810-HI-TX 8 single ended 4-20mA input channels Certified for use in SIL 2 safety applications Non-incendive field circuits 2-, 3- or 4-wire transmitters HART pass-through, acquisition and status reporting* 24V dc Bussed Field Power required from 8914-PS- AC MODULE SPECIFICATION See also System Specification INPUTS Number of channels...8, single-ended Nominal signal range (span)...4 to 20mA Full signal range to 24mA Line fault detection Short circuit current...> 23.5mA Open circuit current...< 0.5mA Output voltage (@ 20mA) V (min.) Output current...28ma (max.) Accuracy (at 25oC)...± 0.1% of span Temperature coefficient...38 ppm/c Resolution...16 bits Repeatability % of span Data format...16-bit unsigned (0-25mA = 0-65,535) HART data format...ieee754 floating point Isolation (any channel to Railbus)...250V ac RMS (between channels)...none CONFIGURABLE PARAMETERS Alarms....high, high-high, low and low-low Alarm deadband (hysteresis)...user defined value Input filter time constant...user defined value Input dead zone...user defined value Drive on fault state...disabled /upscale /downscale HART variable and status reporting... enable /disable RESPONSE TIME Signal change to availability on Railbus 4 20 ma mode...25ms (max.) HART mode s per channel * The first release of SafetyNet will not have full HART capability, contact GE for further information. HAZARDOUS AREA SPECIFICATION Protection Technique...EEx na [nl] IIC T4 Location (FM and CSA)...ss 1, Div.2, Grps A,B,C,D T4 (CSA with non-incendive field terminal, subject to conditions in CSA certificate.) FM non-incendive field wiring parameters (each channel)...voc = 28.7V; Isc = 33mA Gas groups A, B...Ca = 0.17μF; La = 11mH Gas group C...Ca = 0.51μF; La = 33mH Gas group D...Ca = 1.36μF; La = 88mH POWER SUPPLIES System Power Supply...50mA (typical), 70mA (max.) Bussed Field Power Supply...350mA (2-wire TX max.), 110mA (4-wire TX max.) MECHANICAL Module Key Code...A1 MODULE WIDTH...42mm WEIGHT...200g For recommended and compatible Field Terminals, see Field Terminal - Specification and Selection Guide. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:12

55 PAC8000 SafetyNet 8-channel combination 8811-IO-DC General The SafetyNet Discrete Input/Output Module provides the interface to 8 channels that may be configured in any combination of discrete inputs and outputs. The SafetyNet Discrete Input/Output Module is certified for use in safety related applications up to SIL 2. In such applications the module is used with the 8851-LC-MT SafetyNet Controller and 8810-HI-TX SafetyNet Analogue Input Module with HART. Combined inputs and outputs Each of the 8 channels of the SafetyNet Discrete Input/Output Module may be configured, on a channel-by-channel basis, as either an input or an output. When configured as an input, the channel is suitable for use with dry contacts with power supplied from the Module. When configured as an output, the channel is capable of switching up to 2.0A (maximum of 6.0A continuous per module). Output channels are used with solenoids, valves and alarms Diagnostics Comprehensive diagnostic tests are performed on the module and each of its channels, including tests for stuck ON and stuck OFF output switches. Live maintenance The field wiring connections to the SafetyNet Discrete I/O Module are classified as nonsparking and can only be worked on in a Class 1, Division 2 or Zone 2 hazardous area once the Bussed Field Power connection has been isolated. Note: the Bussed Field Power connection must also be isolated before removing or replacing the module. Input configuration Input channels are used to interface to volt free contacts. Line fault detection can be turned OFF or can detect open circuits or both open and short. Input filtering A change in the input state is recorded only if the states observed at the start and end of the filter time interval are the same. If they are different the previous state is maintained. (This reduces the chance of noise being incorrectly interpreted as a change of input value). The filter time interval can be configured between 0 and 8s, in 1ms intervals. Input transition counting A counter can record the number of filtered transitions of a particular type. Depending on the polarity setting, the counter will either count transitions from 0 to 1, or from 1 to 0. The counter wraps around from to zero without indication. Transitions are counted even if the channel is configured to latching. Earth leakage detection Where earth leakage fault detection is required, a single channel of an IODC module must be configured to monitor earth leakage and wired to the appropriate terminals of an 8751-CA-NS Controller Carrier. Input latching Inputs can be configured to latch a particular (filtered) input transition and maintain the output in the latched state until the latch is cleared. Normal Polarity will latch a transition from 0 to 1 as 1, Inverse Polarity will latch a transition 1 to 0 as 0. The operation is described in the figure below. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:13

56 PAC8000 SafetyNet Normally energized and normally de-energized outputs Individual output channels can be either normally energized or deenergized. Each output channel comprises 2 switches that operate in series with the load one on the supply line, the other on the return For normally energized outputs, if a single switch fails short circuit, the other switch can still de-energies the load. If either fails open circuit, the load will be immediately reenergized by the fault. For normally deenergized outputs, if a single switch fails short circuit, the other switch can energize the load. If either fails open circuit, the load cannot be energized. Switches are tested by pulsing them ON or OFF for a maximum of 5 ms the load must not respond to this length of pulse. This test can be disabled if required. Short circuit protection Channels that are configured as outputs and which are short-circuited are protected by over-temperature thermal detection. If an output channel is short-circuited it will briefly conduct an over specification current, but this will be identified by the thermal detection and the relevant channel made inactive. Pulsed output Output channels can be configured to give a pulsed output of either single static, single dynamic, continuous or continuous dynamic form. The single static pulse is ON for a predetermined time. It then remains OFF until a new pulse instruction is received. The single dynamic pulse is ON for a period that may be changed by the application, then remains OFF until a new instruction to write is received. In continuous pulse mode a series of pulses of defined ON period are sent, with a defined OFF period between. Continuous dynamic pulse mode allows the application to continually vary the ON and OFF times of the pulse train. For all types of Pulsed Output, the ON time of the pulse may be between 0 and 60s in 1ms intervals. For the continuous pulse mode, the OFF period can be set between 0 and 60s, in 1ms intervals. Pre-configured output patterns A number of different, pre-defined output patterns are available, which can be used to indicate the occurrence of different events, using the same alarm hardware. The patterns comply with the requirements of NFPA 72 and are shown in figure 2. Input channel line fault detection Line fault detection (LFD) for open and short circuit line faults will normally be enabled for safety related input channels. Series resistors are required for short circuit detection and end of line resistors for open circuit detection, as shown in figure 3. The nominal resistance thresholds employed are shown in the table below. Output channel line fault detection Line fault detection (LFD) for open and/or short circuit line faults can optionally be enabled for normally de-energized outputs. (Normally energized loads would be deenergized by either open or short circuit line faults, of these only short circuit faults will be detected and reported by the IO Module). An open circuit fault will be reported for line resistances above 30k. Short circuit line fault detection can be enabled with forward or reverse biased test currents. With forward biased test currents, the threshold at which a short circuit fault is reported is configurable up to 1k. With reverse biased test currents, the threshold is fixed at 1.95k. LED s For the operation of the Power and Fault LED s see IO Module Overview. Module Channel LED s (yellow) On Input or output ON Off Input or output OFF GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:14

PAC8000 SafetyNet SafetyNet Discrete Input/Output Module 24Vdc, non-isolated, module powered inputs and outputs 8811-IO-DC 8 inputs - any combination of inputs and outputs Certified for use in SIL 2

57 PAC8000 SafetyNet SafetyNet Discrete Input/Output Module 24Vdc, non-isolated, module powered inputs and outputs 8811-IO-DC 8 inputs - any combination of inputs and outputs Certified for use in SIL 2 safety applications Non-arcing inputs and outputs Output channels rated up to 2A continuous Inputs for dry contact switches 24Vdc Bussed Field Power required from 8914-PS-AC Input Signal change to availability on Railbus...5ms (max.) Railbus command to output change...1ms (max.) MODULE SPECIFICATION See also System Specification Number of channels...8 (independently configured as inputs or outputs) INPUTS ON/OFF threshold current...0.9ma (typ.) O/C Voltage...24V dc (typ.) - depends on BFP Supply Wetting current...1.2ma (typ.) Minimum pulse width detected...5ms Max input frequency in pulse counting mode (no debounce) 30Hz Isolation (any channel to Railbus)...250V ac OUTPUTS Maximum Output Current per Channel...2A Maximum Output Current per Module Continuous...6A Non-continuous (<10 seconds)...8a INPUT CONFIGURABLE PARAMETERS Filter time interval...0 to 8s (in 1ms steps) Earth Leakage Detection Channel...ON/OFF Latch inputs...enable /disable Latch polarity...latch on high/latch on low Pulse counting...up transition/down transition/disable Line fault detection... none/open circuit/open & short circuit OUTPUT CONFIGURABLE PARAMETERS Output type...pulse/discrete/pattern Pulse width...1ms to 60s Line fault detection*...open line & short circuit detect /disable * Normally de-energised channels only RESISTANCE MEASUREMENT ACCURACY For normally de-energised output open and short-circuit detection. With forward biased test current... ±(3.4%+5.3ohm for line resistance 220ohm..greater of: ±7% or ±(3.1%+27 for line resistance >220 <1kohm With reverse biased test current...greater of: ±7% or ±(3.1%+430ohm HAZARDOUS AREA SPECIFICATION Protection Technique...EEx na nl IIC T4 Location (FM and CSA)...Class 1, Div.2, Grps A,B,C,D T4 POWER SUPPLIES System Power Supply...50mA (typ.), 70mA (max.) Bussed Field Power Supply All channels configured as inputs...50ma (max) Any channels configured as output...50ma + output load currents MECHANICAL Module key code...b6 Module width...42mm Weight...210g For recommended and compatible Field Terminals, see Field Terminal - Specification and Selection Guide. RESPONSE TIME GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:15

PAC8000 SafetyNet Carriers - overview General Carriers are the backplanes on to which the PAC8000 SafetyNet and PAC8000 Controllers are mounted.

58 PAC8000 SafetyNet Carriers - overview General Carriers are the backplanes on to which the PAC8000 SafetyNet and PAC8000 Controllers are mounted. A Controller Carrier is required for each node, then IO Module Carriers, Carrier Extenders and Cables can be added as required depending on the number of IO Modules needed and their physical distribution within the cabinet or junction box. Power and communication Carriers distribute system power to IO Modules and provide the communications route between Controllers and IO Modules. (Controller power is supplied by direct connections to the Controllers themselves). IO Module Carriers provide connectors through which field power can be supplied (see Bussed Field Power ). Note: field power to Intrinsically Safe IO is managed differently, see the relevant 2/1 data sheets. Multi-pin connectors at the end of each carrier allow further Carriers to be added and the system power supply and Railbus connections to be made. Earthing screens and shields All I/O Module Carriers have their own independent earthing/grounding strip to terminate the screens/shields of field wiring cables. SafetyNet Controller Carrier The SafetyNet Controller Carrier (8751-CANS) is the dedicated Carrier for the SafetyNet System. It can support simplex or redundant SafetyNet Controllers and the Power Supply Monitor (8410-NS-PS). Serial communications Two D-type connectors are provided on the SafetyNet Controller Carrier for connecting to serial devices. These link to Serial Port 1 of Controller A and Controller B. A second pair of D-type connectors is found on the Controllers themselves, to provide connections to Serial Port 2 where redundant serial communication is required. Further details of the serial port connections are given in the data sheet for the SafetyNet Controllers and Carriers. Controller Carriers Two Controller Carriers are available the standard Controller Carrier and the ELFD Controller Carrier. To comply with the earth leakage fault detection (ELFD) requirements of Fire & Gas application standards, the ELFD Controller Carrier (8751-CA- NS) can be used. A single channel of an 8811-IO-DC module must be allocated to earth leakage detection to implement this function. SafetyNet applications that do not require ELFD can use the standard Controller Carrier (8750-CA-NS). Change State buttons Two change state buttons are mounted on the SafetyNet Controller Carrier one for each Controller. The button is used to switch a master to being the standby in a redundant pair, to switch a standby offline and to instruct an offline standby Controller to synchronise itself with the Controller and to enter standby. Terminations for power fail inputs The 8913-PS-AC and 8914-PS-AC power supplies each have an output that indicates the health of the supply. These outputs can be connected to the termination block on the SafetyNet Controller Carrier and are used by the Power Supply Monitor Module to detect failures in any of up to 7 of these external power supplies. Module Carrier SafetyNet Systems use the 8- module Carrier with 64-slot addressing (8709-CA-08) for SafetyNet and standard modules. Up to 8 of these may be used together to provide slots for up to 64 IO Modules. The 4-module Carrier (8710-CA-04) can be used where the application requires four IO Modules or less. This will modify the addressing system and users should contact GE Faniuc when considering this option. Carrier Extenders and Cables To allow for flexibility in cabinet layout, Carrier Extenders are provided which together with the Extender Cables are used to connect Carriers mounted on different sections of the cabinet backplane or DIN rail. Carrier Extenders are used in left- and righthand pairs. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:16

PAC8000 SafetyNet Controller Carrier ELFD Controller Carrier 8751-CA-NS terminals for earth leakage fault detection accommodates two SafetyNet Controllers accommodates Power Supply Monitor module two

59 PAC8000 SafetyNet Controller Carrier ELFD Controller Carrier 8751-CA-NS terminals for earth leakage fault detection accommodates two SafetyNet Controllers accommodates Power Supply Monitor module two serial port connections manual change state buttons The ELFD Controller Carrier provides a mounting platform for up to two SafetyNet Controllers (8851-LC-MT). It can also accommodate a Power Supply Monitor module (8410-NS-PS) which can monitor the health of up to two 8913-PS-AC, four 8914-PS-AC power supplies and the 12V supply to Intrinsically Safe Modules (when these are used). For each Controller there is a serial port connector and a manually operated " Change State button. The Carrier also provides terminals that are used when earth leakage fault detection is required. CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULES SafetyNet Controller (x2) lc-mt Power Supply Monitor Module NS-PS ELECTRICAL CONNECTIONS Railbus connector...male out Serial port connectors...9-pin, D-type (female) (x2) Power Fail connections...screw terminals (x7 pairs) Ground connection...m4 screw terminal (x1) BFP0V connection...m4 screw terminal (x1) Earth leakage fault detection connections...screw terminals (1 pair) System Power connections...6-pin (male) (Note: this does not provide power to the SafetyNet Controllers) MECHANICAL Dimensions (w) x 253 (d) mm (footprint) Height...28 mm (top of circuit board)...55 mm (overall) Weight kg (approx.) Mounting methods...flat panel (4 fixings) CONTROLLER CARRIER LAYOUT USER CONTROLS Two change state buttons, one for each SafetyNet Controller, are provided on the carrier. The state change depends upon the controller state before the button is pressed. See table below for effects. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:17

PAC8000 SafetyNet Controller Carrier EARTH LEAKAGE FAULT DETECTION When earth leakage fault detection is NOT required, a link should be made - as shown below - between the BFP0V and GND connection

SERIAL PORT CONNECTORS (X2) 8751-CA-NS (continued) SYSTEM POWER SUPPLY CONNECTIONS When earth leakage fault detection IS required, then the terminals of connector CON12 must be wired to a channel of

Note: earth leakage fault detection can only operate when BFP0V and all field wiring and field instruments are isolated from ground (GND).

60 PAC8000 SafetyNet Controller Carrier EARTH LEAKAGE FAULT DETECTION When earth leakage fault detection is NOT required, a link should be made - as shown below - between the BFP0V and GND connection studs. Note: the BFP0V connection stud must still be connected to Bussed Field Power 0V, marked - on the 8914-PS-AC power supply, and the GND connection must still be connected to ground. SERIAL PORT CONNECTORS (X2) 8751-CA-NS (continued) SYSTEM POWER SUPPLY CONNECTIONS When earth leakage fault detection IS required, then the terminals of connector CON12 must be wired to a channel of an 8810-IO-DC module - as shown below - that has been configured for earth leakage. Note: earth leakage fault detection can only operate when BFP0V and all field wiring and field instruments are isolated from ground (GND). Two pairs of System Power supply connections (terminals 2/3 and terminals 4/5) are provided for wiring a redundant pair of 8913-PSAC power supplies. Note: The Controllers do not draw their power from these connections, they are supplied with Controller Power via connections on the Controllers themselves. GND AND BFP0V CONNECTION The GND terminal must always be connected to the main instrument earth or the star-point bus-bar. (Note: the 0V of the 8913-PS-AC power supplies is GND). The BFP0V terminal must always be connected to 0V of the 8914-PSAC power supplies. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:18

PAC8000 SafetyNet Controller Carrier PSU POWER FAIL CONNECTIONS An 8410-NS-PS Node Services Power Supply Monitor Module must be installed on the Controller Carrier to make use of this capability.

61 PAC8000 SafetyNet Controller Carrier PSU POWER FAIL CONNECTIONS An 8410-NS-PS Node Services Power Supply Monitor Module must be installed on the Controller Carrier to make use of this capability. If an 8410-NS-PS is not being used, then it is not necessary to make any connections to the PSU Power Fail terminals CA-NS (continued) Terminal pairs 7 and 8 These terminal pairs are used to monitor the AUX (or power fail) output from up to two 8913-PS-AC power supplies. The upper terminal of each pair is connected directly to the AUX terminal of the 8913-PS-AC that is to be monitored. It is not necessary to connect the lower terminal - as this is internally connected to the GND terminal on the Carrier. If a pair is unused, a shorting link must be placed between the upper and lower terminals, otherwise the Power Supply Monitor Module will continuously report a fault. Terminal pair 9 If a Railbus Isolator (8922-RB-IS) is not used in the node, this terminal pair must be fitted with a shorting link to prevent an alarm condition being signalled to the Controller. If a Railbus Isolator is used, internal connections are made to monitor the failure of any power supplies used to provide power for the Intrinsically Safe IO Modules. Terminal pairs 1, 2, 4 and 5 These terminal pairs are used to monitor the AUX (or power fail) output from up to four 8914-PS-AC power supplies. The upper terminal of each pair is connected directly to the AUX terminal of the 8914-PS-AC that is to be monitored. It is not necessary to connect the lower terminal - as this is internally connected to the BFP0V terminal on the Carrier. If any of the 8914-PS-AC supplies are acting as redundant pairs, then these should be connected to terminal pairs 1 and 2 and/ or terminal pairs 4 and 5. If a pair is unused, a shorting link must be placed between the upper and lower terminals, otherwise the Power Supply Monitor Module will continuously report a fault. Terminal pair 3 The upper terminal of this pair should be connected to the 24V dc supply of the 8914-PS-AC supply monitored by terminal pairs 1 and 2. The lower should be connected to the 24Vdc supply of the PS-AC monitored by terminal pairs 4 and 5. If a single pair of 8914-PS-AC power supplies is being monitored, then it is only necessary to make single connection to appropriate terminal of pair 3. Terminal pair 6 This terminal pair is unconnected and should not be used. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:19

PAC8000 SafetyNet Module Carrier 8-module Carrier - extended addressing 8709-CA-08 64-slot address bus accepts up to eight SafetyNet and/or standard I/O modules DIN rail or panel mounting carries

62 PAC8000 SafetyNet Module Carrier 8-module Carrier - extended addressing 8709-CA slot address bus accepts up to eight SafetyNet and/or standard I/O modules DIN rail or panel mounting carries control signals and data on Railbus distributes System Power to modules distributes Bussed Field Power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification ELECTRICAL CONNECTIONS Railbus connectors...female in, male out Cable screens/shield connections...m4 screw terminals (x34) Bussed field power supply connectors...8-pin male (x2) The two 8-pin connectors provided at the top rear of the carrier connect power supplies for field power. These supplies are routed through I/O modules that require power for their field circuits. MECHANICAL Dimensions (w) x 170 (d) x 22 (h)mm Weight...680g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5mm rail or 35 x 15mm rail to EN G-section rail to EN Note: For applications with up to 4 IO Modules, it is possible to use the 4-module Carrier (8710-CA-04). For further information, contact MTL. BUSSED FIELD POWER CONNECTOR CONNECTOR AND TABLE The table above gives the connection details for modules 1 to 4. The second connector provides identical connections for modules 5 to 8. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:20

PAC8000 SafetyNet Carrier Extender Left-hand/right-hand 802x-CE-Xh ensures Railbus and power supply continuity pairs (left & right hand) link separate carrier runs sub-d connectors linked via

63 PAC8000 SafetyNet Carrier Extender Left-hand/right-hand 802x-CE-Xh ensures Railbus and power supply continuity pairs (left & right hand) link separate carrier runs sub-d connectors linked via multi-way cable multi-pin connector to carrier maximum of 3 extender pairs per node 32- and 64-slot address capable CARRIER SPECIFICATION See also System Specification ELECTRICAL CONNECTIONS Railbus carrier connector 8020-CE-RH...female in 8021-CE-LH...male out Extender cable connector...sub-d, 37-pin female System Power cable connections*...screw terminal (x6) System Power cable conductor size...2.5mm2 (max.) * The six terminals for the System Power connections must be made in addition to connecting the Extender cable. The Terminals on the left- and right- hand extenders indicate which connections need to be made for System Power (HVCC + and HVCC -) and an internal ground connection (SGND). MECHANICAL Dimensions (overall)...42 (w) x 168 (d) x 37 (h)mm Weight g Mounting method...integral DIN-rail fixings DIN rail types... Top hat, 35 x 7.5mm or 35 x 15mm to EN G-section, to EN PART NUMBERS Carrier Extender, Right-hand Carrier Extender, Left-hand 8020-CE-RH 8021-CE-LH GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:21

PAC8000 SafetyNet Carrier Extender Cable 0.35m, 0.85m 1.2m 800x-CC-xx Railbus data extender cables three lengths - 0.35, 0.85 and 1.

64 PAC8000 SafetyNet Carrier Extender Cable 0.35m, 0.85m 1.2m 800x-CC-xx Railbus data extender cables three lengths , 0.85 and 1.2 m Sub-D cable connectors SPECIFICATION See also System Specification ELECTRICAL CONNECTIONS Extender cable connectors...sub-d, 37-pin male (X2) Carrier Extension Cable, 0.35m 8001-CC-35 Carrier Extension Cable, 0.85m 8002-CC-85 Carrier Extension Cable, 1.2m 8003-CC-12 GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:22

65 PAC8000 SafetyNet Field Terminals overview General Field terminals are removable units for terminating wiring from field instruments. Each IO Module combines with a Field Terminal to which the wiring from field instrumentation is connected. Recommended and compatible Field Terminal types are given in the Field Terminal Specification and Selection Guide. They can be selected to optionally include loop disconnection and fusing eliminating the need for additional terminals and wiring between the Field Terminal and the instrumentation. By wiring directly to the Field Terminal, there is no need for additional terminals or wiring. 8-channel Field Terminals SafetyNet IO Modules use standard 8000 Process I/O 8-channel Field Terminals. Depending on the application, the Field Terminals may be for general purpose, non-arcing or non-incendive field wiring, may incorporate fused disconnects and may be for 2-, 3- or 4-wire transmitters. Fused disconnect The fused disconnect Field Terminals incorporate a 2A fuse that can be partially withdrawn from the Field Terminal to act as a loop disconnect. Tag strip Each Field Terminal is supplied with an integral tag strip, which is hinged to provide access to the wiring terminals and the fuse disconnects. Field Terminal clicks on to Carrier The Field Terminal is easily removed from the Carrier it is held in place by a sprung latch that can be released without the need for tools. This simplifies connection of the field wiring. The Field Terminal is secured in place by the insertion of the IO Module. Wiring to Field Terminals SafetyNet IO Modules all use 8- channel Field Terminals, to which wiring with a cross section of up to 2.5mm2 can be connected. Each termination point is clearly numbered to simplify recognition of each terminal. The two rows of terminals are offset to allow access to the lower row when wiring is in place. Keying Rotary keys in the Field Terminal are adjustable to allow insertion of certain modules. Modules that would cause field wiring to be unsafe (in respect of hazardous areas) cannot be inserted. The four types of Field Terminal can be identified from the diagram below GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:23

PAC8000 SafetyNet Field Terminal - Specification and Selection Guide Field Terminals 86xx-FT-xx a range of Field Terminals standard, fused

voltage...250v ac Maximum current per I/O channel...3a Fuse rating (where fitted)...2a Conductor size...0.14 2.

5 (h)mm Weights (typical - including tagging strip) Unfused type...78g Fused type.

66 PAC8000 SafetyNet Field Terminal - Specification and Selection Guide Field Terminals 86xx-FT-xx a range of Field Terminals standard, fused and loop-disconnect tag strip fitted to all Field Terminals FIELD TERMINAL SPECIFICATION See also System Specification ELECTRICAL Rated voltage...250v ac Maximum current per I/O channel...3a Fuse rating (where fitted)...2a Conductor size mm2 MECHANICAL Dimensions - approx (including tagging strip)...42 (w) x 88 (d) x 39.5 (h)mm Weights (typical - including tagging strip) Unfused type...78g Fused type...86g PART NUMBERS CONNECTION DIAGRAM The connection diagram below applies to all Field Terminals usedwith SafetyNet IO Modules. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:24

67 PAC8000 SafetyNet Power Supplies overview Redundancy Redundancy is implemented by pairing each power supply with a second power supply. If the optional Nodes Services Power Supply Monitor (8410-NS-PS) is used, then this can detect if there has been a failure in any one of up to six 8913-PS-AC/ 8914-PSAC power supplies and the 2/1 power supplies for nodes including Intrinsically Safe IO and will then report that such a failure has occurred. Wide range of input voltages The 8913-PS-AC and 8914-PS-AC power supplies accept AC input voltages in the range V ac. Hazardous area mounting Each power supply can be mounted in Class 1, Division 2 or Zone 2 hazardous areas. General In order to meet the relevant safety requirements, the power supplies are specifically designed for use with PAC8000 SafetyNet and are used to power the SafetyNet Controller and IO Modules. The 8913-PS-AC power supply must be used to supply the 12V dc for the SafetyNet Controller and System Power, and the 8914-PS-AC power supply must be used for the 24V dc Bussed Field Power supply to the SafetyNet IO Modules. Operating ambienttemperature When mounted with the optimum orientation for cooling, the power supplies will provide their full rated output in operating ambient temperatures of +70C (provided the input range is in excess of 125V ac). GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:25

68 PAC8000 SafetyNet Power Supply System Power 12V 5A System and Controller power 24V 5A for powering local instrumentation V ac input voltage Zone 2/Div 2 hazardous area mounting 12V output supports load sharing for redundancy 8913-PS-AC used to supply 24Vdc Bussed Field Power.voltage dependent resistor POWER SUPPLY SPECIFICATION See also System Specification ELECTRICAL CONNECTIONS AC Input connections...screw terminals (x3) DC Output connections...screw terminals (x8) Power fail signal connection...screw terminal (x1) INPUT SPECIFICATION Input voltage V ac Input frequency Hz Power efficiency...up to 87 % Input protection..internal (6.3A) slow-blow fuse and VDR* OUTPUT SPECIFICATION DC24V output voltage v dc ± 10% DC12V output voltage v dc ± 5% DC24V output current...5a (nominal - see Figure1) DC12V output current...5a (nominal - see Figure 1) Input-output isolation v dc Hold-up time (at full rated load)...15ms (typ.) Thermal protection....reduced output power Supply health indicator....led POWER-FAIL SIGNALLING - DC12V output only Threshold to trigger "power-fail" signal v (max.) v (min.) Power-fail signal output (open collector) Power supply "OK"...Low impedance to ve of DC12V output Power supply "failure"...high impedance to ve of DC12V output HAZARDOUS AREA SPECIFICATION Protection Technique...EEx na II T4 Location (FM)...Class 1, Div.2, Grps A,B,C,D T4 Location (CSA)...Class 1, Div.2, Grps A,B,C,D T3C MECHANICAL Dimensions (w) x 138 (h) x (d)mm (see Figure 4) Mounting methods...35 mm x 7.5 mm T-section DIN rail (see also Accessories overleaf) Weight...750g APPROVALS EN 61204: 1995 Low-voltage power supply devices, d.c. output - Performance characteristics and safety requirements EN : 2002 Safety of information technology equipment EN 61326: A1: A2: 2001 Electrical equipment for measurement, control and laboratory use - EMC requirements (Class A equipment) EN50021: 1999 Electrical apparatus for potentially explosive atmospheres - Type of protection n Figure 1 - DC24V and DC12V output current de-rating The 24Vdc output does not support load sharing and should only be used for supplying local 24Vdc instrumentation. It should not be GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:26

Platforms Americas: 1 800 433 2682 or 1 434 978 5100 Global Regional

69 PAC8000 SafetyNet Power Supply System Power 8913-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:27

70 PAC8000 SafetyNet Power Supply Bussed Field Power 8914-PS-AC 24V 10A for Bussed Field Power V ac input voltage Zone 2/Div 2 mounting supports load sharing for redundancy POWER SUPPLY SPECIFICATION See also System Specification ELECTRICAL CONNECTIONS AC Input connections...screw terminals (x3) DC Output connections...screw terminals (x8) Power fail signal connection...rew terminal (x1) INPUT SPECIFICATIONS Input voltage V ac Input frequency Hz Power efficiency...up to 87 % Input protection...internal (6.3A) slow-blow fuse and VDR* OUTPUT SPECIFICATIONS Output...24V dc ± 10% Output current...10a (nominal - see Figure 1) Input-output isolation v DC Hold-up time (at full rated load)...15ms (typ.) Thermal protection...reduced output power Supply health indicator...led POWER-FAIL SIGNALING Threshold to trigger "power-fail" signal v (max.) v (min.) Power-fail signal output (open collector) Power supply "OK"...low impedance to ground Power supply "failure"...high impedance to ground HAZARDOUS AREA SPECIFICATION Protection Technique...EEx na II T4 Location (FM)...Class 1, Div.2, Grps A,B,C,D T4 Location (CSA)...Class 1, Div.2, Grps A,B,C,D T3C MECHANICAL Dimensions (w) x 138 (h) x (d)mm (see Figure 4) Mounting methods...35 mm x 7.5 mm T-section DIN rail (see also Accessories overleaf) Weight...750g APPROVALS EN 61204: 1995 Low-voltage power supply devices, d.c. output - Performance characteristics and safety requirements EN : 2002 Safety of information technology equipment EN 61326: A1: A2: 2001 Electrical equipment for measurement, control and laboratory use - EMC requirements (Class A equipment) EN50021: 1999 Electrical apparatus for potentially explosive atmospheres - Type of protection n GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:28

PAC8000 SafetyNet Power Supply Field Power 8914-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Output connector screw terminals ACCESSORIES Heavy duty DIN rail mounting kit*.

71 PAC8000 SafetyNet Power Supply Field Power 8914-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Output connector screw terminals ACCESSORIES Heavy duty DIN rail mounting kit* fk- DN Surface panel mounting kit fk- SU For high vibration environments GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:29

PAC8000 SafetyNet Node Services Power Supply Monitor 8410-NS-PS power supply status monitoring for 8913-PS-AC and 8914-PS-AC power supplies indicates supply failures to SafetyNet Controller monitors

72 PAC8000 SafetyNet Node Services Power Supply Monitor 8410-NS-PS power supply status monitoring for 8913-PS-AC and 8914-PS-AC power supplies indicates supply failures to SafetyNet Controller monitors up to two 8913-PS-AC, four 8914-PS-AC power supplies and the 2/1 supply for nodes including IS IO modules Zone 2/Div 2 hazardous area mounting mounts on 8571-CA-NS Carrier The Power Supply Monitor can monitor the health of supplies powering a SafetyNet node and signal the Controller in the event of any one of them failing. The module can receive power supply status signals from up to two 8913-PS-AC and four 8914-PS-AC power supplies. It can also monitor the status of 8920-PS-DC supplies powering intrinsically safe I/O modules. Where power supply redundancy is employed, the module enables failed power supplies to be identified and replaced without interference to the process. The module itself may be removed and replaced in a Zone 2/ Div 2 hazardous area without gas clearance. MODULE SPECIFICATION See also System Specification LED INDICATOR PWR (i.e. System power supply present) HAZARDOUS AREA SPECIFICATION Protection Technique...EEx nl IIC T4 Location (FM and CSA)...Class 1, Div.2, Grps A,B,C,D T4 POWER SUPPLIES System Power Supply...5mA (typ.), 10mA (max.) MECHANICAL Mounting method...(captive x2) screw fixing Weight (approx.)...75g DIMENSIONS Dimensions in mm GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:30

PAC8000 SafetyNet System Specification System Specification ENVIRONMENTAL Operating Ambient Temperature Optimum orientation*...-40oc to +70oC Non-optimum orientation...-40oc to +50oC Storage.

73 PAC8000 SafetyNet System Specification System Specification ENVIRONMENTAL Operating Ambient Temperature Optimum orientation*...-40oc to +70oC Non-optimum orientation...-40oc to +50oC Storage...-40oC to +85oC Relative Humidity...5 to 95% (non-condensing) Ingress protection...ip20 to BS EN60529: 1992 Corrosion resistance...designed to meet ten year service in Class G3 corrosive environment, as per ISA S-71.04: 1985 Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants. * With field terminals vertically above or below the IO Modules. Operating vibration resistance DIN rail mounted* g (sinusoidal vibration Hz to EN )...1g (random vibration Hz to BS2011: Part 2.1) Surface mounted g (sinusoidal vibration Hz to EN )...5g (random vibration Hz to BS2011: Part 2.1) * The ELFD Controller Carrier 8751-CA-NS can only be surface mounted. Operating, Storage and Transportation vibration resistance...30g peak acceleration, with 11ms pulse width (EN ) Storage and Transportation shock resistance...1m drop onto flat concrete (EN ) MECHANICAL DIN-rail types... Top hat, 35 x 7.5mm to EN Top hat, 35 x 15 mm to EN G-section, to EN ISOLATION Between SafetyNet channels...none Channel (any) to railbus...250v ac rms NODE SIZE LIMITATIONS Maximum physical length of railbus*...6.8m Maximum number of extender cables...3 Maximum number of IO Modules...64 Maximum number of SafetyNet nodes overall including backplanes and extender cables EN : 2005 Electrical apparatus for explosive gas atmospheres. Part 15: Construction, test and marking of type of protection n electrical apparatus. ELECTRICAL STANDARDS AND APPROVALS Applicable EMC standards EN : Electrical equipment for measurement, control and laboratory use EMC requirements. Part 1: General requirements. Applicable Electrical Safety standards IEC : Programmable controllers - Part 2: Equipment requirements and tests. SAFETY APPROVALS Applicable Functional safety standards IEC 61508:2000. Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems IEC 61511:2004. Functional Safety - Safety Instrumented Systems for the Process Sector. System Specification System Specification CABLE PARAMETERS FOR NON-INCENDIVE FIELD WIRING HAZARDOUS AREA APPROVAL SafetyNet node location...safe area or...zone 2, IIC, T4 hazardous area...class 1, Div 2, Groups A-D T4* hazardous location * 8913-PS-AC and 8914-PS-AC power supplies T3C Field equipment and wiring location...safe area or...zone 2, IIC hazardous area...class 1, Div 2, Groups A-D hazardous location (Temperature classification will be determined by the field apparatus) Applicable hazardous area standards: Factory Mutual Research Co., 3611: Non-incendive Electrical Equipment for use in Class I and II, Division 2, and Class III Divisions 1 and 2, Hazardous (Classified) Locations. CSA C22.2 No 213-M1987, Reaffirmed Nonincendive Electrical Equipment for Use in Class I, Division 2 Hazardous Locations. EN :2004 Electrical apparatus for explosive gas atmospheres. Part 0: General Requirements. GE Intelligent Platforms Americas: or Global Regional phone numbers are available on our website Page:31

GE Intelligent Platforms PAC8000 Controllers The PAC8000 Controllers are the latest addition to GE Intelligent Platforms family of controllers.

75 GE Intelligent Platforms PAC8000 Controllers The PAC8000 Controllers are the latest addition to GE Intelligent Platforms family of controllers. The PAC8000 Controllers are designed specifically to provide a solution where a controller needs to be field mounted in the extreme environments found in process applications. PAC8000 Controllers, with their rugged and redundancy characteristics will help you improve your operational performance and productivity for a sustainable advantage. 6 PAC8000 Process Controller 6 PAC8000 Logic Controller 6 PAC8000 Hybrid Controller 6 PAC8000 RTU Controller Powerful Open Controllers The PAC8000 Controllers consist of a Process Controller, Logic Controller, and RTU Controller with DNP3 Ethernet. These controllers provide a tight control loop response, generating a control output in response to input data within 100 ms. Ethernet Bus Interface Modules (EBIM) provide for communications between controllers and remote I/O. Environmental & Hazardous Area Operation PAC8000 Controllers can go where other controllers cannot. They can be field mounted and subjected to the following: 40 C to +70 C operating range ISA Level G3 corrosion 30G shocks and 5G vibration Operation in Class I, Division 2 and Zone 2 hazardous areas with I/O module field wiring extending into Division 1 and Zone 1/0 areas Peer-to-Peer Communications PAC8000 Controllers communicate directly with each other and share data on a peerto-peer basis without having to route data through a centralized database or controller. Critical information can be shared efficiently between controllers HART Support PAC8000 Controllers can pass HART information from smart field devices to a separate PC workstation running asset management software applications to remotely manage smart instrument configuration and calibration. HART pass through from smart field devices HART data and diagnostics can also be used directly in control applications Reduces: - commissioning time - process downtime - loop maintenance costs using - field device diagnostics Controller Redundancy Application reliability is improved with controller redundancy. Redundant controllers in same carrier for increased reliability and small footprint Redundant controllers operate in parallel, checking status multiple times through the processing loop, enabling the backup controller to continuously monitor the health of the master controller, thereby assuring a rapid and bumpless change over, as required A redundant controller is also capable of receiving a firmware upgrade in the field Network Redundancy Network redundancy helps assure stable and consistent communications. The controller has two high speed Ethernet ports that use Fault Tolerant Ethernet to provide redundant communications Each port can be connected to an independent LAN which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communications Engineering Tools The Workbench provides an integrated project development environment coupled with development modules and tools and a comprehensive set of diagnostic utilities. This development environment centralizes project engineering including I/O (Instrument Index) and control strategy configuration A comprehensive function block diagram library for addressing advanced process control requirements is provided for process, logic & hybrid controllers Supports all five IEC programming languages (Ladder Logic Diagram, Structured Text, Instruction List, Sequential Function Chart and Function Block Diagram) plus Flow Chart

76 PAC8000 Controllers Ordering Information Controllers and Carriers Part Number Description Part Number Description 8410-NS-PS Node services power supply monitor 8521-LC-MT Logic Controller 8521-EB-MT Ethernet BIM 8521-RT-DE RTU Controller 8521-HC-MT Hybrid Controller 8750-CA-NS Carrier, simplex or redundant, power monitoring 8000 General Purpose I/O * Part Number Description Part Number Description 8101-HI-TX 8-channel AI, 4-20mA with HART 8116-DO-AC 8-channel DO, Vac non-isolated, module powered 8102-HO-IP 8-channel AO, with HART for 4-20mA 8117-DO-DC 8-channel DO, 2-60Vdc isolated, unpowered 8103-AI-TX 8-channel AI, 4-20mA 8118-DO-AC 8-channel DO, Vac isolated, unpowered 8104-AO-IP 8-channel AO, 4-20mA 8119-VI-05 8-channel Voltage Input, 1-5Vdc 8105-TI-TC 4-channel THC/mV input 8121-DI-DC 16-channel DI, 24Vdc non-isolated, module powered 8106-TI-RT 4-channel RTD input 8122-DI-DC 16-channel DI, 24Vdc isolated, sinking 8109-DI-DC 8-channel DI, 24Vdc isolated, sinking 8123-PI-QU 2-channel Pulse Quadrature Input 8110-DI-DC 8-channel DI, 24Vdc non-isolated, module powered 8125-DI-DC 32-channel DI, non-isolated, module-powered 8111-DI-AC 8-channel DI, 115Vac isolated, sinking 8127-DI-SE 32-channel SOE module 8112-DI-AC 8-channel DI, 115Vac non-isolated, module powered 8129-IO-DC 8-channel supervised DI 8113-DI-AC 8-channel DI, 230Vac isolated, sinking 8132-AI-UN 8-channel Isolated Universal AI 8114-DI-AC 8-channel DI, 230Vac non-isolated, module powered 8133-HI-TX 8-channel supervised AI with HART 8115-DO-DC 8-channel DO, 2-60Vdc non-isolated, module powered Field Terminals and Accessories Part Number Description Part Number Description 8601-FT-NI Field terminal, non-incendive (Div 2) 8610-FT-NA Field terminal, non-arcing (Div 2) 8602-FT-ST Field terminal, standard 8611-FT-FU Field terminal, non-arcing, fused (Div 2) 8603-FT-FU Field terminal, non-incendive, fused (Div 2) 8615-FT-4W Field terminal, 4wire (current sinking) 8604-FT-FU Field terminal, fused 8617-FT-NI Field Terminal, non-incendive, for 16 ch DI 8605-FT-TC Field terminal, thermocouple 8618-FT-MT 16-pin Mass Termination Assembly (Div 2) 8606-FT-RT Field terminal, RTD 8619-FT-MT 44-pin Mass Termination Assembly (Div 2) 8607-FT-TC Field terminal, 8-channel with T/C 8650-FT-PX 32-channel PX/Switch FTA for 8125/ FT-NI Field terminal, 8-channel, non-incendive 8000 I/O Carriers Part Number Description Part Number Description 8707-CA-08 8 module carrier 8710-CA-04 4 module carrier 8709-CA-08 8 module carrier, 64-address system 8000 I/O Carrier Cables Part Number Description Part Number Description 8020-CE-RH Carrier extender, right hand 8080-FC pin cable for 8618 (1m) 8021-CE-LH Carrier extender, left hand 8081-FC pin cable for 8618 (2m) 8041-CC-35 Carrier extension cable, 0.35m 8082-FC pin cable for 8618 (3m) 8042-CC-85 Carrier extension cable, 0.85m 8085-FC pin cables for 8619 (1m) 8043-CC-12 Carrier extension cable, 1.2m 8086-FC pin cables for 8619 (2m) 8044-CC-20 Carrier extension cable, 2m 8087-FC pin cables for 8619 (3m) 8000 I/O Power Supplies and Components Part Number Description Part Number Description 8413-FK-DN 8913/4 PS DIN Rail Mounting Kit 8914-PS-AC 10A 24VDC A/C Input P/S 8414-FK-SU 8913/4 PS Surface Mounting Kit BQ2320-9R-EX 24 to 12VDC Voltage Converter 8913-PS-AC 5A 12VDC & 5A 24VDC A/C Input P/S *Note: Intrinsically Safe I/O also available. GE Intelligent Platforms Contact Information Americas: or Global regional phone numbers are listed by location on our web site at GE Intelligent Platforms, Inc. All rights reserved. All other brands or names are property of their respective holders. Specifications are subject to change without notice GFA-1754

77 GE Intelligent Platforms PAC8000 Process Controller The PAC8000 Process Controller is a rugged, field-mountable control platform intended for those process applications that may have utilized programmable controllers (PLCs) because of their ability to scale to fit smaller applications. Designed for process applications, the PAC8000 Process Controller provides you with an effective alternative to PLC solutions. Combined with the 8000 Process I/O TM system components, it offers cost savings over control room mounted systems as well as flexible system design and high system availability. A PAC8000 Process Control system can utilize any off-the-shelf HMI package. Open control platform The PAC8000 Process Controller executes your control strategies and manages all control activities for the I/O modules. It also manages communications on the control network. The controller has a tight control loop response, rapidly providing a control output in response to input data. The controller incorporates a rigorous redundancy model, fieldbus integration for connecting to HART and a fault tolerant Ethernet implementation to deliver reliable system operation in your application. Applications The PAC8000 Process Controller, with its process oriented function block programming, is designed to satisfy the process automation market, which includes industries like: power generation and electrical distribution, food and beverage, chemicals and petrochemicals, water and waste water, oil and gas pipelines, cement and pulp and paper. Benefits Cost saving solution The PAC8000 Process Controller takes advantage of Windows 2000 & XP based object-oriented technology, graphical user interfaces and easy to learn software solutions to reduce process control system life cycle expenditures by 30 40%. One Step Engineering The PAC8000 Process Controller eliminates expensive, laborious, and sometimes error prone manual engineering work typically required during control projects. Manual generation of design documents, bill of materials and wiring diagrams is eliminated. Similarly, repetition of advanced control strategies is no longer necessary; eliminating re-entry of program information and significantly reducing system configuration time. Function block based Workbench software (part number 8459-PC-MT) is used to configure the control strategy. When your application is completed, it can also generate an export table that is used to create the operator interface database for popular HMI packages. On-line changes PAC8000 Process Controllers allow on-line configuration changes during testing, start-up, and maintenance phases. This significantly accelerates system start-up and reduces operation downtime. It is easy to configure the control project in a single step and automatically generate the point database. Comprehensive Self-Documentation PAC8000 Process Controllers automatically generate as-built system documentation including I/O configuration reports, cross reference analysis, bill of materials, instrument index, system start-up, maintenance information and wiring diagrams. Since the drawings are used to develop the control strategy, they are continuously maintained, as the final control strategy is adjusted to an optimum level. You no longer need to update the documentation at the end of the project to assure that it reflects the actual plant configuration; the system drawings are automatically kept current providing you with significant time savings. Built-in diagnostics Extended diagnostics are available to provide module and channel status information, including high and low alarm, open circuit detection and line fault detection at the device level and "fail-safe" perform level PC-MT PAC8000 Strategy Builder Logic diagrams are developed using the PAC8000 Strategy Builder. The control strategy is built by selecting the appropriate function blocks, assigning symbolic tags and then connecting the blocks with analog or digital lines using standard drawing forms and commands. SAMA style drawings define all the function and parameters that form a process loop. Function block choices include: manual/ auto station, function-generators, pulse-controller, sequencers, bumpless transfers, PID, etc. Complex control strategies are available, including such as feed forward, cascade and multi-variable control are also supported. Template diagrams can be created and reuses within the current project or another future project. Advanced control strategies PAC8000 Process Control algorithms provide the logic and analytical functions for complex control strategies such as feed forward, cascade and multi-variable control. Adaptive tuning functions for PID control is supported. Two and three state device drivers provide the functionality for motor and valve operations with alarms, remote operation and interlocks. Sequential step functions with interlocks and first out functionality are easily configured. Reduced cable costs Instrumentation cable pairs terminate locally instead of being run across the plant to the control room. Heavy, expensive sensor cables are replaced by the LAN cable. High system availability - easy maintenance Maximize up-time through use of redundant PAC8000 controllers, power supplies and network connections. Hot swap modules without affecting system operation or re-configuring even in hazardous areas.

PAC8000 Process Controller powerful, robust controller for advanced control strategies PAC8000 Strategy Builder for process control applications redundancy with bumpless transfer dual-redundant

78 PAC8000 Process Controller powerful, robust controller for advanced control strategies PAC8000 Strategy Builder for process control applications redundancy with bumpless transfer dual-redundant high-speed Ethernet connections field mountable in harsh process environments peer to peer communications between controllers on-line configuration and reconfiguration HART pass-through of process and status variables Integrated general-purpose and IS signals 8521-PC-MT Controller redundancy Redundant controllers can be used for critical control applications. The redundant controller pair operates in parallel, checking status multiple times through the processing loop enabling the backup controller to continuously monitor the health of the master controller, assuring a rapid and bumpless transfer to the standby controller. Network redundancy In addition to controller redundancy, the PAC8000 Process Controller has two high-speed Ethernet ports to provide security of communication. Each port can be connected to an independent LAN which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communication. Executable control programs The control programs are held in nonvolatile memory to enable them to be restored automatically after power cycling of the controller. The use of a redundant controller also enables a new control program to be downloaded to the standby unit while the process continues. When the download has been completed and verified, the standby can be switched to master status to employ the new program. Remote Modbus Devices The PAC8000 Process Controller communicates via Modbus TCP over Ethernet and can operate in either Modbus Master or Modbus Slave mode to communicate with remote Modbus devices. Each controller also has 2 serial ports that can be configured as a Modbus Master to control and obtain information from Modbus Slaves and other serial devices, such as weigh scales, barcode readers, etc. The serial ports can also be configured as a Modbus Slave, accepting write commands from Modbus Master devices and providing information on its data registers. Failsafe and automatic cold start In the event of complete loss of communication the controller will adopt a user-defined failsafe mode and similarly instruct the I/O to take up user-defined failsafe values. In the event of power loss the PAC8000 Process Controller will perform a cold restart which restores the program(s) and assumes a predefined status. Peer to peer communications PAC8000 Process Controller can communicate with each other on a peerto-peer basis, enabling controllers to share data with each other. This capability ensures that critical information can be efficiently shared between controllers instead of requiring data to be passed to each controller from the control room. I/O module configuration The PAC8000 Process Controller receives full details of all the I/O modules under its control and stores the information in non-volatile memory. At start-up the controller downloads to the modules their configuration details, which also include the failsafe states they should adopt in the event of communication failure. Firmware updates In keeping with its ability to maintain operations on a continuous basis, a redundant PAC8000 Process Controller is also capable of receiving a firmware upgrade. In a manner similar to that used for strategy updates, a controller can receive an update to its firmware while in the field. When the upgrade has been confirmed as successful, the controller can be returned to full operation as a master or as a protective standby. HART pass-through The PAC8000 Process Controller has the ability to pass smart HART information from field devices to a separate PC workstation, which allows you to readily interface to asset management software applications, to remotely manage the HART information contained in your HART -based field instruments. The PAC8000 Process Controller works with a variety of asset management packages, including Applied System Technologies' Cornerstone software or Emerson's Asset Management Solutions. Environmental stability Like all of the 8000 series equipment, the PAC8000 Process Controller is designed for use in harsh environments. It operates over a temperature range of 40 C to +70 C and is resistant to shock, vibration and corrosive environments. Hazardous area operation The PAC8000 Process Controller is designed also to operate in Class I, Division 2 and Zone 2 hazardous areas and can control I/O modules that have field wiring extending into the more hazardous Division 1, Zone 1 and Zone 0 areas. Grows as your needs grow The system is scalable to your needs. You can add modular I/O to your system as your needs increase. Redundant controllers can be added without the need to power off your system - the backup controller powers up automatically and is seamlessly brought online. Maximum number of nodes Multiple PAC8000 controller nodes can reside on the same network allowing peer-to-peer communications, as explained above. However, too many nodes can degrade performance, so GE Intelligent Platforms recommends placing no more than 25 nodes on the same subnet of a network.

79 PAC8000 Process Controller 8521-PC-MT 8000 Process I/O hardware Overview 8000 is a completely modular I/O solution for both general purpose and hazardous area applications. It is based on a carrier system that supports a range of modules and offers a wide variety of I/O functions, including AC mains and intrinsic safety signals, even within the same node. I/O Modules I/O modules transfer signals to and from field instruments. Input modules receive signals from transmitters and sensors and convert them into a digital form for presentation to the Controller. Output modules receive commands from the Controller and transfer them to actuators. A wide range of modules is available, including types for low-level instrumentation, AC mains and intrinsically safe signals, I/O modules typically have 4, 8 or 16 field channels. Field terminals Field terminals provide the interface between the I/O modules and the field wiring. They include fusing and loopdisconnect as options. A mechanical keying system prevents an I/O module from being connected to the wrong type of field terminal. Field terminals mount onto the module carrier, one to each I/O module. They are clamped firmly by the I/O module to form an electrical and mechanical assembly of high integrity. They may be replaced in service without removing carriers or disturbing the operation of other modules. Carriers Carriers form 8000's physical and electrical backbone by providing a mounting to support and interconnect the controller, power supplies, I/O modules and field terminals, and carry the address, data and power lines of the internal Railbus. They provide termination points for the LAN and to the I/O modules. I/O module carriers are available to support four or eight I/O modules. System power supplies System power supplies are available for the node to convert local AC or DC supplies to power the node or pro-vide field power for I/O modules. 8000's innovative Bussed Field Power scheme for distributing field power avoids complex wiring at the field terminal and minimizes the carrier wiring. 'HART-ability' The use of 'smart' instruments on process plants is growing but this investment is not always fully exploited. Whether it is for a new installation, or the upgrade of an existing one, GE Intelligent Platforms has solutions that provide the connections between the HART field instruments, the control systems and the process automation maintenance software. Specifically, the 8000 Process I/O system has been designed to be transparent to HART signals, thus allowing the host control software and any HART field instruments to communicate directly with each other. In addition, 8000's HART connection system provides on-line access from a PC to the HART field devices for monitoring device performance. HART devices may be selected for regular status monitoring and alerts can be issued if the status changes. The benefits from this approach are: reduced commissioning time and cost reduced process downtime through status monitoring power loop maintenance costs by using field device diagnostics in your system Each PAC8000 node can address up to 64 I/O modules which, depending upon the number of channels per module, can provide up to 1024 I/O points at a single node! A node can consist of a mixture of analog and discrete modules and this gives maximum flexibility to the system designer. Full HART pass-through is provided - the 8000 appears "transparent", allowing the inquiring "agent" to access the HART capabilities of field instruments. GE Intelligent Platforms recommends placing no more than 25 nodes on the subnet of a network. Redundancy options 8000 has been designed to increase availability and minimize downtime. Redundant controllers, LAN Channels and power supplies can be specified as options to increase system availability. Possible downtime is further reduced by ensuring that the system components using active circuitry can be removed and replaced quickly and easily. Even the field terminals can be replaced without interrupting the operation of adjacent I/O modules. Carriers have no active circuitry and are unlikely to need replacement. Hazardous area applications The 8000 is a truly field mountable system even in areas where flammable gases are present. It is available in versions to suit different area classification schemes: a) Equipment and field wiring located in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas. b) Equipment mounted in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas, with field wiring located in Division 1 hazardous locations or Zone 0 hazardous areas. Time stamping data PAC8000 Controllers can be time synchronized to within approximately 10ms or 2ms if an external SNTP clock is used. Controllers can be configured to time stamp a change to any data field with a time stamping resolution equal to the execution cycle length (typically in the range 50ms to 250ms). Controllers can record approximately 8000 events (7800 worst case) in this way, before the data is over-written by new data. If more accurate time stamping is required, the dedicated Sequence of Events (SOE) module may be used. This can provide a channel-to-channel time stamp accuracy of 0.5ms, within the same module (based on a per-channel resolution of 0.25ms).

80 PAC8000 Process Controller A control node Many industry applications do not present an explosion risk from gas or dust hazards. In others, the environment may be classified as a Zone 2 or Division 2 hazardous area, where flammable material is expected to occur only in abnormal conditions. For both of these the 2/2 system provides effective distributed I/O for process control supports a full range of I/O module types covering inputs and outputs for both analog and discrete circuits. The node can be mounted out on the plant in a suitable enclosure that is capable of providing protection against the environment. The diagram shows a node containing the basic components: one (or two) PAC8000 Logic Controllers, I/O modules on their carriers linked by carrier-extenders and an extension cable PC-MT 8000 with intrinsic safety field wiring The 8000 Process I/O System is also capable of supporting I/O modules with intrinsic safety (IS) field wiring, for connection to certified or 'simple apparatus' field devices in Division 1 or Zone 0 hazardous areas. A range of I/O module types with IS field circuits for industry-standard DI, DO, AI, AO and pulse applications is supported. Integrated power supplies Power for IS I/O modules is derived from integrated, modular power supply units. Each power unit is capable of supplying between eight and twenty I/O modules, depending on the I/O type and mix. Optional power supply redundancy is supported by means of an additional, redundant supply unit connected in an 'n+1' arrangement. In applications with mixed IS and non-is field wiring, the full facilities of the 'Bussed Field Power' regime are retained for the non-is part of the system. In nodes populated only with IS I/O modules, a separate system power supply module provides power for the Bus Interface Module and 'node services'. Redundancy of this supply is also supported. PAC8000 The mission of GE Intelligent Platforms is to design, manufacture and distribute modular, open hardware and software technologybased components for use in the most demanding real-time system applications. These field-proven components can be snapped together to create sophisticated control systems. ORDERING INFORMATION Controller Order using the following part number: PAC8000 Process Controller PC-MT (This Controller includes PAC8000 Process control software) Workbench Workbench software is required to configure the control strategy for each controller. PAC8000 Process Workbench PC-MT (Will configure PAC8000 Process controllers and PAC8000 EBIM) CONTROLLER SPECIFICATION See System Specification for other parameters Modbus is a trademark of Schneider Automation Inc HART is a registered trademark of the HART Communication Foundation LAN INTERFACE Transmission medium...100basetx or 10BaseT Ethernet Transmission protocol...modbus over High Speed Ethernet Transmission rates Mbits/s LAN connector type (x2)...rj45 (8-pin) LAN Insulation (Dielectric withstand) V Action on software malfunction... Halt CPU / Reset CPU Max. nodes on a subnet of a network SERIAL INTERFACES (COM 1 & COM 2) Transmission rates kbits/s (async.) Transmission standard... RS485 half-duplex COM 1 connector (on carrier)...9-pin D-type connector (F) COM 2 connector (on controller)...9-pin D-type connector (M) POWER SUPPLIES Voltage V dc Current A ( typ.) A (max.) HAZARDOUS AREA APPROVALS Location of controller... Zone 2, IIC T5 hazardous area...or Class 1, Div 2, Groups A, B, C, D T5 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class 1, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n UL Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements, 2nd Edition MECHANICAL Module dimensions...69 (w) x 232 (d) x 138 (h) mm Weight (approx.) kg GE Intelligent Platforms Information Center Headquarters: GE GE Intelligent Platforms, Inc. All Rights Reserved. *Trademark of GE Intelligent Platforms, Inc. All other brand names or names are property of their respective holders. Additional Resources For more information, please visit the GE Intelligent Platforms website at:

81 GE Intelligent Platforms PAC8000 Hybrid Controller 8521-HC-MT Overview PAC8000 Hybrid Control provides a fully integrated solution for process control, logic automation and strategy development. PAC8000 Hybrid Control provides a process engineer with the tools to design, implement, document, and maintain a process control system using advanced control strategies. PAC8000 Hybrid Control consists of a number of open system components. The PAC8000 Hybrid Workbench is an integrated development environment that centralizes and coordinates project data including instrument indexes, control strategies (process and logic) and project management. It configures the control logic and generates an export database to create the operator (HMI) database. A rugged field-mountable Control Platform, consisting of the PAC8000 Hybrid controller (8521- HC-MT) and the 8000 Process I/O system. Applications PAC8000 Hybrid Control is designed to satisfy the process automation market, which includes industries like: power generation and electrical distribution, food and beverage, chemicals and petrochemicals, water and waste water, oil and gas pipelines, cement and pulp and paper. PAC8000 Hybrid Control, with its simultaneous support of both process and logic automation strategies, is an ideal solution for process applications that may also require some sequential logic control in a process environment. PAC8000 Process Control PAC8000 Process Control is an open, easy-to-use process control engineering and management solution that delivers comprehensive, distributed control system functionality. PAC8000 Process Control is a fully integrated advanced process control and instrument engineering system offering configuration tools, modeling, simulation, troubleshooting utilities, project drawing management and self-documentation. It is a robust solution that provides the flexibility to configure control systems ranging from a few loops to thousands of points. A flexible, scalable design allows cost effective system expansion. In addition, the system's extensive use of industry standards simplifies integration with other applications. PAC8000 Logic Control The PAC8000 Hybrid Workbench is your complete tool kit for creating IEC programs. The Workbench fully supports the five IEC automation languages - Ladder Diagram (LD), Sequential Function Chart (SFC), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL) - plus Flow Chart and is used to develop, download, simulate, debug, monitor, and edit application programs. PAC8000 Logic Control lets you mix programming languages in the same project. Its true Windows interface will guide you through development of your project. The Workbench Simulator will test your programs before startup. Then use the Workbench to dynamically view programs as they run in real-time and make changes on-the-fly. PAC8000 Control Platform The PAC8000 controller executes your control strategies and manages all control activities for the I/O modules. It also manages communications on the control network. The controller provides a tight control loop response, providing a control output in response to input data within 100 ms. The controller incorporates a rigorous redundancy model, fieldbus integration for connecting to HART and a Fault Tolerant Ethernet implementation to deliver reliable system operation in your application. The controller can concurrently execute both PAC8000 Process Control strategies for process control and an IEC control language for logic control applications. PAC8000 Remote I/O Remote I/O can be used with PAC8000 controllers, allowing you to further distribute control capability in your plant. Connected with an Ethernet Bus Interface Module (EBIM), Remote I/O communicates with the controller using high-speed peer-to-peer communications. The Workbench configures both Remote I/O and local I/O in the same way, providing a fully integrated Remote I/O solution. The PAC8000 Control Platform and Remote I/O are built for harsh process applications, operating over the industrial 40 C to +70 C temperature range that is typically associated with field transmitters and meeting ISA's stringent G3 corrosion resistance requirements. The Controller and I/O solution can both be mounted directly in Division 2 /Zone 2 hazardous areas and, when required, can provide a cost effective intrinsic safety solution.

82 PAC8000 Hybrid Controller 8521-HC-MT Because the system can be mounted in the field, it can also provide extensive cost savings by eliminating the need to wire all sensors back to a central controller. With the PAC8000 Controller and its I/O mounted in the field, the only wiring back to a control room is the high-speed control network. Redundant PAC8000 Controllers PAC8000 Hybrid Control offers extensive redundancy choices to provide you with several options to assure that your system provides the required system availability, including: Redundant controllers Control networks System power supplies Peer to Peer Communications PAC8000 Controllers can communicate with each other on a peer-to-peer basis, enabling controllers to share data with each other. This capability assures that critical information can be efficiently shared between controllers instead of requiring data to be passed to each controller from the control room. Benefits Cost saving solution PAC8000 Hybrid Control takes advantage of Windows 2000 & XP based object-oriented technology, graphical user interfaces and easy to learn software solutions to reduce process control system life cycle expenditures by 30 40%. One Step Engineering PAC8000 Hybrid Control eliminates expensive, laborious, and sometimes error prone during control projects. Manual generation of design documents, bill of materials and wiring diagrams is eliminated. Similarly, repetition of advanced control strategies is no longer necessary; eliminating re-entry of program information and significantly reducing system configuration time. The Workbench configures the control logic and generates and export table that is used to create the operator interface database for many popular HMI packages. On-line changes PAC8000 Hybrid allows on-line configuration changes during testing, start-up, and maintenance phases. This significantly accelerates system start-up and reduces operation downtime. It is easy to configure the control project in a single step and automatically generate the point database. Comprehensive Self-Documentation PAC8000 Hybrid Control automatically generates as-built system documentation including I/O configuration reports, cross reference analysis, bill of materials, instrument index, system start-up, maintenance information and wiring diagrams. Since the drawings are used to develop the control strategy, they are continuously maintained, as the final control strategy is adjusted to an optimum level. You no longer need to update the documentation at the end of the project to assure that it reflects the actual plant configuration; the system drawings are automatically kept current, providing you with significant time savings. Bussed Field Power This is a unique, flexible feature that allows field circuits to be powered with a minimum of wiring and termination effort. A single power supply connection to the module carrier can supply two I/O modules (up to 32 channels), without the need for "daisychaining" at the field terminals. Built-in diagnostics Extended diagnostics are available to provide module and channel status information, including high and low alarm, open circuit detection and line fault detection at the device level and "fail-safe" performance at the module level. Reduced cable costs Instrumentation cable pairs terminate locally instead of being run across the plant to the control room. Heavy, expensive sensor cables are replaced by the LAN cable. Reduced termination costs Field wiring goes directly to the I/O terminals in the local field enclosure. This means there is no additional cross wiring to marshalling panels. Flexible system design Combine analog and logic modules for maximum flexibility and use of space. High system availability - easy maintenance Maximize up-time through use of redundant PAC8000 controllers, power supplies and network connections. Hot swap modules without affecting system operation or reconfiguring, even in hazardous areas.

PAC8000 Hybrid Controller 8521-HC-MT 8000 Process I/O hardware Overview 8000 is a completely modular I/O solution for both general purpose and hazardous area applications.

83 PAC8000 Hybrid Controller 8521-HC-MT 8000 Process I/O hardware Overview 8000 is a completely modular I/O solution for both general purpose and hazardous area applications. It is based on a carrier system that supports a range of modules and offers a wide variety of I/O functions, including AC mains and intrinsic safety signals, even within the same node. I/O Modules I/O modules transfer signals to and from field instruments. Input modules receive signals from transmitters and sensors and convert them into a digital form for presentation to the Controller. Output modules receive commands from the Controller and transfer them to actuators. A wide range of modules is available, including types for low-level instrumentation, AC mains and intrinsically safe signals, I/O modules typically have 4, 8 or 16 field channels. Field terminals Field terminals provide the interface between the I/O modules and the field wiring. They include fusing and loopdisconnect as options. A mechanical keying system prevents an I/O module from being connected to the wrong type of field terminal. Field terminals mount onto the module carrier, one to each I/O module. They are clamped firmly by the I/O module to form an electrical and mechanical assembly of high integrity. They may be replaced in service without removing carriers or disturbing the operation of other modules. Carriers Carriers form 8000's physical and electrical backbone by providing a mounting to support and interconnect the controller, power supplies, I/O modules and field terminals, and carry the address, data and power lines of the internal Railbus. They provide termination points for the LAN and to the I/O modules. I/O module carriers are available to support four or eight I/O modules. System power supplies System power supplies are available for the node to convert local AC or DC supplies to power the node or pro-vide field power for I/O modules. 8000's innovative Bussed Field Power scheme for distributing field power avoids complex wiring at the field terminal and minimizes the carrier wiring. 'HART-ability' The use of 'smart' instruments on process plants is growing but this investment is not always fully exploited. Whether it is for a new installation, or the upgrade of an existing one, GE Intelligent Platforms has solutions that provide the connections between the HART field instruments, the control systems and the process automation maintenance software. Specifically, the 8000 Process I/O system has been designed to be transparent to HART signals, thus allowing the host control software and any HART field instruments to communicate directly with each other. In addition, 8000's HART connection system provides on-line access from a PC to the HART field devices for monitoring device performance. HART devices may be selected for regular status monitoring and alerts can be issued if the status changes. The benefits from this approach are: reduced commissioning time and cost reduced process downtime through status monitoring power loop maintenance costs by using field device diagnostics in your system Each PAC8000 node can address up to 64 I/O modules which, depending upon the number of channels per module, can pro-vide up to 1024 I/O points at a single node! A node can consist of a mixture of analog and discrete modules and this gives maximum flexibility to the system designer. Full HART passthrough is provided - the 8000 appears "transparent", allowing the inquiring "agent" to access the HART capabilities of field instruments. GE Intelligent Platforms recommends placing no more than 25 nodes on the subnet of a network. Redundancy options 8000 has been designed to increase availability and minimize downtime. Redundant controllers, LAN Channels and power supplies can be specified as options to increase system availability. Possible downtime is further reduced by ensuring that the system components using active circuitry can be removed and replaced quickly and easily. Even the field terminals can be replaced without interrupting the operation of adjacent I/O modules. Carriers have no active circuitry and are unlikely to need replacement. Hazardous area applications The 8000 is a truly field mountable system even in areas where flammable gases are present. It is available in versions to suit different area classification schemes: a) Equipment and field wiring located in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas. b) Equipment mounted in general purpose areas, Class 1, Division 2 hazardous locations or Zone 2 hazardous areas, with field wiring located in Division 1 hazardous locations or Zone 0 hazardous areas.

PAC8000 Hybrid Controller 8521-HC-MT 8000 with general purpose field wiring Many industry applications do not present an explosion risk from gas or dust hazards.

84 PAC8000 Hybrid Controller 8521-HC-MT 8000 with general purpose field wiring Many industry applications do not present an explosion risk from gas or dust hazards. In others, the environment may be classified as a Zone 2 or Division 2 hazardous area, where flammable material is expected to occur only in abnormal conditions. For both of these the 2/2 system provides effective distributed I/O for process control supports a full range of I/O module types covering inputs and outputs for both analog and discrete circuits. The node can be mounted out on the plant in a suit-able enclosure providing protection against the environment. Figure 1 shows a node containing all the key components: a PAC8000 Controller, I/O modules on their carriers and a pair of carrier-extenders linked with an extension cable with intrinsic safety field wiring The 8000 Process I/O System is capable of supporting I/O modules with intrinsic safety (IS) field wiring, for connection to certified or 'simple apparatus' field devices in Division 1 or Zone 0 hazardous areas (see Figure 2). A range of I/O module types with IS field circuits for industry-standard DI, DO, AI and AO applications is supported. I/O modules with built-in protection All voltage and current-limiting components required for IS protection are incorporated within the I/O module housings, so no external, add-on Zener barriers or galvanic isolators are necessary. IS field terminals are distinguished from other types by blue coloring of the terminal housing. A unique and sophisticated mechanical keying mechanism prevents modules with different protection techniques from being interchanged, so that potentially explosive or damaging conditions cannot occur. Integrated power supplies Power for IS I/O modules is derived from integrated, modular power supply units. Each power unit is capable of supplying between eight and twenty I/O modules, depending on the I/O type and mix. Optional power supply redundancy is supported by means of an additional, redundant supply unit connected in an 'n+1' arrangement. In applications with mixed IS and non-is field wiring, the full facilities of the 'Bussed Field Power' regime are retained for the non-is part of the system. In nodes populated only with IS I/O modules, a separate system power supply module provides power for the Bus Interface Module and 'node services'. Redundancy of this supply is also supported. Mixed I/O types within a single node IS and non-is field wiring types can also be incorporated within one 8000 node. In this arrangement, the two parts of the node are separated by a 'Railbus Isolator' module. The Railbus Isolator provides a section of internal communications bus ('Railbus') for the IS I/O modules which is protected from invasion by damaging fault voltages Uniquely, a single 8000 node (under the command of one Bus Interface Module) can then support a mixture of certified IS field devices, certified Division 2 or Zone 2 field devices and general purpose I/O, including AC mains circuits. Only one Railbus Isolator is used per 8000 node.

PAC8000 Hybrid Controller powerful, robust controller for advanced control strategies PAC8000 Strategy Builder for process control applications IEC 61131-3 software for logic control applications

85 PAC8000 Hybrid Controller powerful, robust controller for advanced control strategies PAC8000 Strategy Builder for process control applications IEC software for logic control applications process & logic control strategies execute concurrently redundant controllers with bumpless transfer dual redundant high speed Ethernet connections field mountable in harsh process environments peer to peer communications between controllers on-line configuration and reconfiguration HART pass-through of process and status variables 8521-HC-MT Open control platform The PAC8000 Hybrid Controller is a powerful process controller that can receive, store and execute process strategies and sequential or discrete logic applications concurrently. The controller provides a tight control loop response, providing a control output in response to input data within 100ms. The controller communicates at 10/100MB/sec-ond, providing very efficient communications and assuring the system has the capacity for advanced control strategies. Controller redundancy Redundant controllers can be used for critical control applications. The redundant controller pair operates in parallel, checking status multiple times through the processing loop enabling the backup controller to continuously monitor the health of the master controller, assuring a rapid and bumpless transfer to the standby controller. Network redundancy In addition to controller redundancy, the PAC8000 Controller has two high-speed Ethernet ports to provide security of communication. Each port can be connected to an independent LAN which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communication. Executable control programs Control programs are downloaded to the PAC8000 Controller to pro-vide process control with PAC8000 Strategy Builder and logic control with IEC compatible programming languages. The control programs are held in non-volatile memory to enable them to be restored automatically after power cycling of the controller. The use of a redundant controller also enables a new control program to be downloaded to the standby unit while the process continues. When the download has been completed and verified, the standby can be switched to master status to employ the new program. Remote Modbus Devices The PAC8000 Logic Controller communicates via Modbus TCP over Ethernet and can operate in either Modbus Master or Modbus Slave mode to communicate with remote Modbus devices. Each controller also has 2 serial ports that can be configured as a Modbus Master to control and obtain information from Modbus Slaves and other serial devices, such as weighscales, barcode readers, etc. The serial ports can also be configured as a Modbus Slave, accepting write commands from Modbus Master devices and providing information on its data registers. Failsafe and automatic cold start In the event of complete loss of communication the controller will adopt a user-defined failsafe mode and similarly instruct the I/O to take up user-defined failsafe attitudes. In the event of power loss the PAC8000 Controller will perform a cold restart which restores the program(s) and assume a predefined status. Peer-to-peer communications PAC8000 Controllers can communicate with each other on a peerto-peer basis, enabling controllers to share data with each other. This capability assures that critical information can be efficiently shared between controllers instead of requiring data to be passed to each controller from the control room. I/O module configuration The PAC8000 Controller receives full details of all the I/O modules under its control and stores the information in non-volatile memory. At startup the controller downloads to the modules their configuration details, which also include the failsafe states they should adopt in the event of communication failure. Firmware updates In keeping with its ability to maintain operations on a continuous basis, a redundant PAC8000 Controller is also capable of receiving a firmware upgrade. In a manner similar to that used for strategy updates, a controller can receive an update to its firmware while in the field. When the upgrade has been confirmed as successful the controller can be returned to full operation as a master or as a protective standby. HART pass-through The PAC8000 controller has the ability to pass smart HART information from field devices to a separate PC workstation, which allows you to readily interface to asset management software applications, to remotely manage the HART information contained in your HART based, field instruments. It works with a variety of asset management packages, including Applied System Technologies' Cornerstone Software or Emerson's Asset Management Solutions. HART pass-through is supported via a serial port and will soon be available over the Ethernet Control Network. Consult the factory for availability of the Ethernet solution. Environmental stability Like all of the 8000 series equipment, the PAC8000 Controller is designed for use in harsh environments. It operates over a temperature range of 40 C to +70 C and is resistant to shock, vibration and corrosive environments. Hazardous area operation The PAC8000 Controller is designed also to operate in Class I, Division 2 and Zone 2 hazardous areas and can control I/O modules that have field wiring extending into the more hazardous Division 1 and Zone 1 and Zone 0 areas.

86 PAC8000 Hybrid Controller Grows as your needs grow The PAC8000 Hybrid Control System is scaleable to your needs. You can add modular I/O to your system as your needs increase. Redundant controllers can be added without the need to power off your system -the backup controller powers up automatically and is seamlessly brought online. Don't worry about expanding your system software; your original PAC8000 Hybrid Workbench can address all of your software needs. Maximum number of nodes Mutliple PAC8000 controller nodes can reside on the same network allowing peer-to-peer communications, as explained above. However, too many nodes can degrade performance, so GE Intelligent Platforms recommends placing no more than 25 nodes on the same subnet of a network. The PAC8000 Hybrid Controller 8521-HC-MT contains two powerful embedded software environments that will run executable files downloaded to it from the Workbench. PAC8000 Process allows the controller to perform the functions of process automation while PAC8000 Logic is intended for logic automation applications. PAC8000 PROCESS OVERVIEW PAC8000 Process is a process control engineering and management software solution with full distributed process control system functionality. The system is a fully integrated advanced process control and instrument engineering system offering configuration tools, modeling, simulation, troubleshooting utilities, project drawing management and self-documentation. PAC8000 Process is an open, easy-to-use, robust system providing the flexibility to configure control systems ranging from a few loops to thousands of points. The user can also scale their design allowing cost effective system expansion. In addition, the system's extensive use of industry standards simplifies integration with other application. Note: For users interested in process applications only, the PC-MT PAC8000 Process Controller is available. This is the same physical controller but containing only the PAC8000 Process application. This controller can be programmed with the PAC8000 Process Workbench or the PAC8000 Hybrid Workbench. PAC8000 Process Workbench PAC8000 Workbench consists of modular software building blocks that are integrated into a process control solution. The system comprises two integrated components; the Instrument Index and the PAC8000 Strategy Builder. Instrument Index The Instrument Index is used to model the process systems input/out-put by assigning controller, module and point destinations. Using a predetermined template, this task is accomplished as a simple "fill in the blanks" procedure. The Instrument Index uses this information to build the I/O configuration data file. This data file will subsequently be used to cross-link the point attributes to the algorithms on the process control diagrams. PAC8000 Strategy Builder Process control logic diagrams are developed using the PAC8000 Strategy Builder. The control strategy is built by selecting the appropriate blocks, assigning symbolic tags, and then connecting the blocks with analog or digital lines, using standard drawing 8521-HC-MT forms and commands. SAMA style drawings define all the functions and parameters that form a process loop. Function block choices include; manual/auto station, function generators, pulse controllers, sequencers, bumpless transfers, PID and other standard function blocks. To further reduce development time template diagrams can be created and reused within the current project or another future project. For example, a cascade loop can be created and saved for repetitive use to generate additional control loops. When the drawing model is completed, the project diagrams are cross-linked with the I/O database to create: Comprehensive control system engineering documentation. Advanced control strategies. Operator interface database, alarms and faceplates. System maintenance tools. There is no need to review function block codes, re-enter tags, generate spare parts listings, or match control logic to the operator interface. This allows the user to concentrate on designing control strategies and eliminate the repetitive tasks. Project Components In addition to these key design features, PAC8000 Hybrid Control has a wealth of tools and features that simplify the management of the project and provide easy to use interfaces for the user. Comprehensive Self-Documentation PAC8000 automatically generates as-built system documentation including I/O configuration reports, cross reference analysis, bill of materials, instrument index, system start-up, maintenance information, and wiring diagrams. The instrument index provides instrument details such as manufacturer, model number, group number, shift and day log, panel wiring information including panel in/out terminal block and panel in/out position, and field wiring information including cable color, size and type. Database and Tag Import utility The system generates the appropriate database, tag attributes and alarm parameters. The Tag Import Utility can be used to import a tag list that is already defined in a spreadsheet format. The utility imports a.csv, tab or space separated file directly into the Workbench, saving the need to manually recreate this information if it already exists. Advanced Control Strategies The system automatically configures control solutions from straight-forward single loops to advanced control strategies. With over sixty process control algorithms, PAC8000 has the solution; whether for regulatory, logic or sequential control. The algorithms provide the logic and analytic functions for complex control strategies such as feed forward, cascade, and multi-variable control. Functions are provided for easily configuring biased multioutput loops as found in steam and water header pressure control. The system automatically accounts for different device capacities, devices in service, and devices in automatic mode. Adaptive tuning functions for PID control is supported. Two and three state device drivers provide the functionality for motor and valve operations with failure alarms, local and remote operation, and interlocks. Sequential step functions with interlocks and first out functionality are easily configured. The system automatically assigns controller addresses, optimizes controller communications and provides I/O card and point alarm status. By supporting portability between alternative open controller platforms, PAC8000 provides considerable flexibility in specifying system hardware.

87 PAC8000 Hybrid Controller On-line Maintenance, Tuning and Troubleshooting Savings in time and system costs are not limited to initial development and start-up. The system provides suggestive tuning capabilities, on-line and off-line control configuration, and intelligent control schematics from which the system can be modified and tuned. PAC8000 Simulator The PAC8000 Simulator allows the animation of logic diagrams with either simulated data or live, real-time process data. The Simulator is also used for tuning and operator control purposes. I/O diagnostic tags are provided for the operator interface for troubleshooting assistance. Verification of control loop integrity and troubleshooting loop problems can be accomplished quickly and efficiently. PAC8000 LOGIC OVERVIEW PAC8000 Logic is a 32-bit software application for distributed control applications. It supports all five IEC languages: Ladder Diagram (LD), Structured Text (ST), Instruction List (IL), Sequential Function Chart (SFC) and Function Block Diagram (FBD), plus the Flow Chart (FC) language The PAC8000 Hybrid Workbench is used for creating and editing the control code, for simulation, debugging, and on-line monitoring. The code generated by the Workbench is then downloaded to the PAC8000 Controller. Note: For users interested in logic applications only, the 8521-LC- MT PAC8000 Logic Controller is available. This is the same physical controller but containing only the PAC8000 Logic application. This controller can be programmed with the PAC8000 Logic Workbench or the PAC8000 Hybrid Workbench. PAC8000 Logic Workbench The Workbench contains a powerful project management tool that graphically represents and organizes programs, resources, configurations, and networks within a project. The Workbench provides powerful and intuitive graphical and textual editors. Docking toolbars and resizable split windows, drag-and-drop and cut-and-paste are all implemented to enhance ease-of-use. The Ladder Diagram (LD) is one of the PAC8000 familiar methods of representing logical equations and simple actions. Contacts represent input arguments and coils represent output results. Each block in the selection list has a description text. The Structured Text (ST), is a high level structured language with a syntax similar to Pascal but more intuitive to the automation engineer. This language is mainly used to implement complex procedures that cannot be easily expressed with graphical languages. The ST text editor guides the user to the correct syntax and punctuation and provides the best validation and programmer assistance facilities. The Instruction List (IL) is a low-level language, similar to the simple textual PLC languages. IL is a register-level programming language. PAC8000 Logic has a set of more than 60 IEC functions and function blocks. Users can enlarge this set by writing functions and function blocks in the LD, FBD, ST, and IL languages. The Sequential Function Chart (SFC) language divides the process cycle into a number of well-defined steps, separated by transitions. The Workbench fully supports graphical Function Chart programming, which is familiar to many engineers. Function Block Diagram (FBD) is a graphical language which allows the user to build complex procedures by taking existing 8521-HC-MT function blocks from the Workbench library, and wiring them together on screen. The FBD editor allows manual input of variables. The diagrams can be zoomed to view the whole diagram or specific areas in more detail. User can mix LD and FBD programming in the same chart. The Flow Chart is an easy to read decision diagram where actions are organized in a graphic flow. The Flow Chart Editor has full support for connectors and sub-programs. The development process begins with the division of a project into several PLC Loops, also called Resources, identifying their host hardware platforms, and defining the links between them. The physical division of a project is represented by configurations and communications networks. A Configuration represents a hardware platform which contains a single resource. Program development process A resource contains several programming units called Program Organization Units (POUs). POUs can be programs, functions or function blocks. Programs can be described in any of the five IEC languages plus Flow Chart. Linking variables to I/O channels Before defining the project code, the I/O is defined in the Workbench in the form of a tag database, which identifies the I/O channels and their respective field devices. Once a device is selected, a simple mouse-click 'connects' a variable to a channel. The Build To validate the project, the project code must be built. This step is also very useful for syntax checking; all detected errors can be easily located with a simple mouse-click. The generated code is fully publicly documented and supported. The code generator produces the code for each resource. Simulation Simulation enables the validation of the project without any hardware. Each resource can be executed cycle-by-cycle, and various system variables, such as the cycle time, can be monitored. Any variable can be monitored or forced. For debugging with real platforms, or to perform maintenance operations on 'live' systems, changes can be downloaded on-line without stopping the running resources. During the testing phase I/O devices can be set as virtual, if the PAC8000 Controller is not completely ready, or is unavailable to the programmer. Function block instances can be directly debugged from editors. The workbench is intuitive and user-friendly, but to further assist the user, PAC8000 Logic provides HTML-based cross-referenced online help system that includes a complete language reference. The Workbench also offers a document generator. Project items are shown as a tree, the table of contents of the project documentation can be customized by a simple click on each item. To allow re-use of code, libraries of IEC functions and function blocks can now be developed. Functions and function blocks are designed and tested as in any other projects, but other projects can be linked to these "library project" to allow the use of their functions and function blocks. Once a "library project" has been selected, its blocks can be selected as standard blocks. As libraries, import/export functionality allows the sharing of POUs between projects. It is also a comfortable way to integrate the work of several programmers to constitute the final project.

88 PAC8000 Hybrid Controller The Control System Each downloaded application is a complete distributed application running on the target controller. Multiple applications, running on separate controllers, can be linked together using the peer-topeer tool, which identifies tagnames for use across the network. This data exchange mechanism provides a very efficient way of sharing information between multiple controllers. Project backup and restore You can create a backup file of your project at any time. This useful feature enables you to save your application in a known state, and if necessary, restore the project to that state. You can import and export resources from one project to another, enabling you to re-use prior work. If the results of importing or exporting resources are unsatisfactory, you can choose to restore the project. Downloader The Workbench Downloader is used to download the firmware and control strategy to the controller. With Redundant Controllers, strategy changes can be downloaded to a backup controller without disrupting control in the primary controller. When the download is complete, the backup controller will take over control and update the primary controller with the changes. Control can revert back to the primary controller after these changes are incorporated. Downloading to a simplex controller can be done on-line and without initializing data, the new strategy starting on the next execution cycle. Remote data table builder for Modbus import The remote data table is used for connecting to remote Modbus master or Modbus slave devices. Tagnames are assigned to these devices, which are then included in the control strategy. An example of a remote Modbus device is a Modbus TCP compliant H1 Linking device that could be used to bring Foundation Fieldbus H1 data into the control system. PAC8000 The mission of GE Intelligent Platforms is to design, manufacture and distribute modular, open hardware and software technologybased components for use in the PAC8000 demanding real-time system applications. These field-proven components can be "snapped" together to create sophisticated control systems. ORDERING INFORMATION Controller Order using the following part number: PAC8000 Hybrid Controller HC-MT (This Controller includes PAC8000 Process and PAC8000 Logic control software) Other available options are: PAC8000 Process Controller PC-MT (This Controller includes PAC8000 Process control software) PAC8000 Logic Controller LC-MT (This Controller includes PAC8000 Logic control software) PAC8000 Ethernet BIM EB-MT (Used for Remote I/O option with any controller) 8521-HC-MT Workbench Workbench software is required to configure the control strategy for each controller. PAC8000 Hybrid Workbench HC-MT (Will configure PAC8000 Hybrid, Process and Logic controllers and PAC8000 EBIM) Other available options are: PAC8000 Process Workbench PC-MT (Will configure PAC8000 Process controllers and PAC8000 EBIM) PAC8000 Logic Workbench LC-MT (Will configure PAC8000 Logic controllers and PAC8000 EBIM) CONTROLLER SPECIFICATION See System Specification for other parameters LAN INTERFACE Transmission medium...100basetx or 10BaseT Ethernet Transmission protocol...modbus over High Speed Ethernet Transmission rates Mbits/s LAN connector type (x2)...rj45 (8-pin) LAN Insulation (Dielectric withstand) V Action on software malfunction... Halt CPU / Reset CPU Max. nodes on a subnet of a network SERIAL INTERFACES (COM 1 & COM 2) Transmission rates kbits/s (async.) Transmission standard... RS485 half-duplex COM 1 connector (on carrier)...9-pin D-type connector (F) COM 2 connector (on controller)...9-pin D-type connector (M) HART is a registered trademark of the HART Communication Foundation. FOUNDATION is a trademark of Fieldbus Foundation, Austin, TX. Modbus is a registered trademark of Schneider Automation Inc., North Andover, MA. POWER SUPPLIES Voltage V dc Current A ( typ.) A (max.) Railbus (12 V) via carrier...15 ma (max.) HAZARDOUS AREA APPROVALS Location of controller... Zone 2, IIC T5 hazardous area...or Class 1, Div 2, Groups A, B, C, D T5 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class 1, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n UL Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements, 2nd Edition MECHANICAL Module dimensions...69 (w) x 232 (d) x 138 (h) mm Weight (approx.) kg GE Intelligent Platforms Information Center Headquarters: GE GE Intelligent Platforms, Inc. All Rights Reserved. *Trademark of GE Intelligent Platforms, Inc. All other brand names or names are property of their respective holders. Additional Resources For more information, please visit the GE Intelligent Platforms website at:

89 GE Intelligent Platforms /x System Specification System specification MECHANICAL Mounting method Flat panel or DIN-rail DIN-rail types Top hat, 35 x 7.5 mm to EN or 35 x 15 mm to EN or G-section, to EN RAILBUS (Backplane) Maximum physical length* of node. 6.8 m Maximum number of extender cables 3 * Overall, including backplanes and extender cables NODE SIZE BIM/Controller type 8502-BI-DP 8505-BI-MB 8521-xx-MT NOTE: I/O module carriers used with these must conform to the same module address limits. See I/O module carrier datasheets for details. ELECTRICAL EMC compliance To BS EN 61326:1998 Electrical safety EN Module limit 32 max. 32 max. 64 max. ISOLATION I/O Modules - 2/2 Between isolated channels 250 V ac rms (to EN ) (Tested at 2.3 kv ac rms) Channel (any) to Railbus 250 V ac rms (Except where stated on individual module specifications) I/O Modules - 2/1 Between hazardous area terminals and Railbus 60 V ac rms Between IS field circuits of separate I/O modules 500 V ac rms Between any IS field circuit & non-is field circuit 250 V ac rms Between individual channels of an I/O module Refer to individual module specifications 60 second test ENVIRONMENTAL Ambient temp Operating, optimum orientation * 40 C to +70 C (except where stated in individual module specifications) Operating, non-optimum orientation * 40 C to +50 C (except where stated in individual module specifications) Storage 40 C to +85 C * Optimum orientation is when the carrier is mounted in a vertical plane with field terminals located below the modules. Relative Humidity 5 to 95% RH (non-condensing) Ingress Protection IP20 to BS EN60529:1992 (Additional protection by means of enclosure) Corrosive atmospheres Designed to meet ten year service in Class G3 corrosive environment, as defined by ISA Standard SP71.04 Vibration - Storage & Transport EN (Sinusoidal Vibration) BS2011:Part 2.1 (Random Vibration) Vibration - Operating EN (Sinusoidal Vibration) BS2011:Part 2.1 (Random Vibration) Shock - Storage & Transport EN Shock - Operating EN Hz. 5 g for surface mounting 1 g for DIN-rail mounting Hz 5 g for surface mounting 1 g for DIN-rail mounting Hz. 5 g for surface mounting 1 g for DIN-rail mounting Hz 5 g for surface mounting 1 g for DIN-rail mounting 1 m drop onto flat concrete 30 g peak acceleration with 11 ms pulse width

90 8000 2/x System Specification HAZARDOUS AREA APPROVALS - 2/2 NODE 8000 node equipment location * Safe area or Zone 2, IIC T4 hazardous area or Class 1, Div 2, Groups A-D, T4 hazardous location * Except for 8101-HI-TX, 8103-AI-TX and 8119-VI-05 Safe area or Zone 2, IIC T4 (Tamb = 60 C), T3 (Tamb = 70 C), hazardous area or Class 1, Div 2, Groups A-D, T4 (Tamb = 60 C), T3 (Tamb = 70 C) hazardous location Field equipment and wiring location Safe area or Zone 2, IIC hazardous area or Class 1, Div 2, Groups A-D hazardous location (Temperature classification will be determined by the field apparatus) 2/2 module cable parameters for non-incendive field wiring Note For module types 8109-DI-DC and 8122-DI-DC, each pair of field terminals may be considered as non-incendive when connected into a field circuit with the following parameters: Vmax = 30 V dc Imax = 100 ma. The values of capacitance and inductance seen at the module s input terminals are: Ci = 0 μf Li = 0 mh. Module (each channel) FM Gas Group C a (μf) L a (mh) A+B HAZARDOUS AREA APPROVALS - 2/1 NODE 8000 node equipment location Safe area or Zone 2, IIC T4 hazardous area or Class 1, Div 2, Groups A-D, T4 hazardous location Field equipment and wiring location Zone 0, IIC hazardous area or Class 1, Div 1, Groups A-D hazardous location (Temperature classification will be determined by the field apparatus) Applicable standards Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations Factory Mutual Research Co., Class No for Class I, II, III, Division 1, 2 Groups A-G hazardous locations EN 50014: 1992 Electrical apparatus for potentially explosive atmospheres, general requirements EN 50020: 1995 Electrical apparatus for potentially explosive atmospheres, intrinsically safe i EN 50021: 1999 Electrical apparatus for potentially explosive atmospheres, type of protection n EC Directive 94/9/EC (ATEX 100A) LOCAL AREA NETWORK Fieldbus protocols supported Modbus (RTU mode) Profibus - DP Note 1. Protocols are selected by choice of Bus Interface Module 2. For other protocols consult GE Configuration 1) via host LAN (if supported by LAN) 2) via PC connected locally at configuration port Node address setting Software settable in the BIM LAN physical medium (configurable on carrier) LAN A - RS485 or RS422, 5- wire LAN B (where available) - RS485 or RS422, 5- wire LAN isolation LAN A to LAN B (if applicable) V ac LAN A or B to system ground V ac (to EN 61010) POWER SUPPLIES System Supply Local supply input V dc input Supply redundancy Supported Railbus supply voltage 12 V dc ± 5% 8101-HI-TX 8102-HO-IP 8103-AI-TX 8104-AO-IP 8105-TI-TC 8106-TI-RT 8110-DI-DC 8119-VI DI-DC 8123-PI-QU C D A+B C D A+B C D A+B C D A+B C D A+B C D A+B C D A+B C D A+B C D A+B C D

91 8000 2/x System Specification 2/1 module cable parameters for IS field wiring Module (each channel) BASEEFA Gas Group μf mh or μh/ω Gas Group C a (μf) L a (mh) FM IIC A+B HI-IS IIB C IIA D IIC HO-IS IIB IIA IIC A+B AO-IS IIB C IIA D Channels 1, 2, 3, 4, 7 and 8 wired as separate IS circuit IIC A+B IIB C TI-IS IIA D Channels 5 and 6 wired as separate IS circuit IIC A+B IIB C IIA D IIC A+B TI-IS IIB C IIA D IIC A+B DO-IS IIB C IIA D IIC A+B DI-IS IIB C IIA D IIC A+B PI-IS IIB C IIA D IIC AI-IS IIB IIA

92 8000 2/x System Specification Characterisation errors for module 8205-TI-IS Thermocouple Type Characterization error Temperature Range +0 to -42 C 0 to 42 C +0.3 to -0.6 C +42 to +109 C B +0.1 to C +109 to +200 C ±0.06 C +200 to C ±0.11 C to C to -0.1 C -270 to -264 C E to C -264 to -237 C ±0.04 C -237 to C J ±0.04 C -210 to C +0 to -2.0 C -270 to -265 C K ±0.15 C ±0.06 C -265 to -200 C -200 to -100 C ±0.04 C -100 to C +0 to -2.3 C -270 to -265 C N ±0.15 C ±0.06 C -265 to -200 C -200 to -100 C ±0.04 C -100 to C to -0 C -50 to -49 C R ±0.06 C -49 to +1 C ±0.04 C +1 to C S to -0 C -50 to -49 C ±0.04 C -49 to C T +0 to -2.0 C -270 to -265 C ±0.04 C -265 to +400 C W3 ±0.06 C 0 to C W5 ±0.055 C 0 to C Russian K to -0 C -200 to -199 C ±0.04 C -199 to C Russian L ±0.032 C -200 to +800 C

93 8000 2/x System Specification 2/2 system approvals for mounting and field wiring Standard EUROPE USA (FM) CANADA (CSA) pren50021 & EN Class No C22.2 No. 213 Approved for Zone 2 installation and field wiring ATEX Category II 3 G Div 2 installation non-incendive apparatus suitable for installation in Class 1, Div 2, Grps A-D Div 2 installation non-incendive apparatus suitable for installation in Class 1, Zone 2/Div 2, Grp IIC I/O MODULES Class Code Certificate Nos. Certificate Nos. Certificate Nos HI-TX 8-channel AI, 4-20mA with HART 8102-HO-IP 8-channel AO, 4-20mA with HART 8103-AI-TX 8-channel AI, 4-20mA 8104-AO-IP 8-channel AO, 4-20mA 8105-TI-TC 4-channel THC/mV input 8106-TI-RT 4-channel RTD input 8109-DI-DC 8-channel DI, 24V dc isolated, sinking 8110-DI-DC 8-channel DI, 24V dc non-isolated, module-powered 8111-DI-AC 8-channel DI, 115V ac isolated, sinking 8112-DI-AC 8-channel DI, 115V ac non-isolated, module-powered 8113-DI-AC 8-channel DI, 230V ac isolated, sinking 8114-DI-AC 8-channel DI, 230V ac non-isolated,module-powered 8115-DO-DC 8-channel DO,2-60V dc non-isolated, module-powered 8116-DO-AC 8-channel DO, V ac non-isolated, module-powered 8117-DO-DC 8-channel DO, 2-60V dc isolated, unpowered 8118-DO-AC 8-channel DO, V ac isolated, unpowered 8119-VI-05 8-channel AI, 1-5V dc 8121-DI-DC 16-channel DI, 24V dc non-isolated, module-powered 8122-DI-DC 16-channel DI, 24V dc isolated, sinking 8123-PI-QU 2-channel, pulse/quadrature input Non-incendive2 EEx n L IIC T33 MTL00ATEX8101 1B3A9.AX Non-incendive2 EEx n L IIC T4 MTL00ATEX8102 1B3A9.AX Non-incendive2 EEx n L IIC T33 MTL00ATEX8103 1B3A9.AX Non-incendive2 EEx n L IIC T4 MTL00ATEX8104 1B3A9.AX Non-incendive2 EEx n L IIC T41 MTL98ATEX8105 1B3A9.AX Non-incendive2 EEx n L IIC T41 MTL98ATEX8106 1B3A9.AX Non-incendive2 EEx n L IIC T41 MTL98ATEX8109 1B3A9.AX Non-incendive2 EEx n L IIC T41 MTL98ATEX8110 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8111 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8112 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8113 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8114 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8115 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8116 1B3A9.AX Non-arcing EEx n VL IIC T41 MTL98ATEX8117 1B3A9.AX Non-arcing EEx n VL IIC T31&3 MTL98ATEX8118 1B3A9.AX Non-incendive2 EEx n L IIC T33 MTL00ATEX8119 1B3A9.AX Non-incendive2 EEx n L IIC T4 MTL00ATEX8121 1B3A9.AX Non-incendive2 EEx n L IIC T4 MTL00ATEX8122 1B3A9.AX Non-incendive2 EEx n L IIC T4 MTL01ATEX8123X 1B3A9.AX Note 1 EN50021 was available only in draft form (pr) when this apparatus was certified. When EN50021 was finally published, the designation EEx nv had been changed to EEx na for non-arcing apparatus. EEx nv is equivalent to EEx na. Note 2 In Europe, the preferred term is Energy Limited. See EN Note 3 For +60 C the T class may be reduced to T4. T3 only applies for an ambient temperature of +70 C. Note 4 These products are listed in the document ATEX Documentation for ancillary components used with the 8000 Zone 2 System.

94 8000 2/x System Specification 2/2 system approvals for mounting and field wiring Standard EUROPE USA (FM) CANADA (CSA) pren50021 & EN Class No C22.2 No. 213 Approved for Zone 2 installations and field wiring ATEX Category II 3 G Div 2 installation non-incendive apparatus suitable for installation in Class 1, Zone 2, Grp IIC Div 2 installation non-incendive apparatus suitable for installation in Class 1, Zone 2/Div 2, Grp IIC FIELD TERMINALS Class Code Certificate Nos. Certificate Nos. Certificate Nos FT-NI Field terminal, non-incendive - unfused 8602-FT-ST Field terminal, standard - unfused 8603-FT-FU Field terminal, non-incendive - fused 8604-FT-FU Field terminal, standard - fused 8605-FT-TC Field terminal RTD 8606-FT-RT Field terminal thermocouple 8610-FT-NA Field terminal, non-arcing - unfused 8611-FT-FU Field terminal, non-arcing - fused 8615-FT-4W Field terminal, 4-wire transmitter 8617-FT-NI Field terminal, 16-channel See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX BIMs 8410-NS-PS Power supply monitor module 8502-BI-DP Profibus-DP BIM 8505-BI-MB Modbus BIM 8512-IF-HA HART interface module 8510-MO-NS Node services module 8521-xx-xx Process Controller/EBIM - see Note 5 EEx nl IIC T4 MTL02ATEX8410X-01 1B3A9.AX EEx nvl IIC T4 1 MTL99ATEX8502 1B3A9.AX EEx nvl IIC T4 1 MTL98ATEX8505 1B3A9.AX EEx na IIC T4 MTL00ATEX8512 1B3A9.AX EEx nl IIC T4 MTL01ATEX8510X 1B3A9.AX EEx nl IIC T5 MTL02ATEX8521X 1B3A9.AX Power Supply 8910-PS-DC Power supply, V dc input 8913-PS-AC Power supply, V ac input, 12/24 V dc output 8914-PS-AC Power supply, V ac input, 24 V dc output EEx nvl IIC T4 1 MTL98ATEX8910 1B3A9.AX II3G EEx n A II T4 TÜV01ATEX1774X II3G EEx n A II T4 TÜV01ATEX1774X Note 1 EN50021 was available only in draft form (pr) when this apparatus was certified. When EN50021 was finally published, the designation EEx nv had been changed to EEx na for non-arcing apparatus. EEx nv is equivalent to EEx na. Note 2 In Europe, the preferred term is Energy Limited. See EN Note 3 For +60 C the T class may be reduced to T4. T3 only applies for an ambient temperature of +70 C. Note 4 These products are listed in the document ATEX Documentation for ancillary components used with the 8000 Zone 2 System. Note 5 The -xx-xx indicates a range of modules with the same initial digits in the part number.

95 8000 2/x System Specification 2/2 system approvals for mounting and field wiring Standard EUROPE USA (FM) CANADA (CSA) pren50021 & EN Class No C22.2 No. 213 Approved for Zone 2 installations and field wiring ATEX Category II 3 G Div 2 installation non-incendive apparatus suitable for installation in Class 1, Zone 2, Grp IIC Div 2 installation non-incendive apparatus suitable for installation in Class 1, Zone 2/Div 2, Grp IIC CARRIERS Class Code Certificate Nos. Certificate Nos. Certificate Nos CA-08 8-module carrier 8709-CA-08 8-module carrier 8710-CA-04 4-module carrier 8711-CA-NS Node services carrier, screw terminal LAN 8712-CA-NS Node services carrier, sub-d terminal LAN 8715-CA-BI Universal BIM carrier 8717-CA-PS 8910-PS-DC power supply carrier 8718-CA-NS BIM + node services module carrier 8750-CA-NS Redundant controller and power fail module carrier See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 See note 4 1B3A9.AX See note 4 1B3A9.AX CARRIER EXTENDERS 8020-CE-RH Carrier extender, right-hand 8020-CE-LH Carrier extender, left-hand See note 4 1B3A9.AX See note 4 1B3A9.AX EXTENDER CABLES 8001-CC-35 Signal extension cable, 0.35m 8002-CC-85 Signal extension cable, 0.85m 8003-CC-12 Signal extension cable, 1.2m See note 4 1B3A9.AX See note 4 1B3A9.AX See note 4 1B3A9.AX Note 1 EN50021 was available only in draft form (pr) when this apparatus was certified. When EN50021 was finally published, the designation EEx nv had been changed to EEx na for non-arcing apparatus. EEx nv is equivalent to EEx na. Note 2 In Europe, the preferred term is Energy Limited. See EN Note 3 For +60 C the T class may be reduced to T4. T3 only applies for an ambient temperature of +70 C. Note 4 These products are listed in the document ATEX Documentation for ancillary components used with the 8000 Zone 2 System.

96 8000 2/x System Specification 2/1 system approvals for mounting and field wiring Standard EUROPE USA (FM) CANADA (CSA) pren50021 & EN EN50014:1997 & EN :1994 Class No Class No CAN/CSA E CAN/CSA E Approved for Zone 2 installations ATEX Category II 3 G IS Field Wiring ATEX Category II [1] G Div 2 installation Non-incendive apparatus suitable for installation in Class 1, Div 2, Grps A-D IS field wiring IS field terminals for Classes I, II, III, Grps A-G Div 2 installation non-sparking apparatus suitable for installation in Class 1, Zone 2/ Div 2, Grp IIC IS field wiring for Class I, Zones 0, 1, Grp IIC I/O MODULES Code Certificate Nos. Code Certificate Nos. Certificate Nos. Certificate Nos HI-IS 8-channel, AI, 4-20 ma with HART 8202-HO-IS 8-channel, AO, 4-20mA with HART 8204-AO-IS 8-channel, AO, 4-20 ma EEx nl IIC T4 MTL99ATEX8201 [EEx ia]iic BAS98ATEX7207U EEx nl IIC T4 MTL01ATEX8202X [EEx ia]iic BAS01ATEX7185U EEx nl IIC T4 MTL99ATEX8204 [EEx ia]iic BAS98ATEX7205U X / Ex na[ia] IIC T X / Ex na[ia] IIC T TI-IS 8-channel, THC/mV input 8206-TI-IS 8-channel, RTD input EEx nl IIC T4 MTL00ATEX8205X [EEx ia]iic BAS99ATEX7316U TBA EEx nl IIC T4 MTL00ATEX8206 [EEx ia]iic BAS99ATEX7316U TBA 8215-DO-IS 4-channel, DO, solenoid driver, IIC gas groups 8220-DI-IS 16-channel, DI, switch/proximity detector 8223-PI-IS 2-channel, pulse/frequency input 8230-AI-IS 8-channel, AI, 0-10V/potentiometer FIELD TERMINALS EEx nl IIC T4 MTL99ATEX8215 [EEx ia]iic BAS98ATEX7204U EEx nl IIC T4 MTL99ATEX8220 [EEx ia]iic BAS98ATEX7206U EEx nl IIC T4 MTL02ATEX8223X [EEx ia]iic BAS00ATEX7202U EEx nl IIC T4 MTL02ATEX8230X [EEx ia]iic BAS01ATEX7346U X / Ex na[ia] IIC T X / Ex na[ia] IIC T FT-IS IS standard 8622-FT-IS IS loop disconnect 8623-FT-IS IS 16-channel 8624-FT-IS IS 16-channel, DI, loop disconnect 8625-FT-IS IS THC 8626-FT-IS IS RTD See note 6 [EEx ia] BAS98ATEX7211U X See note 6 [EEx ia] BAS98ATEX7211U X See note 6 [EEx ia] BAS98ATEX7211U X See note 6 [EEx ia] BAS98ATEX7211U X See note 6 [EEx ia] BAS98ATEX7211U X See note 6 [EEx ia] BAS98ATEX7211U X RAILBUS ISOLATOR 8922-RB-IS Railbus isolator module Power SUPPLY 8920-PS-DC IS Power supply, 18-36V DC input EEx nl IIC T4 MTL99ATEX8922 [EEx ia] BAS98ATEX7208U EEx nv IIC T4 MTL99ATEX [EEx ia] BAS98ATEX7209U X / Ex na IIC T X / Ex na IIC T4 Note 1 Applies to railbus interface. Note 2 The railbus interface and I/O field wiring are covered by a single certificate. The railbus interface code is ExnA. Note 3 The railbus interface and I/O field wiring are covered by a single certificate and no distinction is made between non-incendive and non-arcing railbus interface connections. Note 4 EN50021 was available only in draft form when this apparatus was certified. When EN50021 was finally published, the designation EEx nv had been changed to EEx na for non-arcing apparatus. EEx nv is equivalent to EEx na. Note 5 BASEEFA node certificate no BAS98ATEX BASEEFA system certificate no. Ex98E2203. Note 6 These products are listed in the document ATEX Documentation for ancillary components used with the 8000 Zone 2 System.

97 2/1 system approvals for mounting and field wiring Standard EUROPE USA (FM) CANADA (CSA) pren50021 & EN EN50014:1997 & EN :1994 Class No Class No CAN/CSA E CAN/CSA E Approved for Zone 2 installations ATEX Category II 3 G IS Field Wiring ATEX Category II [1] G Div 2 installation Non-incendive apparatus suitable for installation in Class 1, Div 2, Grps A-D IS field wiring IS field terminals for Classes I, II, III, Grps A-G Div 2 installation non-sparking apparatus suitable for installation in Class 1, Zone 2/ Div 2, Grp IIC IS field wiring for Class I, Zones 0, 1, Grp IIC CARRIERS Code Certificate Nos. Code Certificate Nos. Certificate Nos. Certificate Nos CA-08 IS carrier, 8 module 8720-CA-04 IS carrier, 4 module 8723-CA-RB IS carrier, Railbus isolator 8724-CA-PS IS carrier, IS module power supply 8729-CA-08 IS carrier, 8 module 64-address system See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7208U X See note 6 [EEx ia] BAS98ATEX7209U X See note 6 [EEx ia] BAS98ATEX7210U CARRIER EXTENDERS 8030-CE-RH IS carrier extender, right-hand 8030-CE-LH IS carrier extender, left-hand See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X EXTENDER CABLES 8011-CC-35 IS carrier extension cable, 0.35m 8012-CC-85 IS carrier extension cable, 0.85m 8013-CC-12 IS carrier extension cable, 1.2m 8016-CC-35 IS power extension cable, 0.35m 8017-CC-85 IS power extension cable, 0.85m 8018-CC-12 IS power extension cable, 1.2m 8032-CC-35 IS carrier extension cable set, 0.35m 8033-CC-85 IS carrier extension cable set, 0.85m 8034-CC-12 IS carrier extension cable set, 1.2m See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X See note 6 [EEx ia] BAS98ATEX7210U X Note 1 Applies to railbus interface. Note 2 The railbus interface and I/O field wiring are covered by a single certificate. The railbus interface code is ExnA. Note 3 The railbus interface and I/O field wiring are covered by a single certificate and no distinction is made between non-incendive and non-arcing railbus interface connections. Note 4 EN50021 was available only in draft form when this apparatus was certified. When EN50021 was finally published, the designation EEx nv had been changed to EEx na for non-arcing apparatus. EEx nv is equivalent to EEx na. Note 5 BASEEFA node certificate no BAS98ATEX BASEEFA system certificate no. Ex98E2203. Note 6 These products are listed in the document ATEX Documentation for ancillary components used with the 8000 Zone 2 System.

98 8000 2/x System Specification About GE Intelligent Platforms GE Intelligent Platforms, a General Electric Company (NYSE: GE), is an experienced high-performance technology company and a global provider of hardware, software, services, and expertise in automation and embedded computing. We offer a unique foundation of agile, advanced and ultra-reliable technology that provides customers a sustainable advantage in the industries they serve, including energy, water, consumer packaged goods, government and defense, and telecommunications. GE Intelligent Platforms is a worldwide company headquartered in Charlottesville, VA and is part of GE Home and Business Solutions. For more information, visit GE Intelligent Platforms Contact Information Americas: or Global regional phone numbers are listed by location on our web site at GE Intelligent Platforms, Inc. All rights reserved. All other brands or names are property of their respective holders. Specifications are subject to change without notice GFA-1740

99 GE Intelligent Platforms 8000 Process I/O 8000 Process I/O is the latest addition to GE Intelligent Platforms line up of I/O products. Designed to meet the rugged environmental specifications required in process environments, 8000 Process I/O helps you keep your critical operations running allowing you to improve your operational performance and productivity for a sustainable advantage. Environmental & Hazardous Area Operation 8000 Process I/O can go where other I/O cannot. It can be field mounted and subjected to the following: 40 C to +70 C operating range ISA Level G3 corrosion 30G shocks and 5G vibration Operation in Class I, Division 2 and Zone 2 hazardous areas with field wiring extending into Division 1 and Zone 1/0 areas HART Support 8000 Process I/O can pass HART information from smart field devices to controllers or a separate PC workstation running asset management software applications to remotely manage smart instrument configuration and calibration. Network Redundancy Network redundancy helps assure stable and consistent communications. The Ethernet Bus Interface Modules (BIM) have two high speed Ethernet ports that use Fault Tolerant Ethernet to provide redundant communications Each port can be connected to an independent LAN which is continuously monitored for its integrity. If the primary port detects a network failure, traffic is immediately switched to the other LAN to maintain full communications The Profibus BIM supports full LAN redundancy Ordering Information Bus Interface Modules & Carriers Part Number Description Part Number Description 8410-NS-PS Node services power supply monitor (Ethernet BIM) 8521-EB-MT Ethernet BIM 8505-BI-MB Modbus BIM 8701-CA-BI MultiBIM Carrier 8507-BI-DP Profibus Version of the MultiBIM 8718-CA-NS BIM only carrier 8510-MO-NS Configuration Memory Module (Modbus & Profibus BIMs) 8750-CA-NS Carrier, simplex or redundant, power monitoring 8000 General Purpose I/O Part Number Description Part Number Description 8101-HI-TX 8-channel AI, 4-20mA with HART 8116-DO-AC 8-channel DO, Vac non-isolated, module powered 8102-HO-IP 8-channel AO, with HART, 4-20mA 8117-DO-DC 8-channel DO, 2-60Vdc isolated, unpowered 8103-AI-TX 8-channel AI, 4-20mA 8118-DO-AC 8-channel DO, Vac isolated, unpowered 8104-AO-IP 8-channel AO, 4-20mA 8119-VI-05 8-channel Voltage Input, 1-5Vdc 8105-TI-TC 4-channel THC/mV input 8121-DI-DC 16-channel DI, 24Vdc non-isolated, module powered 8106-TI-RT 4-channel RTD input 8122-DI-DC 16-channel DI, 24Vdc isolated, sinking 8109-DI-DC 8-channel DI, 24Vdc isolated, sinking 8123-PI-QU 2-channel Pulse Quadrature Input 8110-DI-DC 8-channel DI, 24Vdc non-isolated, module powered 8125-DI-DC 32-channel DI, non-isolated, module-powered 8111-DI-AC 8-channel DI, 115Vac isolated, sinking 8127-DI-SE 32-channel SOE module 8112-DI-AC 8-channel DI, 115Vac non-isolated, module powered 8129-IO-DC 8-channel supervised DI/DO 8113-DI-AC 8-channel DI, 230Vac isolated, sinking 8132-AI-UN 8-channel Isolated Universal AI 8114-DI-AC 8-channel DI, 230Vac non-isolated, module powered 8115-DO-DC 8-channel DO, 2-60Vdc non-isolated, module powered

100 Ordering Information (Continued) Field Terminals and Accessories Part Number Description Part Number Description 8601-FT-NI Field terminal, non-incendive (Div 2) 8610-FT-NA Field terminal, non-arcing (Div 2) 8602-FT-ST Field terminal, standard 8611-FT-FU Field terminal, non-arcing, fused (Div 2) 8603-FT-FU Field terminal, non-incendive, fused (Div 2) 8615-FT-4W Field terminal, 4wire (current sinking) 8604-FT-FU Field terminal, fused 8617-FT-NI Field Terminal, non-incendive, for 16 ch DI 8605-FT-TC Field terminal, thermocouple 8618-FT-MT 16-pin Mass Termination Assembly (Div 2) 8606-FT-RT Field terminal, RTD 8619-FT-MT 44-pin Mass Termination Assembly (Div 2) 8607-FT-TC Field terminal, 8-channel with T/C 8650-FT-PX 32-channel PX/Switch FTA for 8125/ FT-NI Field terminal, 8-channel, non-incendive 8000 I/O Carriers Part Number Description Part Number Description 8707-CA-08 8 module carrier 8710-CA-04 4 module carrier 8709-CA-08 8 module carrier, 64-address system 8000 I/O Carrier Cables Part Number Description Part Number Description 8020-CE-RH Carrier extender, right hand 8080-FC pin cable for 8618 (1m) 8021-CE-LH Carrier extender, left hand 8081-FC pin cable for 8618 (2m) 8041-CC-35 Carrier extension cable, 0.35m 8082-FC pin cable for 8618 (3m) 8042-CC-85 Carrier extension cable, 0.85m 8085-FC pin cables for 8619 (1m) 8043-CC-12 Carrier extension cable, 1.2m 8086-FC pin cables for 8619 (2m) 8044-CC-20 Carrier extension cable, 2m 8087-FC pin cables for 8619 (3m) 8000 I/O Power Supplies and Components Part Number Description Part Number Description 8413-FK-DN 8913/4 PS DIN Rail Mounting Kit 8914-PS-AC 10A 24VDC A/C Input P/S 8414-FK-SU 8913/4 PS Surface Mounting Kit BQ2320-9R-EX 24 to 12VDC Voltage Converter 8913-PS-AC 5A 12VDC & 5A 24VDC A/C Input P/S 8000 Intrinsically Safe I/O Part Number Description Part Number Description 8201-HI-IS 8-channel IS AI, 4-20mA with HART 8215-DO-IS 4-channel IS DO, solenoid driver IIC gas groups 8202-HO-IS 8-channel IS AO, 4-20 ma with HART 8220-DI-IS 8/16-channel IS DI, switch/promixmity detector 8204-AO-IS 8-channel IS AO, 4-20 ma 8223-PI-IS 2-channel IS Pulse Counter, 1 ch Quadrature w/ DI/DO (MB only) 8205-TI-IS 8-channel IS THC/mV input 8230-AI-IS 8-channel IS AI, 0-10V, pot., 0-20mA/4-20mA, sinking 8206-TI-IS 8-channel IS RTD input IS Field Terminals and Accessories Part Number Description Part Number Description 8621-FT-IS IS Field terminal, standard 8624-FT-IS IS Field terminal with loop-disconnect for 8-channel DI only 8622-FT-IS IS Field terminal, loop-disconnect (not for 8 channel DI) 8625-FT-IS IS Field terminal, THC 8623-FT-IS IS Field terminal for 8220-DI-IS 16 ch DI & V/Pot inputs 8626-FT-IS IS Field terminal, RTD 8000 IS Carrier / Cables Part Number Description Part Number Description 8030-CE-RH IS Carrier extender, right hand 8014-CC-20 IS extension cable, 2.0m 8031-CE-LH IS Carrier extender, left hand 8016-CC-35 IS Power extension cable, 0.35m 8011-CC-35 IS Signal extension cable, 0.35m 8017-CC-85 IS Power extension cable, 0.85m 8012-CC-85 IS Signal extension cable, 0.85m 8018-CC-12 IS Power extension cable, 1.2m 8013-CC-12 IS Signal extension cable, 1.2m 8019-CC-20 IS Power extension cable, 2.0m 8000 IS Power Supplies and Accessories Part Number Description Part Number Description 8724-CA-PS IS Module Power Supply Carrier 8920-PS-DC IS Module DC Power Supply (8 modules) 8725-CA-RB Railbus Isolator Carrier with Power Fail Monitor 8922-RB-IS Railbus Signal Isolator GE Intelligent Platforms Information Center Headquarters: GE Additional Resources For more information, please visit the GE Intelligent Platforms website at: Global Regional phone numbers Are available on our website GE Intelligent Platforms, Inc. All Rights Reserved. *Trademark of GE Intelligent Platforms, Inc. All other brand names or names are property of their respective holders.

16-channel Discrete Input 115V ac, block isolated, sinking DISCRETE INPUTS 8140 - DI - AC 16 input channels 115V ac field voltage sources pulse counting option channels isolated in four blocks of

101 16-channel Discrete Input 115V ac, block isolated, sinking DISCRETE INPUTS DI - AC 16 input channels 115V ac field voltage sources pulse counting option channels isolated in four blocks of four channels MODULE SPECIFICATION See also System Specification INPUTS Number of configurable channels Number of isolated IO blocks..4 blocks of 4 channels Off voltage....< 34V ac On voltage....> 84V ac Input impedance....60kω (nom) Wetting current. 1.9mA (nom) Frequency 50 / 60Hz POWER SUPPLIES Railbus (12V) Current.. 110mA Bussed Field Power.not required MECHANICAL Module Key Code E3, non-arcing Module width 42mm Weight g CONFIGURABLE PARAMETERS Latch inputs.enable / disable Latch polarity...latch on high / latch on low Pulse counting...enable / disable ELECTRICAL ISOLATION Channel to railbus v ac (max) Between blocks (1-4, 5-8, 9-12, 13-16) V ac (max) Channel to Channel and Ch+ to Ch- Within one block Ch. 1-4, 5-8, 9-12, V ac (max) RESPONSE TIME I/O response time Field event to new data available on Railbus. 33ms (max) FIELD TERMINAL Field wiring Recommended Compatible Field Terminal Field Terminal General Purpose 8612-FT-NA - Class 1, Div. 2 or Zone 2 Hazardous Area 8612-FT-NA - Specification subject to change without notice September 2009

102

16-channel Discrete Output 24V dc, non-isolated, module powered DISCRETE OUTPUTS 8142 - DO - DC 16 output channels controls solenoids and relays common load supply for up to 42V dc discrete or pulsed

103 16-channel Discrete Output 24V dc, non-isolated, module powered DISCRETE OUTPUTS DO - DC 16 output channels controls solenoids and relays common load supply for up to 42V dc discrete or pulsed outputs 0.5A per channel switched current 12-42V dc bussed field power required MODULE SPECIFICATION See also System Specification OUTPUTS Number of channels Output voltage range V dc ON voltage 0.5A for one channel on 6A total for module OFF leakage current < 1mA Output current Per channel...0.5a (max) Per module a (max) Channel current... Thermally limited to 3A (typ) at 25 C Short circuit protected RESPONSE TIME I/O response time Railbus command to output change.. 2ms (max) POWER SUPPLIES Railbus (12V) Current 125mA (max) 80mA (typ) Bussed Field Power.. 12 to 42V dc, 6A (max) CONFIGURABLE PARAMETERS Channel Status *..Active/Inactive Output initialization state... predefined value Fail-safe......predefined value / last value Output...discrete, momentary or continuous pulse Pulse width ms to 60s * It is recommended that all unused channels be set to inactive to assure proper LFD operation ELECTRICAL ISOLATION Channel to railbus vrms (max) Channel to Channel and Ch+ to Ch-... <50V MECHANICAL Module Key Code.B4, non-arcing Module width. 42mm Weight g FIELD TERMINAL Field wiring Recommended Field Terminal Compatible Field Terminal General Purpose 8612-FT-NA 8619-FT-MT Class 1, Div. 2 or Zone 2 Hazardous Area 8612-FT-NA - NB: When using the 8619-FT-MT, the channel current should be externally limited to 250mA; ensure both ribbon cables are in place. Specification subject to change without notice January 2010

104 16-channel Discrete Output 24V dc, non-isolated, module powered DISCRETE OUTPUTS DO - DC Short circuit protection Channels which are short-circuited are protected by over-temperature thermal detection. If a channel is short-circuited it will be identified by the thermal detection circuit and the relevant channel made inactive. Pulsed output Channels can be configured to give a pulsed output of either single static, single dynamic, continuous or continuous dynamic form. The single static pulse is ON for a predetermined time. It then remains OFF until a new pulse instruction is received. The single dynamic pulse is ON for a period that may be changed by the application, then remains OFF until a new instruction to write is received. In continuous pulse mode a series (a) Fire Alarm sec sec (b) Supervisory 0.1 sec 0.1 sec (c) Trouble 2.0 sec 1.5 sec of pulses of defined ON period are sent, with a defined OFF period between. Continuous dynamic pulse mode allows the application to continually vary the ON and OFF times of the pulse train. For all types of Pulsed Output, the ON time of the pulse may be between 500ms and 60s in 1ms intervals. For the continuous pulse mode, the OFF period can be set between 0 and 60s, in 1ms intervals. Pre-defined Pulse Patterns A number of different, pre-defined output patterns (shown in the figure below) are available, which can be used to indicate the occurrence of different events, using the same alarm hardware. Line Fault Detection The smart switch used in the channels provides line fault detection (LFD). Two conditions can be detected, these are: (a) Short circuit to ground or over-temperature when the channel is energised. (b) Short circuit to Bussed Field Power +ve (BFP+) when the channel is de-energised. Every channel is tested for a line fault at least once a second. A channel with a line fault is energised every 5 seconds to discover if the fault has been cleared. Line fault detection on deenergised outputs can be inhibited by the channel configuration and is not performed on a channel that is inactive. LEDs For the operation of the Power and Fault LED s see IO Module Overview. Module Channel LEDs (yellow) On output ON Off output OFF Flashing (equal:mark space ratio) channel fault (d) Gas 0.5 sec 5.0 sec sec sec 3.0 sec Specification subject to change without notice January 2010

105 GE Intelligent Platforms Bus Interface Modules LAN connection An 8000 node uses a Bus Interface Module (BIM) to communicate with the host controller via a local area network (LAN). Different BIMs can be chosen to operate with a range of popular fieldbus protocols. The BIM mounts on a carrier and receives all of its communication and power links from it. The BIM uses the RS485 communications standard. Other alternatives are RS422, by changing switches (where available) on the carrier, or RS232 by fitting an in-line converter. Switch options sometimes offer alternative methods for terminating the LAN. Some BIMs also have a second LAN connection to maintain communications in the event of damage occurring to the main communications link. This technique is illustrated (right) for a Modbus host where a second master is shown. HART management interface An interface module is available, to link HART devices with the instrument management software. One 8512-IF-HA module is required per BIM. One port connects to the BIM and the other connects, via a daisy-chained RS485 link, to the PC running the software. Internal Railbus connection The BIM communicates with the individual I/O modules via Railbus - a proprietary, serial bus. I/O information from the modules is gathered and stored in the BIM for reporting to the host. Similarly, all host commands are interpreted by the BIM and the relevant messages relayed to the I/O modules. In addition to the I/O data, status and diagnostic data is relayed over the same route, to monitor and maintain the health of the I/O system. Failsafe mode Under certain abnormal or fault conditions, the BIM will adopt a state known as failsafe which, in turn, forces the I/O modules into a similar failsafe state. (See I/O module section). This condition ensures that outputs are put into known states that have been predefined by the user. Failsafe mode can be induced by a direct instruction from the host or if the BIM receives no communication from the host for a predefined length of time. Failsafe recovery The BIM is forced out of failsafe mode by the Master but, before exiting the failsafe state, the BIM will wait until all the I/O modules have been polled, to enable output values to be preconditioned by the Master before the BIM leaves the failsafe state. Heartbeat The BIM is capable of detecting a failed application on the host by using a heartbeat status signal. The application is expected to supply a signal which toggles between 0 and 1. The Master includes this value with every message to indicate that the application is still in control. This value is echoed by the BIM back to the Master, which must then send a new, opposite, value from the application within a defined period, otherwise the BIM adopts a failsafe state. Configuration When power is first applied to a BIM, it has no information about the system to which it is connected and must therefore be configured. This is achieved using dedicated software (Part No SW-CF) that operates on a PC running Windows 95, 98 or NT. After configuration, the user can store the information in the BIM s non-volatile memory (NVM). At future start-ups, the BIM will recall the configuration data from the NVM. The configuring PC can be linked to the BIM by one of three methods: a) via an RS232 link to the sub-d connector on the BIM or b) via the secondary LAN - if available c) via pass-through messaging over the primary LAN, if available

106 Bus Interface Modules Profibus protocol 8502-BI-DP Links 8000 node to Profibus-DP host LAN Supports up to 24 I/O modules HART process & status variables over Profibus-DP Extended diagnostics for module and channel status LAN speeds of up to 6 Mbaud Non-volatile memory for configuration Software configurable via local port or Profibus host HART maintenance via Comms adaptor The 8502-BI-DP Bus Interface Module (BIM) provides the communications link between the 8000 series I/O modules and a Profibus- DP host. Its high speed acquisition of data from the modules and LAN operation speeds of up to 6 Mbaud allows the host to respond rapidly to conditions in the control process. The BIM gathers the data from the I/O modules and makes it available to the host upon request. It is a slave to the Profibus master. As well as cyclic data exchange, which is required for reading input and writing output data, the BIM supports Profibus Extended Diagnostics for status information. It also supports a number of special features which have been implemented to allow high integrity system operation and in-situ maintenance. Parameterisation The 8502 supports parameterisation from the Profibus master. This configures on a per module basis, i.e. all the channels on a single module carry the same configuration. The configuration is created in a Profibus configurator using details provided in a GSD file. This method is fast and enables a configuration to be built based upon logical modules which represent the physical modules. Modules are added one at a time to the configuration and parameters are chosen to apply to all the channels of the module. Logical modules can be selected to provide HART status and process variables in the Profibus-DP cyclic input telegram. In addition, for applications where access to many HART variables is required, the HART mailbox can be used. This technique collects HART variable as they are required; saving space in telegrams that are sometimes overworked with data. This method is available only when using parameterisation. The configuration is passed down from the Profibus master to the BIM at the start of the session. If the system is stopped and re-started, the configuration file is re-transmitted to the BIM. Configuration The alternative to parameterisation is the use of the 8455-SW-CF configuration software. This enables the user to configure individual channels and alarms and store the configuration in the BIM. The configuration can also be saved to the 8510-MO-NS Node Services Module for instant recovery if a BIM has to be replaced. Configuration by this method uses a different GSD file to the one used for parameterisation and the data frame is based on data blocks rather than on a by module approach. The 8455 software automatically provides a map of the data created in the telegram to enable host programmers to identify the data passed. HART status and process variables can be communicated to the Profibus-DP host in the cyclic input telegram. I/O & HART data requires space in the DP data frame as shown in the table below. STAndard AND EXTENDED DIAGNOSTICS The Profibus BIM supports both Standard and Extended Diagnostics. While the Standard Diagnostics provide standard PROFIBUS status information, the Extended Diagnostics provide detailed information relating to the status of the BIM, the health of the modules and the status of I/O channels. Depending on the I/O module type, events such as high and low alarm, open circuit and line fault are detected. Extended Diagnostic messages are generated on detection of an anomaly and also when it is cleared. Use of the diagnostic capability requires suitable support in the host application. For hosts unable to use diagnostic data in the control algorithm, it is possible to map the diagnostic data into the input dataframe. Hart Device Maintenance Pass through messaging to HART devices is available via the local configuration port and the 8512 HART Comms interface. This allows multi-dropping of a number of BIMs on an RS485 link to a PC running a wide range of instrument management software. DATA TYPE INPUT WORDS OUTPUT WORDS Analog data 1 per input channel 1 per output channel Digital data 1 per input module 1 per output module HART variable 2 per variable Not applicable HART status 1 per channel Not applicable

107 Bus Interface Modules Profibus protocol 8502-BI-DP MODULE SPECIFICATION See also System Specification LAN INTERFACE LAN protocol PROFIBUS-DP (to EN50170) Transmission rates 9.6, 19.2, 93.75, 187.5, 500 kbaud and 1.5 and 6 Mbaud Maximum bus segment length (metres) depends upon speed Speed (kbaud) Max Length NOTE: Table applies to cables with an impedance of W and a capacitance per unit length that does not exceed 30 pf/m. Transmission standard RS 485 Isolation (LAN to Railbus to Power Supply) V Action on software malfunction Modules go to failsafe I/O & DIAGNOSTIC DATA DP Data frame Size configurable up to 244 bytes Input data, including Status word (2 bytes) 244 bytes max Output data, including Control word (2 bytes) 244 bytes max Total Input plus Output data 296 bytes max Diagnostic telegram 78 bytes CONFIGURATION The BIM can be configured using 8455-SW-CF software running on a PC, by parameterisation from a Profibus configurator or by transfer of a configuration from the 8510-NS-MO Node Services Module. The 8510 also has an autoconfiguration option. Address setting POWER SUPPLIES Railbus (12V) current MECHANICAL Module width Weight (approx.) Software settable in BIM, by Profibus Set Slave Address command or by switch setting on 8510-NS MO module 420 ma ( typ.) 520 ma -40 C) 63 mm 350 g LED INDICATORS Power (green) OFF ON Flashing Power fail Power OK Fault (red) OFF ON Flashing Normal Failsafe or fault Comm (yellow) OFF ON Flashing Internal Comms. Failure LAN A (yellow) Internal Comms. OK On power up OFF ON Flashing Power OFF LAN activity Slow flash = no LAN active Config (yellow) OFF ON Flashing Not defined (i.e. error) Railbus (yellow) Configurator connected Configurator not connected OFF ON Flashing Railbus Fault Railbus OK

Bus Interface Modules Modbus protocol 8505-BI-MB Links 8000 node to Modbus host LAN LAN speeds of up to 115.

108 Bus Interface Modules Modbus protocol 8505-BI-MB Links 8000 node to Modbus host LAN LAN speeds of up to kbaud Supports up to 32 I/O modules HART process and status variables via Modbus Module status and channel status flags Automatic scan optimisation Configuration data held in non-volatile memory Software configurable via local port or LAN B HART maintenance via comms adaptor * In this mode of operation, writes to outputs are inhibited on the secondary LAN during normal operation but enabled if the BIM detects failure of the primary LAN. Modbus Software The implementation of the Modbus protocol in the 8000 Series is according to Revision G of the Modicon Specification. Only RTU mode is supported. Communication speeds of up to 115k baud are possible with single LAN systems, 57k baud with twin connections. The LAN node address is set by configuration. The BIM supports the Modbus function codes that are required to read and write input, output and status data, and also supports a number of special features which have been implemented to allow high integrity system operation and in-situ maintenance. Dual LAN Operation While LAN-A is the primary port for host communications, a second host may be connected to LAN-B as either an active or a passive standby in a redundant configuration. This is intended to provide fault tolerance against failure of either the primary host or its associated LAN connection. Active Standby mode is intended for use with a simple pair of duplicated hosts. * Passive Standby mode is for a redundant host pair where Host B is capable of detecting the failure of Host A or LAN-A and taking action to assume active control. A further mode of operation Dual Comms allows two hosts simultaneous read/write privileges. This is appropriate for manual control via duplicate HMI/SCADA workstations. LAN-B may also be used for remote configuration and maintenance of both an 8000 sub-system and intelligent (HART) field devices connected to the I/O modules. Diagnostic and Status Information The BIM provides detailed information relating to the status of the BIM, the health of I/O modules and the status of I/O channels. Depending on the I/O module type, information such as high and low alarm, open circuit and line fault is reported. Automatic Scan Optimisation The gathering of input data from the I/O modules and the issuing of output data to them is not determined by a fixed scan rate. A scan optimisation algorithm is used to gather and distribute data virtually as soon as it becomes available. A maximum scan period can be set for each module to ensure that the data is collected within this defined time period. Packed Data Mapping The dynamic data that is exchanged with the host application is mapped to consecutive memory locations. This eliminates the need for piecemeal read and write commands to separate data locations. A single Modbus read instruction will gather all of the current data from the BIM, resulting in a rapid interchange of information between the node and the host. Writes to the BIM s database can similarly be made with a single command. HART Device Maintenance Pass through messaging to HART devices is available via the local configuration port and the 8512 HART Comms interface. This allows multi-dropping of a number of BIMs on an RS485 link to a PC running AMS, Cornerstone and other instrument management software. Built-In Non Volatile Memory The BIM contains a section of non volatile memory (NVM) in which the configuration is stored. At switch on, the configuration is copied from NVM into working memory and the BIM can then initialise itself together with the I/O modules. Node Services Module Option The BIM also supports the use of the MO-NS - Node Services Module - which can store a BIM s configuration. This enables the BIM to be swapped with another and, at switch on, the configuration from the NSM will be uploaded to the BIM and will overwrite its previous contents. In addition, the NSM will monitor the dc supplies that power the node. If any power supply fail signal becomes active, the BIM receives a fault signal; a particularly important feature for systems having redundant power supplies. The failed PSU can then be identified quickly and replaced, restoring fault tolerant operation. Autoconfiguration The BIM has an autoconfiguration mode that can be triggered by a software command or by switches on the Node Services Module. This causes the BIM to delete its current configuration and reset the modules to their default values. The BIM then scans the Railbus and creates a new configuration file based upon the module types fitted and using their default values, which is then saved to NVM.

109 Bus Interface Modules Modbus protocol 8505-BI-MB MODULE SPECIFICATION LAN INTERFACE Transmission protocol Modbus (RTU mode) Transmission rates kbits/s By mode Single LAN mode kbit/s (max.) Passive standby mode kbit/s (max.) Active standby mode 19.2 kbit/s (max.) Dual comms. mode 19.2 kbit/s (max.) Remote config mode 19.2 kbit/s (max.) Transmission standard RS485 or RS422 Bus Insulation 500 V Action on software malfunction Halt CPU / Reset CPU CONFIGURATION The BIM can be configured either by using 8455-SW-CF software running on a PC or by transfer of a configuration from the 8510-NS-MO Node Services Module. An autoconfiguration option is also provided. Address setting Software settable in BIM or switch settable using 8510-NS MO Node Services Module. RESPONSE TIMES Modbus message response time < 4 ms POWER SUPPLIES Railbus (12V) current 260 ma ( typ.) 300 ma (max.) MECHANICAL Module width 63 mm Weight (approx.) 320 g See System Specification for other parameters. LED INDICATORS Power (green) Fault (red) OFF ON Flashing Power fail Power OK OFF ON Flashing Normal Failsafe or fault Configuration required LAN A & LAN B (yellow) OFF ON Flashing LAN disconnected Internal Comms. OK No comms. or fault Config (yellow) OFF ON Flashing Configurator not connected Railbus (yellow) Configurator connected to local port Configuring via LAN OFF ON Flashing Railbus Fault Railbus OK MODBUS FUNCTIONS SUPPORTED Read Coil Status (Function 01) Reads a range of single-bit flags that show the status of Discrete Output channels. This allows the host to confirm the states to which the BIM has set the Discrete Outputs. Read Input Status (Function 02) Reads a range of single-bit flags that show the status of Discrete Input channels. This allows the host to monitor the latest reported state of the Discrete Inputs. Read Holding Registers (Function 03) Reads a range of 16-bit registers that contain the status of Analog Outputs. This allows the host to confirm the states to which the BIM has set the Analog Outputs. Read Input Registers (Function 04) Reads a range of 16-bit registers that contain the status of Analog Input channels. This allows the host to monitor the latest reported state of the Analog Inputs. Force Single Coil (Function 05) Requests the BIM to force a specified coil to a 1 or a 0. This could be used, for example, to switch a DO channel or make it pulse. Preset Single Register (Function 06) Writes a 16-bit value to a specified BIM register - either to set an Analog Output or. to preset a DI counter. Return Diagnostic Register (Function 08) Requests that the slave reads the contents of its diagnostic register and returns the binary data values to the master, according to the specified sub-function code; i.e. Return Query Data (00) or Return Diagnostic Register (02) Force Multiple Coils (Function 15) Requests the BIM to force a specified range of coils to a 1 or a 0. This could be used, for example, to switch DO channels or make them pulse. Preset Multiple Registers (Function 16) Writes a 16-bit value to a specified range of BIM registers - for example to set Analog Outputs. Report Slave ID (Function 17) The Report Slave ID function permits the user to obtain information on the slave type and RUN status.

Bus Interface Modules Configuration Software 8455-SW-CF Windows Explorer - style interface Used to configure Bus Interface Modules Local or remote configuration via LAN Dynamic viewing of real-time

It runs on a PC, under the familiar WindowsTM operating system. The PC can be linked to the BIM using either a local cable link or via a secondary LAN connection, where available.

110 Bus Interface Modules Configuration Software 8455-SW-CF Windows Explorer - style interface Used to configure Bus Interface Modules Local or remote configuration via LAN Dynamic viewing of real-time data Single project file for mulitple nodes The 8455 software is one of the methods for configuring Bus Interface Modules (BIMs) in an Process I/O node. It runs on a PC, under the familiar WindowsTM operating system. The PC can be linked to the BIM using either a local cable link or via a secondary LAN connection, where available. The BIM is the interface between the I/O modules and the host controller, and must be configured to permit correct operation. The BIM needs to be told the identity of each I/O module fitted and values of relevent parameters. Parameters must also be defined for LAN communication with the host controller. Project File The configuration information is contained in a project file. A project file can be created for a single BIM or for multiple BIMs, e.g. on a network, each of which can accommodate up to 32 I/O modules. The configuration information may then be downloaded to the individual BIMs on the network. User Interface The main screen of the Configurator has a conventional Windows Menu and Toolbar display at the top. The main body of the screen is then split to show a navigation tree for the network on the left-hand side and the BIM/module parameters on the right. Module Attributes & Parameters The software can display the hardware and software revision levels of the both the BIM and the I/O modules. Each module has its own set of parameters and these appear with default values when the module is first added to the system. These can then be edited individually to specify the required system. Dynamic data Real-time data is available on-screen if the configuration link (serial or LAN) is in place. The viewable data includes primary variables as well as status parameters. This can be refreshed continually or when the operator requires a screen refresh. When in continuous refresh mode, the time between module data reads can also be viewed. Alternatively, the Configurator can be operated offline for simple project file creation. Upload BIM Data Configuration data already contained in a BIM can be uploaded to the Configurator. This can be saved as a PC file and copied to other BIMs. PC files that were created for earlier reversions of the BIM firmware can also be opened and edited for use with the latest versions of the BIM. Open Database Structure The Configurator contains a Microsoft Access open structure database in which the configuration data is held. Simple Tabbed Pages The right hand side of the screen contains information on any item that is highlighted in the navigation tree to the left. With the network icon selected, three tabbed pages of information are available (see Fig 1). Fig 1 - Configuration file details These pages define and describe the network protocol, the BIMs that are attached to the network and the details of the project contained in the overall configuration file. Selection of the BIM icon in the navigation area reveals five pages of information and settings (see Fig 2) for the BIM. These pages provide information that relate to the selected BIM and its specific network settings and the I/O modules attached to it. Fig 2 - BIM attributes Finally, clicking on an I/O module provides a further set of five pages of module information and settings (Fig 3). These pages contain details of the software and hardware revision levels of the chosen module,

111 Bus Interface Modules the condition of its various status flags, the user definable variables and, if connected live, the current value of each variable. Configuration Software 8455-SW-CF Fig 3 - I/O module dynamic data All of these pages are provided automatically when a module is added. SPECIFICATIONS PC SYSTEM REQUIREMENTS Intel Pentium processor (recommended) Microsoft Windows 95, 98, 2000 or NT4 operating system RAM capacity as appropriate for operating system At least one available serial port (COM1,2,3 or 4) 1 MB hard disk space + space for user created configuration files BIM COMMUNICATION PORT SETTINGS Speeds 1,200 38,400 baud Parity Odd, Even or None Data bits 8 Stop bits 1 Protocol SLIP ASSOCIATED LITERATURE INM8455 Instruction manual, BIM Configuration Software TO ORDER Configurator with RS232 cable 8455-SW-CF Configurator without RS232 cable 8456-SW-CF RS232 cable 8460-CA-CF (The software and any release notes are supplied on a CD ROM.) IMPORTANT NOTE: This software is designed for use with the latest 8505-BI-MB BIM that has version 2.x firmware. It is NOT compatible with version 1 BIMs. However,.csv or.ssf files created for use in version 1 BIMs can be imported to create configuration files for version 2 BIMs. Windows is a trademark of Microsoft Corporation Intel and Pentium are trademarks of Intel Corporation

112 Bus Interface Modules Node Services Module 8510-MO-NS Safe area or Zone 2/Div 2 hazardous area Auto Config. Switch THC mode RTD mode Switch 2 Type K 3-wire Pt100 2/2 fail Fault 2/1 fail Power Comms Switch 3 Type J 4-wire Pt100 Address Switches Switch 2 & 3 mv 3-wire resistance TABLE 1 Voltage Regulator ADDRESS SWITCHES (Fig. B) LAN A address Rotary (x3), 0 9 LAN B offset Rotary (x1), µp Memory x1 x1 x10 x100 LAN B offset LAN A address FIGURE B Address Switches /2 power supply fail signals BIM control signals LED INDICATORS Power, Fault, Comms, 2/2 fail, 2/1 fail POWER SUPPLIES Railbus (12V) current 30 ma (max.) Stores node configuration Retains configuration on BIM swap Used to define LAN address of node Used to transfer configurations between nodes Manages redundant PSU failure MODULE SPECIFICATION See also System Specification INPUTS 8910 PSU signal inputs /4 PSU external power fail signal inputs 8 Incoming power fail signal levels PSU OK < ma PSU failed < V DC Input voltage ± 15 V DC (max.) CONFIGURATION MEMORY Memory type Serial EEPROM, non-volatile Data retention period > 40 years Write cycles > 100,000 Configuration read or write time 7.5 s (typ.) 15 s (max.) MECHANICAL Weight 100 g (nom.) Mounting Compatible with 8711, 8712 & 8718 carriers DIMENSIONS (MM) 89 CONFIGURATION SWITCHES (See Fig. A and Table 1) Write protect (Sw 1) DIL, on/off Auto configure (Sw 2 & 3) DIL (x2), on/off 2/2 only system (Sw 4) DIL, on/off FIGURE A Configuration Switches

113 Bus Interface Modules HART Interface Module 8512-IF-HA LED INDICATORS LEDs for status indication of HOST and 8000 port RS232/RS485 Converter Workstation PC Running AMS software (Asset Management Solutions) Safe area ELECTRICAL Power supply voltage (Vs) Current required at 20 V at 24 V at 35 V Connections Conductor cross-section V dc 135 ma (max.) 115 ma (max.) 75 ma (max.) Screw terminals 2.5 mm 2 (max.) 8000 node Safe area or Zone 2/Div 2 hazardous area 8000 node 2 31 nodes max. MECHANICAL Mounting Casing Module width Weight CIRCUIT AND WIRING DIAGRAM 8512-IF-HA RS232 to 8000 Configuration Port 7 Rx 8 Tx 9 GND Directly on to T- or G- section DIN rail Polyamide 40 mm 100 g D Interface Microprocessor section Supply Host interface V DC 3 4 Data (+) 5 Data ( ) 6 GND RS485 to PC Workstation DIMENSIONS AND MOUNTING (MM) Supports up to 256 HART devices per node Supports AMS software Simplifies maintenance of HART field devices Mountable in Zone 2 or Div 2 hazardous areas Only one required per 8000 node MODULE SPECIFICATION See also System Specification HOST INTERFACE Electrical specification RS485 Physical medium 2-wire multidrop Number of nodes per workstation 31 (max.) Unit addresses (software configurable) 1-31 Baud rate (software configurable) 1.2, 9.6, 19.2 and 38.4 baud Instrument management software supported AMS (contact GE Intelligent Platforms for further options) To 8000 Configurator port Terminals 7,8,9,10,11,12 Lever out with screwdriver to release module T-section rail (DIN 46277) G-section rail (DIN 46277) Terminals 1,2,3,4,5, 8000 INTERFACE Connection to BIM HART devices per mode Via Configurator port 256 (max.) HAZARDOUS AREA APPROVALS Location of 8512-IF-HA Safe area or Class 1, Div 2, Groups A, B, C, D, T4 Hazardous location or Zone 2, IIC T4 Hazardous location ISOLATION Port to port psu 250 V ac rms (to EN ) (tested at 2.3 kv ac rms for 1 min.) 15 40

114 Bus Interface Module About GE Intelligent Platforms GE Intelligent Platforms, a General Electric Company (NYSE: GE), is an experienced high-performance technology company and a global provider of hardware, software, services, and expertise in automation and embedded computing. We offer a unique foundation of agile, advanced and ultra-reliable technology that provides customers a sustainable advantage in the industries they serve, including energy, water, consumer packaged goods, government and defense, and telecommunications. GE Intelligent Platforms is a worldwide company headquartered in Charlottesville, VA and is part of GE Home and Business Solutions. For more information, visit GE Intelligent Platforms Contact Information Americas: or Global regional phone numbers are listed by location on our web site at GE Intelligent Platforms, Inc. All rights reserved. All other brands or names are property of their respective holders. Specifications are subject to change without notice GFA-1713

115 Module carriers - Overview General Carriers are the building blocks on which the 8000 system is assembled. They distribute the basic power supply services to the modules, and provide the communications route between the Bus Interface Module (BIM) or Controller and the I/O modules. Most carriers can be mounted on DIN rail or directly to a flat surface and may be joined end-to-end to extend the size of an installation. Multipin connectors at the end of each carrier carry the system power supply and internal Railbus communications across to the next carrier. All I/O module carriers have their own independent earthing/ grounding strip, with screw terminals, to terminate the screens/shields of field-wiring cables. At each end of the strip there is a separate terminal to enable it to be linked to other carriers, or to the system ground, as required. Node services carrier-nsm This node services carrier will accommodate one BIM and a node services module. It is the recommended BIM carrier for all AC powered nodes because it supports power health management. This carrier will support Modbus or Profibus-DP BIMs. It is also recommended for DC powered nodes that are exclusively 2/1, i.e. where no 2/2 I/O modules are required. For these applications, it is commonly used with the power supply carrier (see this page). BIM-only carrier This carrier provides an alternative to a node services carrier - NSM when a node services module is not required. This carrier will support Modbus or Profibus-DP BIMs. It is commonly used with the power supply carrier (see this page). Node services carrier-bim These two node services carriers will accommodate one BIM, a node services module, two system DC power supplies and four 2/2 I/O modules. One carrier (8711) supports the Modbus BIM and the other (8712) supports the Profibus-DP BIM. These carriers are recommended for DC powered nodes that use 2/2, or a mixture of 2/2 and 2/1 I/O modules. Controller carrier The controller carrier provides a mounting platform for up to two controllers or EBIMs (8521-XX-XX). It can also accommodate a Power Supply Monitor module (8410-NS- PS), to monitor up to seven system power supplies in the node and alert the controller to failures. I/O Module carriers I/O Module carriers are available in general purpose (2/2) and 2/1 format. As a safeguard, these two types cannot be connected to each other because of the different multipin connectors used. The only way to connect the two types is by placing a Railbus Isolator (on its carrier) between them. Within these basic formats, 4 and 8 module carriers are available and they may be joined in any combination to suit node requirements. 64 module addressing The 8521 controller/ebim is capable of addressing up to 64 modules, unlike the BIM models 8502 and 8505, which will address a maximum of 32. Two carriers, models 8709-CA-08 (2/2) and 8729-CA-08 (2/1), are available with additional addressing lines to build a node with up to 64 modules. If 64-slot addressing is required for a node, these carrier types must be used exclusively, i.e. they cannot be mixed with 32-slot address carriers. Note: The 8521 controller/ebim can also be configured to a 32 module limit and may then use 32-slot address carriers. Power supply carrier This carrier is used to mount the 8910-PS-DC system power supply module which provides system power for DC power nodes. It is often used to support the node services carrier- NSM or the BIM-only carrier. IS power supply module carrier The 8920-PS-DC field power supply module provides power for 2/1 I/O modules and requires its own carrier to mount it. The carrier mounts in-line with 8- and 4-module 2/1 carriers, maintaining the Railbus connections through its edge connectors. This carrier may be used in 32-slot or 64-slot address nodes. Railbus isolator carrier When a node has IS field wiring terminating on it, an 8922-RB-IS Railbus isolator must be used between 2/2 and 2/1 carrier types. This is to prevent possible mains-voltage fault conditions from being propagated, via the Railbus, to the IS field wiring. The Railbus isolator has its own carrier CA-RB. This carrier may be used in 32-slot or 64-slot address nodes. Carrier extenders If the chosen field enclosure will not accommodate a single, end to end line of carriers, extenders can be fitted to enable the carriers to be continued on another line. The extenders are left and right handed and connect to the ends of the I/O module carriers using the multipin connectors. A multicore cable is used to link the data and address bus between the carriers. General purpose (2/2) and 2/1 extenders have different connectors to prevent accidental cross connection of the two types. Carrier extenders may be used in 32-slot or 64-slot address nodes. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

116 Module carriers - Listing 2/2 carriers 8-module carrier (32-slot addressing) ca-08 8-module carrier (64-slot addressing) ca-08 4-module carrier (32-slot addressing) ca-04 Node services carrier (Modbus) CA-NS Node services carrier (Profibus) CA-NS BIM carrier ca-bi Power supply (8910-PS-DC) carrier ca-ps Node services carrier (NSM) CA-NS Controller/EBIM carrier ca-ns Carrier extender (right hand) ce-rh Carrier extender (left hand) ce-lh Carrier extender cable 0.35m CC-35 Carrier extender cable 0.85m CC-85 Carrier extender cable 1.2m CC-12 2/1 carriers IS 8-module carrier (32-slot addressing) ca-08 IS 8-module carrier (64-slot addressing) ca-08 IS 4-module carrier (32-slot addressing) ca-04 Railbus isolator carrier ca-rb IS module power supply carrier ca-ps Carrier extender (right hand) ce-rh Carrier extender (left hand) ce-lh IS carrier extender cable, 0.35m CC-35 IS carrier extender cable, 0.85m CC-85 IS carrier extender cable, 1.2m CC-12 IS power extension cable, 0.35m CC-35 IS power extension cable, 0.85m CC-85 IS power extension cable, 1.2m CC-12 IS carrier extension cable set, 0.35m CC-35 IS carrier extension cable set, 0.85m CC-85 IS carrier extension cable set,,1.2m cc-12 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers 8-module carrier 32-slot address bus* accepts up to eight I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control

117 Module carriers 8-module carrier 32-slot address bus* accepts up to eight I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules distributes Bussed Field Power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location Location of field wiring...as node Field terminals accepted...general purpose, 2/2 I/O modules accepted... General purpose, 2/2 ELECTRICAL Railbus connectors...female in, male out Module address range Bussed field power supply (optional) Two 8-pin connectors are provided at the top rear of the carrier to connect power supplies for field power. Such supplies are routed through certain I/O module to provide power to field circuits. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet 8707-CA-08 BUSSED FIELD POWER CONNECTIONS Terminal Bussed Field Power } 1 I/O Modules 1 & 2 2 ve (or Neutral) } 3 I/O Modules 1 & 2 4 +ve (or Live) } 5 I/O Modules 3 & 4 6 +ve (or Live) } 7 I/O Modules 3 & 4 8 ve (or Neutral) Note: A second connector uses the same pin assignments for modules 5 & 6 and 7 & 8. * Must not be mixed with 64-slot address carriers MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

118 Module carriers 8-module carrier - extended addressing 64-slot address bus* accepts up to eight I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules distributes Bussed Field Power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of carrier...class 1, Div 2, Groups A, B, C, D T6 hazardous location or...zone 2, IIC T6 hazardous location Location of field wiring...as carrier Field terminals accepted...general purpose, 2/2 I/O modules accepted... General purpose, 2/2 Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation)to EN50021:1999 protection type n ELECTRICAL Railbus connectors...female in, male out Module address range Bussed field power supply (optional) Two 8-pin connectors are provided at the top rear of the carrier to connect power supplies for field power. These supplies are routed through I/O modules that require power for their field circuits. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate BUSSED FIELD POWER CONNECTIONS Terminal } } } } Function 1 I/O modules 1 & 2 2 ve (or Neutral) 3 I/O modules 1 & 2 4 +ve (or Live) 5 I/O modules 3 & 4 6 +ve (or Live) 7 I/O modules 3 & 4 8 ve (or Neutral) 8709-CA-08 ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN Note: A second connector uses the same pin assignments for modules 5 & 6 and 7 & 8. * For use only with 8521-XX-XX controller/ebim, and cannot be mixed with 32-slot address carriers EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

Module carriers 4-module carrier 8710-CA-04 32-slot address bus* accepts up to four I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting

119 Module carriers 4-module carrier 8710-CA slot address bus* accepts up to four I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules distributes Bussed Field Power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location Location of field wiring...as node Field terminals accepted...general purpose, 2/2 I/O modules accepted... General purpose, 2/2 ELECTRICAL Railbus connectors...female in, male out Module address range Bussed field power supply (optional) An 8-pin connector is provided at the top rear of the carrier to connect power supplies for field power. Such supplies are routed through certain I/O module to provide power to field circuits. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate BUSSED FIELD POWER CONNECTIONS Terminal Bussed Field Power } 1 I/O Modules 1 & 2 2 ve (or Neutral) } 3 I/O Modules 1 & 2 4 +ve (or Live) } 5 I/O Modules 3 & 4 6 +ve (or Live) } 7 I/O Modules 3 & 4 8 ve (or Neutral) * Must not be mixed with 64-slot address bus carriers ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers Node services carrier 8711-CA-NS Modbus BIM accommodates one BIM, two PSUs and four I/O modules screw terminals for LAN DIN rail or panel mounting printed wiring board rugged

120 Module carriers Node services carrier 8711-CA-NS Modbus BIM accommodates one BIM, two PSUs and four I/O modules screw terminals for LAN DIN rail or panel mounting printed wiring board rugged polycarbonate moulding routes Bussed Field Power to I/O modules isolated earthing bar for cable screen/shield CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULES PSU Modules (main and redundant) ps-dc Bus Interface Module...(Modbus) 8505-BI-MB Node Services Module NS-MO I/O modules...general purpose (2/2) various HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous area Location of field wiring...as per node Field terminals accepted...general purpose or Zone 2/Div 2 I/O modules accepted...general purpose or Zone 2/Div 2 ELECTRICAL Railbus connector...male out External dc power supply (optional) A 6-pin connector is provided at the top/rear of the carrier to connect a 12.0 V dc (±5%) power supply. This is an alternative to the carrier mounted PSU modules. Bussed field power supply (optional) An 8-pin connector is provided at the top rear of the carrier to connect power supplies for field power. Such supplies are routed through certain I/O module to provide power to field circuits. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight (approx.) g Mounting methods...flat panel (4 fixings) or DIN rail DIN-rail types... Top hat, 7.5 x 35 mm or 15 x 35 mm to EN G-section, to EN LAN CONNECTORS LAN A...6-way, screw-terminal (x2) LAN B...6-way, screw-terminal (x2) EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

121 Module carriers External Power 12V Bussed Field Power 8711-CA-NS continued BIM NSM I/O I/O I/O I/O Main PSU Redundant. PSU F.T. F.T. F.T. F.T. Earth/ground bar terminal (x2) DIL switches LAN A Terminals LAN B Terminals Field wiring cable-shield terminals Railbus Connector LAN INTERFACE POWER SUPPLY CONNECTIONS Terminal Assignment External Power Bussed Field Power 1 Rx + 2 Tx Rx 4 Tx 5 Gnd 6 Gnd Each LAN has duplicate connections wired in parallel - pin 1 to pin 1, pin 2 to pin 2, etc. LAN DIL SWITCHES One switch block per LAN. Operating mode set with switches. Mode 1: RS Mode Switch positions Termination ON ON ON Terminal External Power Bussed Field Power 1 Test Point 1 I/O Modules 1 & V ve (or Neutral) V I/O Modules 1 & V +ve (or Live) 5 0 V I/O Modules 3 & 4 6 Test Point 2 +ve (or Live) 7 Not applicable I/O Modules 3 & 4 8 Not applicable ve (or Neutral) } } } } ON ON OFF Mode 2: RS485 no termination Mode 3: RS485 terminated ON ON OFF W Pins for power supplies are provided in pairs. This enables one pin to be used for the supply input and the second to loop to another connector, when required. Mode 4: RS485 terminated and biased OFF OFF OFF V T 390W + 220W 390W EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers Node services carrier 8712-CA-NS Profibus BIM accommodates one BIM, two PSUs and four I/O modules sub-miniature, 9-pin, D connectors for LAN DIN rail or panel mounting printed wiring

122 Module carriers Node services carrier 8712-CA-NS Profibus BIM accommodates one BIM, two PSUs and four I/O modules sub-miniature, 9-pin, D connectors for LAN DIN rail or panel mounting printed wiring board rugged polycarbonate moulding routes Bussed Field Power to I/O modules isolated earthing bar for cable screen/shield CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULES PSU Modules (main and redundant) ps-dc Bus Interface Module...(Profibus-DP) 8502-BI-DP Node Services Module NS-MO I/O modules...general purpose (2/2) various HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous area Location of field wiring...as per node Field terminals accepted...general purpose or Zone 2/Div 2 I/O modules accepted...general purpose or Zone 2/Div 2 ELECTRICAL Railbus connector...male out External dc power supply (optional) A 6-pin connector is provided at the top/rear of the carrier to connect a 12.0 V dc (±5%) power supply. This is an alternative to the carrier mounted PSU modules. Bussed field power supply (optional) An 8-pin connector is provided at the top rear of the carrier to connect power supplies for field power. Such supplies are routed through certain I/O module to provide power to field circuits. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight (approx.) g Mounting methods...flat panel (4 fixings) or DIN rail DIN-rail types... Top hat, 7.5 x 35 mm or 15 x 35 mm to EN G-section, to EN LAN CONNECTORS LAN A...9-way D sub-miniature, female (x2) EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

123 Module carriers 8712-CA-NS continued External Power 12V Bussed Field Power BIM NSM I/O I/O I/O I/O Main PSU Redundant. PSU LAN A F.T. F.T. F.T. F.T. LAN A Earth/ground bar terminal (x2) LAN cable-shield terminal Field wiring cable-shield terminals Railbus Connector LAN INTERFACE POWER SUPPLY CONNECTIONS External Power Bussed Field Power Terminal External Power Bussed Field Power LAN connections RS485 interface (x2) 9-way (female) terminals 1 Test Point 1 I/O Modules 1 & V ve (or Neutral) Shield/protective ground Pin 1 RxD /TxD + Pin 3 DGND (0V) Pin 5 VP (0V) Pin 6 RxD /TxD - Pin 8 The LAN has duplicate connections wired in parallel - pin 1 to pin 1, pin 2 to pin 2, etc V I/O Modules 1 & V +ve (or Live) 5 0 V I/O Modules 3 & 4 6 Test Point 2 +ve (or Live) 7 Not applicable I/O Modules 3 & 4 8 Not applicable ve (or Neutral) Pins for power supplies are provided in pairs. This enables one pin to be used for the supply input and the second to loop to another connector, when required. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers BIM carrier 8715-CA-BI accommodates Bus Interface Module Modbus or Profibus-DP dual LAN connections (A & B) switchable RS485/RS422 termination options DIN rail or panel mounting

124 Module carriers BIM carrier 8715-CA-BI accommodates Bus Interface Module Modbus or Profibus-DP dual LAN connections (A & B) switchable RS485/RS422 termination options DIN rail or panel mounting CARRIER SPECIFICATION See also System Specification LAN CONNECTORS LAN A...9-pin, D, sub-minature, female LAN B...9-pin, D, sub-minature, female Switchable terminations for Modbus RS485, Modbus RS422 or Profibus-DP CARRIER MOUNTING MODULES Bus Interface Modules...(Profibus-DP) 8502-BI-DP...(Modbus) 8505-BI-MB HAZARDOUS AREA APPROVALS Location of node... Zone 2, IIC T4 hazardous area...or Class 1, Div 2, Groups A, B, C, D T4 hazardous location ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MATERIALS Carrier moulding...modified Poly-Phenylene Oxide Printed wiring board...epoxy Resin Woven Glass Laminate DC POWER External power supply V dc ± 5% (via 6-pin external power connector at top/rear) MECHANICAL Dimensions (overall)...93 (w) x 170 (d) x 35 (h) mm Weight (approx.) g Mounting methods...flat panel (2 fixings) or DIN rail DIN-rail types... Top hat, 7.5 x 35 mm to EN or 15 x 35 mm to EN or G-section, to EN EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

125 Module carriers LAN INTERFACE CA-BI continued 6 1 Modbus applications LAN A Mode Switch positions Termination Terminals Modbus Modbus Profibus-DP RS422 RS485 RS422 not terminated OFF OFF OFF None Pin 1 FGND/Socket FGND/Socket FGND/Socket shroud shroud shroud Pin 2 RxD+ RxD/TxD+ NC Pin 3 TxD+ RxD/TxD+ RxD/TxD+ RS422 terminated receiver OFF ON OFF + 220W Pin 4 RxD RxD/TxD RTS+ Pin 5 GND GND GND Pin 6 V T V T V P RS422 terminated & biased receiver OFF ON ON +V T 390W + 390W 220W Pin 7 RxD RxD/TxD RTS+ Pin 8 TxD RxD/TxD RxD/TxD Pin 9 NC NC NC RS485 not terminated ON OFF OFF None LAN B Terminals Modbus Modbus RS422 RS485 RS485 terminated ON ON OFF + 220W Pin 1 Socket shroud Socket shroud +V T 390W Pin 2 RxD+ RxD/TxD+ Pin 3 TxD+ RxD/TxD+ RS485 terminated & biased ON ON ON + 390W 220W Pin 4 RxD RxD/TxD Pin 5 GND GND Pin 6 V T V T Pin 7 RxD RxD/TxD Pin 8 TxD RxD/TxD Pin 9 NC NC Note: Pins with assignments shown in italics Profibus-DP applications are normally not connected; they occur because of the universal nature of the interface. LAN DIL SWITCHES One switch block per LAN to determine termination and/or bias ON = switch to right; OFF = switch to left (with normal orientation) Set operating mode with switches as follows: Mode Switch positions Termination RS485 not terminated OFF OFF OFF None Note: Any required termination should be implemented in the Profibus D-type plug. Note: Switch model may vary but switching directions remain the same. POWER SUPPLY CONNECTIONS Terminal External power External power 1 No connection 2 0 V V V 5 0 V 6 No connection Power supply pins are provided in pairs. This enables one pin to be used for the supply input and the second to loop to another connector, when required. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers Power supply carrier 8717-CA-PS accomodates one 8910-PS-DC power supply DIN rail or panel mounting use for 2/1 only nodes with DC power feed use with 8718-CA-NS or 8715-CA-BI with DC

126 Module carriers Power supply carrier 8717-CA-PS accomodates one 8910-PS-DC power supply DIN rail or panel mounting use for 2/1 only nodes with DC power feed use with 8718-CA-NS or 8715-CA-BI with DC power feed CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location ELECTRICAL 12V dc output connector...6-way screw terminal MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 167 (d) x 27.4 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN DC OUTPUT POWER CONNECTIONS Terminal Function V dc V dc 6 } } EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers Node services carrier 8718-CA-NS accommodates Bus Interface Module accommodates Node Services Module Modbus or Profibus-DP dual LAN connections (A & B) switchable RS485/RS422

127 Module carriers Node services carrier 8718-CA-NS accommodates Bus Interface Module accommodates Node Services Module Modbus or Profibus-DP dual LAN connections (A & B) switchable RS485/RS422 termination options eight power fail inputs DIN rail or panel mounting CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULES Bus Interface Modules...(Profibus-DP) 8502-BI-DP...(Modbus) 8505-BI-MB Node Services Module MO-NS HAZARDOUS AREA APPROVALS Location of node... Zone 2, IIC T4 hazardous area...or Class 1, Div 2, Groups A, B, C, D T4 hazardous location ELECTRICAL Railbus connector...male out Power fail connector...8 pairs (screw terminal) Carrier ground terminal...m2 screw terminal DC POWER External power V dc (±5%) A 6-pin connector is provided at the top/rear of the carrier for the connection of the power supply. LAN CONNECTORS LAN A...9-pin, D, sub-minature, female LAN B...9-pin, D, sub-minature, female Switchable terminations for Modbus RS485, Modbus RS422 or Profibus-DP Note: The screw terminal beside each LAN connector is a termination for the cable screen and should not be used as system ground. ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MATERIALS Carrier moulding...modified Poly-Phenylene Oxide Printed wiring board...epoxy Resin Woven Glass Laminate MECHANICAL Dimensions (overall) (w) x 170 (d) x 68 (h) mm Weight (approx.) g Mounting methods...flat panel (2 fixings) or DIN rail DIN-rail types... Top hat, 7.5 x 35 mm to EN or 15 x 35 mm to EN or G-section, to EN POWER SUPPLY CONNECTIONS Terminal External power External power 1 No connection 2 0 V V V 5 0 V 6 No connection Power supply pins are provided in pairs. This enables one pin to be used for the supply input and the second to loop to another connector, when required. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: May 2006

128 Module carriers LAN INTERFACE 8718-CA-NS continued LAN DIL SWITCHES One per LAN to determine termination and/or bias ON = switch to right; OFF = switch to left (with normal orientation) Note: Switch model may vary. Modbus applications Mode Switch positions Termination Modbus Modbus Profibus-DP RS422 RS485 Terminals LAN A/B LAN A/B LAN A only RS422 not terminated OFF OFF OFF None Pin 1 Socket Socket Socket shroud shroud shroud Pin 2 RxD+ RxD/TxD+ NC Pin 3 TxD+ RxD/TxD+ RxD/TxD+ RS422 terminated receiver OFF ON OFF + 220W Pin 4 RxD RxD/TxD RTS+ Pin 5 GND GND GND Pin 6 V T V T V P RS422 terminated & biased receiver OFF ON ON +V T 390W + 390W 220W Pin 7 RxD RxD/TxD RTS+ Pin 8 TxD RxD/TxD RxD/TxD Pin 9 NC NC NC RS485 not terminated ON OFF OFF None Note: Pins with assignments shown in italics are normally not connected; they occur because of the universal nature of the interface. PSU POWER FAIL CONNECTOR RS485 terminated ON ON OFF + 220W RS485 terminated & biased ON ON ON +V T 390W + 390W 220W Note: Switch model may vary but switching directions remain the same. Connection pairs AUX ve Pair Pair Pair Pair Pair Pair Pair Pair Eight pairs of terminals are provided for the PSU health signals. If an 8510-MO-NS module is fitted and power fail signalling is being used: a) connect the power supply AUX and ve terminals to a pair as shown in the table (right) b) put individual wire links across each unused terminal pairs to prevent a continual alarm condition being signalled to the BIM. Note: Terminals 15 and 18 are not used. Profibus-DP applications Mode Switch positions Termination RS485 not terminated OFF OFF OFF None Note: Any required termination should be implemented in the Profibus D-type plug. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: May 2006

Module carriers Controller carrier 8750-CA-NS accommodates two controllers/ebims accommodates Power Supply Monitor module serial port connections for controllers manual change state buttons seven*

129 Module carriers Controller carrier 8750-CA-NS accommodates two controllers/ebims accommodates Power Supply Monitor module serial port connections for controllers manual change state buttons seven* power fail inputs panel mounting The controller carrier provides a mounting platform for up to two controllers or EBIMs (8521-XX-XX). It can also accommodate a Power Supply Monitor module (8410-NS-PS) which can monitor up to seven system power supplies in the node and alert the controller to failures. The powerfail signals are brought to the module via a screw terminal block at the rear of the carrier. For each controller /EBIM there is a serial port connection on the carrier and a manually operated change state (failover) button. CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULES Controller/EBIM (x2) xx-xx Power Supply Monitor module ns-ps HAZARDOUS AREA APPROVALS Location of carrier... Zone 2, IIC T6 hazardous area...or Class 1, Div 2, Groups A, B, C, D T6 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n ELECTRICAL Railbus connector...male out Serial port connectors...9-pin, D-type (female) (x2) Power health connections...screw terminals (x7 pairs) Ground terminals...m4 screw terminal (x2) ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System Specification MATERIALS Carrier body...painted 1.6mm ZINTEC to BS EN Printed wiring board...epoxy Resin Woven Glass Laminate MECHANICAL Dimensions (footprint) (w) x 253 (d) mm Height (top of circuit board)...28 mm (overall)...55 mm Weight (approx.) kg Mounting methods...flat panel (4 fixings) USER CONTROLS Two change state buttons, one for each controller/ebim, are provided on the carrier to enable the user to change the state of a controller from master to standby, standby to offline or offline to standby. The controller/ebim affected by each change state button is indicated on the circuit board. The state change depends upon the controller state before the button is pressed. See table below for effects. State Effect DC POWER External power V dc (±5%) A 6-pin connector (see next page) is provided at the top of the carrier. This connection powers the Power Supply Monitor module and other modules on carriers connected to this one. Note: This connection does not provide power to the controller/ebim module(s). Master Standby Backup Change to standby if current standby is healthy Change to offline state Re-synchronize and return to standby * up to six 2/2 power supplies plus one 2/1 power supply. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

130 Module carriers Controller carrier A RAILBUS POWER SUPPLY CONNECTIONS External power 8750-CA-NS continued B POWER FAIL INPUTS + 2/2 NC 2/ PFM Terminal External power 1 No connection 2 0 V V A CHANGE STATE A SERIAL PORT 1 B CHANGE STATE B SERIAL PORT V 5 0 V 6 No connection Power supply pins are provided in pairs. This enables one pin to be used for the supply input and the second to loop to another connector, when required. Note: The controllers/ebims do not draw main power from this supply. See previous page. Ground terminals (A & B) A & B provide the same ground connection. B is recommended for terminating any shielding on the power health cable(s). SERIAL PORT CONNECTORS (X2) Pin # Function 1 0V 2 NC 3 Tx/Rx (+) Tx/Rx (+) 5 Tx/Rx ( ) Tx/Rx ( ) 7 NC 8 NC 9 0V PSU POWER HEALTH CONNECTOR This power health facility is operational only when a Power Supply Monitor module (8410-NS-PS) is fitted on the carrier. Terminal pairs 1 6 These terminal pairs (+ and ) are provided for external 2/2 power supplies, e.g PS-AC or 8914-PS-AC. For each pair: + Power health signal from PSU negative ( ve) connection from PSU Note: On the 8913-PS-AC, it is the 12V output that provides the power health signal, therefore connect the ve terminal from the 12V output to the ve terminal on the power health connector. Each unused terminal pair must be fitted with a shorting link to prevent an alarm condition being signalled to the controller. Terminal pairs 7 & 8 These terminal pairs are disconnected and should not be used. Terminal pair 9 If a Railbus Isolator (8922-RB-IS) is not used in the node, this terminal pair must be fitted with a shorting link to prevent an alarm condition being signalled to the controller/ebim. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Carrier extender Left-hand/right-hand General purpose and non-is field wiring installations ensures Railbus and power supply continuity pairs (LH & RH) link separate carrier runs sub-d connectors

131 Carrier extender Left-hand/right-hand General purpose and non-is field wiring installations ensures Railbus and power supply continuity pairs (LH & RH) link separate carrier runs sub-d connectors linked via multiway cable screw terminals link power supply connections rugged polycarbonate base with DIN rail fixings multipin connector to carrier maximum of 3 extender pairs per node 32- and 64-slot address capable SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node......class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location ELECTRICAL Railbus carrier connector CE-RH...female in 8021-CE-LH...male out Usable with 32-slot or 64-slot address nodes Extender cable connector...sub-d, 37-pin female DC power cable connector...screw terminal DC power cable conductor size mm 2 (max.) MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate 802x-CE-xH ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (overall)...42 (w) x 168 (d) x 37 (h) mm Weight g Mounting method...integral DIN-rail fixings DIN rail types... Top hat, 35 x 7.5 mm or 35 x 15 mm to EN G-section, to EN PART NUMBERS Carrier Extender, Right-hand 8020-CE-RH Carrier Extender, Left-hand 8021-CE-LH EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

132 Carrier extender cables 0.35m, 0.85m and 1.2m 800x-CC-xx Railbus data extender cables general purpose and non-is field wiring installations three lengths , 0.85 and 1.2 m sub-d cable connectors 32- and 64-slot address capable SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location ELECTRICAL Extender cable connectors...sub-d, 37-pin male ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet PART NUMBERS Carrier Extension Cable, 0.35m Carrier Extension Cable, 0.85m Carrier Extension Cable, 1.2m 8001-CC CC CC-12 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers IS 8-module carrier 8727-CA-08 32-slot address bus* accepts up to eight 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel

133 Module carriers IS 8-module carrier 8727-CA slot address bus* accepts up to eight 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location Location of field wiring...class 1, Div 1, Groups A, B, C, D T4 hazardous location or...zone 1 /Zone 0, IIC T4 hazardous location Field terminals accepted...is only I/O modules accepted... 2/1 only ELECTRICAL Railbus connectors...male in, female out Module address range Earth leakage detection 4-pin connectors are provided at the top/rear of the carrier for wiring the individual modules to earth leakage detectors, e.g. MTL2220. (Refer to GE for ear th leakage detection suppor t within I/O modules) MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN * Must not be mixed with 64-slot address bus carriers MODULE NUMBER ( ) Connector is repeated for modules 5 to 8 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers IS 8-module carrier - extended addressing 8729-CA-08 64-slot address bus* accepts up to eight 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding

134 Module carriers IS 8-module carrier - extended addressing 8729-CA slot address bus* accepts up to eight 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of carrier...class 1, Div 2, Groups A, B, C, D T6 hazardous location or...zone 2, IIC T6 hazardous location Field terminals accepted...is only I/O modules accepted... 2/1 only Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n ELECTRICAL Railbus connectors...male in, female out Module address range Earth leakage detection 4-pin connectors (see right) are provided at the top/rear of the carrier for wiring the individual modules to earth leakage detectors, e.g. MTL2220* *Refer to MTL for earth leakage detection support within I/O modules MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN * For use only with 8521-XX-XX controller/ebim, and cannot be mixed with 32-slot address carriers MODULE NUMBER ( ) Connector is repeated for modules 5 to 8 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

Module carriers IS 4-module carrier 8720-CA-04 32-slot address bus* accepts up to four 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel

135 Module carriers IS 4-module carrier 8720-CA slot address bus* accepts up to four 2/1 I/O modules and field terminals printed wiring board rugged polycarbonate moulding DIN rail or panel mounting carries control signals and data on Railbus distributes DC power to modules isolated earthing bar for cable screens/shields CARRIER SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location Location of field wiring...class 1, Div 1, Groups A, B, C, D T4 hazardous location or...zone 1 /Zone 0, IIC T4 hazardous location Field terminals accepted...is only I/O modules accepted... 2/1 only ELECTRICAL Railbus connectors...male in, female out Module address range Earth leakage detection A 4-pin connector is provided at the top/rear of the carrier for wiring the individual modules to earth leakage detectors, e.g. MTL2220. (Refer to MTL for earth leakage detection support within I/O modules.) MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (w) x 170 (d) x 22 (h) mm Weight g Mounting methods...flat panel or DIN rail DIN-rail types... Top hat 35 x 7.5 mm rail or 35 x 15 mm rail to EN G-section rail to EN * Must not be mixed with 64-slot address bus carriers MODULE NUMBER EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Module carriers Railbus isolator carrier 8723-CA-RB accommodates one Railbus Isolator DIN rail or panel mounting printed wiring board rugged polycarbonate moulding 32- and 64-slot address capable

136 Module carriers Railbus isolator carrier 8723-CA-RB accommodates one Railbus Isolator DIN rail or panel mounting printed wiring board rugged polycarbonate moulding 32- and 64-slot address capable CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULE Railbus Isolator RB-IS HAZARDOUS AREA APPROVALS Location of node......class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous area ELECTRICAL Railbus connectors...male in, female out Usable with 32-slot or 64-slot address nodes DC power DC power for the Railbus Isolator is obtained from the system through the multipin Railbus connectors. MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (overall)...93 (w) x 168 (d) x 35 (h) mm Weight (approx.) g Mounting methods...flat panel (3 fixings) or DIN-rail DIN-rail types... Top hat, 7.5 x 35 mm or 15 x 35 mm to EN G-section, to EN EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

137 Module carriers IS module power supply carrier 8724-CA-PS accommodates one 8920 PSU module DIN rail or panel mounting printed wiring board rugged polycarbonate moulding 32- and 64-slot address capable CARRIER SPECIFICATION See also System Specification CARRIER MOUNTING MODULE System Power Supply module ps-dc HAZARDOUS AREA APPROVALS Location of node......class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous area ELECTRICAL Railbus connectors...male in, female out (Usable with 32-slot or 64-slot address nodes) MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (overall)...93 (w) x 168 (d) x 35 (h) mm Weight (approx.) g Mounting methods...flat panel (4 fixings) or DIN-rail DIN-rail types... Top hat, 7.5 x 35 mm or 15 x 35 mm to EN G-section, to EN EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Carrier extender Left-hand/right-hand 803x-CE-xH for IS field wiring installations ensures Railbus and power supply continuity pairs (LH & RH) link separate carrier runs sub-d connectors linked via

138 Carrier extender Left-hand/right-hand 803x-CE-xH for IS field wiring installations ensures Railbus and power supply continuity pairs (LH & RH) link separate carrier runs sub-d connectors linked via multiway cable screw terminals link power supply connections rugged polycarbonate base with DIN rail fixings multipin connector to carrier maximum of 3 extender pairs per node 32- and 64-slot address capable SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node......class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location ELECTRICAL Railbus carrier connector CE-RH...male in 8031-CE-LH...female out Usable with 32-slot or 64-slot address nodes Extender cable connector...sub-d, 50-pin female DC power cable connector...6-pin MATERIALS Carrier moulding...modified poly-phenylene oxide Printed wiring board...epoxy resin woven glass laminate ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet MECHANICAL Dimensions (overall)...48 (w) x 168 (d) x 42 (h) mm Weight g Mounting method...integral DIN-rail fixings DIN rail types... Top hat, 35 x 7.5 mm or 35 x 15 mm to EN G-section, to EN PART NUMBERS Carrier Extender, Right-hand Carrier Extender, Left-hand 8030-CE-RH 8031-CE-LH EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

139 Carrier extender cables IS carrier extender cables 80xx-CC-xx Railbus data & power extender cables for IS field wiring installations three lengths , 0.85 and 1.2 m sub-d cable connectors 32- and 64-slot address capable SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of node......class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous location ELECTRICAL Data extender cable connectors...sub-d, 50 pin male Power extender cable connectors...6-pin ENVIRONMENTAL Ambient temp Operating C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification sheet PART NUMBERS - DATA CABLES IS Carrier Extension Cable, 0.35m IS Carrier Extension Cable, 0.85m IS Carrier Extension Cable, 1.2m 8011-CC CC CC-12 PART NUMBERS - POWER CABLES IS Power Extension Cable, 0.35m IS Power Extension Cable, 0.85m IS Power Extension Cable, 1.2m 8016-CC CC CC-12 PART NUMBERS - CABLE SETS (combining the above) IS Carrier Extension Cable set, 0.35m IS Carrier Extension Cable set, 0.85m IS Carrier Extension Cable set, 1.2m 8032-CC CC CC-12 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Field terminals - Screw clamp General A field terminal is a replaceable unit for terminating the wiring from the field devices.

5mm 2 wire. By wiring virtually directly to the I/O module there is no need for additional patching or terminations.

Fusing & loop-disconnect Field terminals are available that contain a replaceable fuse or a loop-disconnect link for each channel.

140 Field terminals - Screw clamp General A field terminal is a replaceable unit for terminating the wiring from the field devices. Each I/O module requires its own field terminal and the correct type is recommended on the individual I/O module data sheet. The field wiring is terminated on screw terminals that can take up to 2.5mm 2 wire. By wiring virtually directly to the I/O module there is no need for additional patching or terminations. The field terminal attaches to the module carrier first; the I/O module is then mounted on it. A pair of multipin connectors link the field terminal to the I/O module. Fusing & loop-disconnect Field terminals are available that contain a replaceable fuse or a loop-disconnect link for each channel. Fuses have a 2A rating and, like the links, have a mechanical feature that allows them to be partially withdrawn. This provides a break in the field wiring loop which assists servicing and fault finding in the field. Thermocouple modules Thermocouple modules require specific field terminals. The thermocouple modules 8105-TI-TC (4-channel) and 8205-TI-IS (8-channel IS) each have their own specific field terminal containing a cold junction compensation sensor. The 8205-TI- IS can also accommodate a remote cold junction if used, it occupies one of the eight available channels. RTD modules The RTD modules, 8106-TI-RT (4-channel) and 8206-TI-IS (8-channel) use field terminals that are specifically designed to accommodate 2, 3 and 4-wire connections. The field terminals incorporate diodes that become forward biased if a channel becomes open circuited - ensuring that other channels are not affected by this situation. Similarly, an RTD can be removed from, or not fitted to, a channel without affecting the operation. The points where the energisation current enters and leaves the field terminals are shown by the symbols I+ and I, respectively, on the appropriate diagrams. IS field terminals Particular field terminals are required for modules with built-in IS interfaces, and field terminals are coloured blue to mark this difference. Tagging strip A tagging strip is supplied with each terminal (with the exception of the mass termination assemblies). A card is provided for the user to mark the channel assignments for the field wiring and this is protected by a clear plastic panel. Mechanical key coding Field terminals are an important link in the field connection process and a mechanical keying technique is used to prevent incompatible modules from being connected accidentally to a field circuit. This avoids inadvertent damage to I/O modules and field wiring, and maintains safety in hazardous area applications. It is implemented in two complementary ways. Rotatable keys A pair of mechanically rotatable keys form part of the field terminal (see diagram below) and these are set by the user during installation to match the fixed key-code (e.g. A 1) of the I/O module that will be fitted onto it. A module with a different keycode cannot then accidentally be fitted on that field terminal. Keyways The four types of field terminal: general purpose, non-incendive, non-arcing and intrinsically safe, have a further pattern of keys that make each type unique; modules of a corresponding type have a matching keyway. It is therefore impossible to implement a potentially hazardous combination of module and field terminal. The four types of field terminal can be identified from the diagram below. General Purpose Non-Incendive (2/2) Non-Arcing (2/2) F E F E F E Rotary keys on field terminals A D A D A D B 6 C 5 B 6 C 5 B 6 C Intrinsically Safe (2/1) F E A D B 6 C Keys to match keyways on modules EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

Field terminals - Mass Termination Assemblies IDC connectors - save wiring time Link to high-current output relays Quick-connect cable adapters Mass Termination Assembly Mass Termination Assemblies

141 Field terminals - Mass Termination Assemblies IDC connectors - save wiring time Link to high-current output relays Quick-connect cable adapters Mass Termination Assembly Mass Termination Assemblies (MTAs) offer the user a number of different ways to terminate field wiring. Two versions are available, 16-pin (8618-FT-MT) and 44-pin (8619-FT-MT), both of which provide IDC multi-pin connectors instead of screw terminals. Some standard 1, 2 and 3 metre cables, are available from GEF to assist the user; others can be made to order; or users can put together their own custom cables to suit their specific wiring termination requirements. The Mass Termination Assemblies are particularly useful when legacy systems are being replaced and connections must be made to existing field wiring, junction boxes and marshalling cabinets. Mass Termination Assemblies can also be used to interface to signal conditioning units. For example, with devices that require a drive current above the 1A capability of the 8115-DO-DC discrete output module, the 8618-FT-MT can be used to connect to highcurrent relays*. Switch/Proximity Detector Wiring Panel The 8650-FT-PX provides a simple method to terminate up to 32 two-wire field devices. It is DIN-rail mountable and links to the 8619-FT-MT field terminal using a pair of ready terminated, IDC connector cables. For maximum convenience, there is also provision for cable screens to be terminated and grounded. Mechanical key coding This feature is available on these terminals. See the previous page for details. *See Technical Support Note TSN112: Using the 8115-DO-DC with high-current loads. Available from: EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

142 Field terminals range of field terminals standard, fused, loop-disconnect & MTAs blue moulding for IS field wiring THC and RTD versions available tag strip on all screw-clamp field terminals SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of field terminal...zone 2, IIC, T4 hazardous area or Class 1, Div 2, Groups A D, T4 hazardous location Location of I/O field wiring For 860x-FT-xx and 861x-FT-xx...Zone 2, IIC, T4 hazardous...area or Class 1, Div 2, Groups A D, T4 hazardous location For 862x-FT-IS...Zone 0, IIC hazardous area or Div 1, Groups A D hazardous location ELECTRICAL Rated voltage...250v ac Maximum current per I/O channel...3a Fuse rating (where fitted)...2a Conductor size mm 2 MECHANICAL Material...Modified Poly-Phenylene Oxide Dimensions - approx (including tagging strip) 8617-FT-NI and 8623-FT-IS...42 (w) x 88 (d) x 61 (h) mm Others...42(w) x 88 (d) x 39.5 (h) mm Weights (typical - including tagging strip) Unfused type (except THC & RTD)...78g Fused type (including fuses)...86g THC type...70g RTD type...106g 8617-FT-NI and 8623-FT-IS (16-channel)...106g See also datasheets for 8618-FT-MT and 8619-FT-MT PART NUMBERS GENERAL PURPOSE FIELD WIRING Field terminal description Part number Standard 8602-FT-ST Fused 8604-FT-FU THC 8605-FT-TC RTD 8606-FT-RT 4-wire transmitter 8615-FT-4W 16/30-channel DI 8617-FT-NI 16-pin Mass Termination Assembly 8618-FT-MT 44-pin Mass Termination Assembly 8619-FT-MT ZONE 2/DIV2 FIELD WIRING APPLICATIONS Field terminal description Part number THC 8605-FT-TC RTD 8606-FT-RT Non-incendive* 8601-FT-NI Non-incendive, fused* 8603-FT-FU Non-arcing, standard* 8610-FT-NA Non-arcing, fused* 8611-FT-FU 4-wire transmitter 8615-FT-4W 16/30-channel DI 8617-FT-NI 16-pin Mass Termination Assembly 8618-FT-MT 44-pin Mass Termination Assembly 8619-FT-MT ZONE 1, 0/DIV 1 (IS) FIELD WIRING APPLICATIONS Field terminal description Part number IS, standard 8621-FT-IS IS, loop-disconnect IS, 16-channel DI IS, 8-channel DI, loop-disconnect IS, THC IS, RTD 8622-FT-IS 8623-FT-IS 8624-FT-IS 8625-FT-IS 8626-FT-IS ADDITIONAL COMPONENTS Description Switch/Prox. detector wiring panel 2A Fuse pack (10 in pack) Loop-disconnect links (10 in pack) Part Number 8650-FT-PX 8401-FU-2A 8405-LK-ZE *Refer to 2/2 I/O module data sheets for recommended non-incendive or nonarcing field terminal type in Zone 2 and Division 2 applications. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

143 Field terminals Connection diagrams Identify terminal type in the table below, then see named diagram for connections. Diagram 2 Terminal type Diagram No. CH1 CH2 CH3 CH FT-NI FT-ST FT-FU FT-FU FT-TC FT-RT (2-wire) FT-RT (3-wire) FT-RT (4-wire) FT-NA FT-FU 1 Diagram 3 CH1 CH2 CH3 CH FT-4W FT-NI 6 or 6a 8618-FT-MT see datasheet FT-MT see datasheet 8621-FT-IS 1 or 7* 8622-FT-IS 1 or 7* 8623-FT-IS FT-IS FT-IS 8 I+ I Diagram 4 CH1 CH2 CH3 CH FT-IS (2 wire) FT-IS (3 wire) FT-IS (4 wire) FT-PX see datasheet Wire as per diagram 6a only when used with 8125-DI-DC or 8127-DI-SE modules. * Wire as per diagram 7 only when used with 8215-DO-IS module. Diagram 1 I+ I Diagram 5 CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8 CH1 CH2 CH3 CH I+ I EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

144 Field terminals - Standard Connection diagrams Diagram 6 Diagram 9 CH 9 CH 10 CH 11 CH 12 CH 13 CH 14 CH 15 CH 16 I I CH 1 CH 2 CH 3 CH 4 CH 5 CH 6 CH 7 CH 8 CH 1 CH 2 CH 3 CH 4 CH 5 CH 6 CH 7 CH 8 Diagram 6a Diagram CH 24 CH 25 CH 26 CH 27 CH CH 29 CH 30 0V I CH 16 CH 17 CH 18 CH 19 CH 20 CH 21 CH 22 CH CH 8 0V CH 9 CH 1 CH 10 CH 2 CH 11 CH 3 CH 12 CH CH 13 CH 5 CH 14 CH 6 CH 15 CH I- Diagram 7 CH1 CH2 CH3 CH4 CH 1 CH 2 CH 3 CH 4 CH 5 CH 6 CH 7 CH Diagram I Diagram I CH 1 CH 2 CH 3 CH 4 CH 5 CH 6 CH 7 CH 8 CH 1 CH 2 CH 3 CH 4 CH 5 CH 6 CH 7 CH 8 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

145 Field terminals 16-pin mass termination assembly 8618-FT-MT 16-pin IDC connector termination IDC alternative for most screw terminal types use with 8115-DO-DC for high-current relay adapters provides a choice of field wiring terminations clip-on protective cover SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Field terminal location...zone 2, IIC, T4 hazardous area or Class 1, Div 2, Groups A D, T4 hazardous location I/O field wiring location...zone 2, IIC, T4 hazardous area or ELECTRICAL Class 1, Div 2, Groups A D, T4 hazardous location Rated voltage...50v AC Maximum current per I/O channel a MECHANICAL Material...Modified Poly-Phenylene Oxide Dimensions - approx...42(w) x 95(d) x 42*(h) mm Weight...44g * with protective cover fitted CABLE OPTIONS 16-way cables, terminated with 16-pin IDC connectors at each end, are available for the 8618-FT-MT. Description Part number 1 metre cable fc-10 2 metre cable fc-20 3 metre cable fc-30 See also Technical Support Note TSN112 for details of using this product with high-current relays. Notes 1. This field terminal cannot be used with the following I/O module types: 8105-TI-TC, 8106-TI-RT Special functionality required e.g. CJC 8121-DI-DC, 8122-DI-DC } Insufficient terminals - use 8619-FT-MT 8125-DI-DC, 8127-DI-SE 2. AC modules cannot be used with this field terminal because of the 50V AC voltage rating. IDC CONNECTOR PINOUTS When used with the following I/O module types: 8101-HI-TX 8102-HO-IP 8103-AI-TX 8104-AO-IP 8109-DI-DC 8110-DI-DC 8115-DO-DC 8117-DO-DC 8119-VI-05 use this pinout: When used with I/O module type: 8123-PI-QU Pin Function 1 Voltage i/p - Ch 1 2 Current i/p - Ch 1 3 Common - Ch 1 4 NAMUR i/p - Ch 1 5 Power supply +ve - Ch 2 6 Power supply +ve - Ch 1 7 Voltage i/p - Ch 2 8 Current i/p - Ch 2 9 Common - Ch 2 10 NAMUR i/p - Ch 2 11 Common - Ch 1 12 NAMUR gate control - Ch 1 13 o/p ve - Ch 1 14 o/p +ve - Ch 1 15 o/p ve - Ch 2 16 o/p +ve - Ch Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Ch7 Ch8 EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Nov 2006

146 Field terminals 16-pin mass termination assembly 8618-FT-MT USAGE OPTIONS PIN OUT 16-pin output + CABLE 16-pin output TO 14-WAY CABLE + HIGH-CURRENT RELAYS 16-pin output High-current output relays For further details on choosing and using output relays see Technical Support Note TSN112 Using the 8115-DO-DC with high-current loads EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Nov 2006

147 Field terminals 44-pin mass termination assembly 8619-FT-MT 32 channel connection use with 8121/8122 and 8125/8127 use with 8650-FT-PX field terminal provides a choice of field wiring terminations clip-on protective cover SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Field terminal location...zone 2, IIC, T4 hazardous area or Class 1, Div 2, Groups A D, T4 hazardous location I/O field wiring location...zone 2, IIC, T4 hazardous area or Class 1, Div 2, Groups A D, T4 hazardous location ELECTRICAL Rated voltage...50v AC Maximum current per I/O channel a MECHANICAL Material...Modified Poly-Phenylene Oxide Dimensions - approx...42(w) x 95(d) x 42*(h) mm Weight...48g * with protective cover fitted CABLE OPTIONS way cable sets, terminated with IDC connectors at each end, are available for the 8619-FT-MT. These could be used, for example, to connect the 8619-FT-MT to the 8650-FT-PX wiring panel. Description Part number 1 metre length set fc-10 2 metre length set fc-20 3 metre length set fc-30 IDC CONNECTOR PINOUTS J1 8125/ 8121/ Pin Ch 1 Ch 2 2 0V Ch 1 3 Ch 3 Ch 4 4 Ch 2 Ch 3 5 Ch 5 Ch 6 6 Ch 4 Ch 5 7 Ch 7 Ch 8 8 Ch 6 Ch 7 9 Ch 17 Ch Ch 16 Ch 9 11 Ch 19 Ch Ch 18 Ch Ch 21 Ch Ch 20 Ch Ch 23 Ch Ch 22 Ch V n/c 18 Ch 27 n/c 19 Ch 28 n/c 20 Ch 32 n/c Notes: 1. 0V pins are all linked only when the module is fitted. 2. Channels 27, 28 and 32 are common to both J1 and J J2 J J2 8125/ 8121/ Pin Ch 8 Ch 1+ 2 Ch 9 Ch 2+ 3 Ch 10 Ch 3+ 4 Ch 11 Ch 4+ 5 Ch 12 Ch 5+ 6 Ch 13 Ch 6+ 7 Ch 14 Ch 7+ 8 Ch 15 Ch V n/c 10 Ch 26 Ch Ch 24 Ch Ch 25 Ch Ch 27 Ch Ch 28 Ch Ch 29 Ch Ch 30 Ch Ch 31 n/c 18 Ch 32 n/c 19 0V n/c 20 0V n/c 21 0V n/c 22 0V Ch V n/c 24 n/c n/c n/c = no connection EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

148 Field terminals 44-pin mass termination assembly 8619-FT-MT USAGE OPTIONS PIN OUT 32 channel ouputs + CABLE 32 channel ouputs + CABLE WIRING PANEL 32 channel ouputs 32 channel switch/prox. detector wiring panel 8650-FT-PX EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

Field terminals Switch/proximity detector wiring panel 8650-FT-PX simplified 32-channel field wiring connection multipin connectors to 8619-FT-MT field terminal screw terminals for field wiring

149 Field terminals Switch/proximity detector wiring panel 8650-FT-PX simplified 32-channel field wiring connection multipin connectors to 8619-FT-MT field terminal screw terminals for field wiring DIN-rail mounting SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location...Zone 2, IIC, T4 hazardous area or Class 1, Div 2, Groups A D, T4 hazardous location ELECTRICAL System connectors pin & 24-pin Field terminals...rising cage-clamp screw terminals Conductor size mm 2 Rated voltage...50v AC Maximum current per I/O channel a Ground terminals...2 x M4 MECHANICAL DIN rail mounting... T section to EN G section to EN Weight...390g DIMENSIONS in mm CABLE OPTIONS way cable sets to connect with the 8619-FT-MT 1 metre length set fc-10 2 metre length set fc-20 3 metre length set fc TERMINAL ASSIGNMENTS CH 1 CH 2 CH 3 CH 4 CH CH CH CH GND GND EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jan 2007

Mass Termination Field Terminal and High Current Relay Output RELAY OUTPUTS 8918-FT-MT Mass Termination Connectors Save wiring time to High Current Relay Assemblies.

Each Relay includes replaceable Relay and the Din Rail Mounting Assembly Adapter connects 8 relays together in a single package.

to allow a direct cable connection to an external panel. Relay output options are available to provide up to 10A per channel. This option greatly simplifies field wiring.

150 Mass Termination Field Terminal and High Current Relay Output RELAY OUTPUTS 8918-FT-MT Mass Termination Connectors Save wiring time to High Current Relay Assemblies. Quick Connect Cable Adapter for 6 Amp or 10 Amp Relay Outputs Easy Installation, Relay comes complete and ready to snap on to DIN Rail. Each Relay includes replaceable Relay and the Din Rail Mounting Assembly Adapter connects 8 relays together in a single package. High Current Output Capability New: For discrete field devices that require more than the maximum specified current, a standard mass termination field terminal is available with a 16-pin connection to allow a direct cable connection to an external panel. Relay output options are available to provide up to 10A per channel. This option greatly simplifies field wiring. High current output capability beyond the discrete output modules specified 1 Amp per channel is provided with a mass termination assembly and a direct cable interface to 6 or 10 Amp relays. Cable: The direct connect cable comes in standard lengths of 1m and 2m. It converts the 16 pin output of an 8115 Discrete Output module to a 14 pin interface that connects directly to the relays. Additional lengths are available if required. Adapters: There are two different size adapters, one for 6 Amp Relays and a second, larger one for 10 Amp relays. These adapters provide a direct connection to the relays from the mass termination block, assuring a quick installation for higher output power. Specifications For Mass Termination Block Part No. KV Maximum current 1 Amp per Channel ( 6 Amps per Module ) 1 Amp per Cable ( 16 Pin ) Voltage Rating 30 VDC Between Non-Connected signals Max Cable Length 4 meters Key Position Set the Key to match the Discrete Output Module being Used, For Example : A1 Hazardous Area FM Approved Class I, Div 2, Groups A, B, C & D Approvals Atex 3 G IIC T4 UL US and Canada

151 Mass Termination Field Terminal and High Current Relay Output RELAY OUTPUTS 8918-FT-MT PLC Adapter for Eight 6-Amp Relays - Cable from the Mass termination unit plugs directly into the adapter which connects directly to the 8 relays, providing both a cost savings and space savings over conventional wiring approaches. Adapters (pictured below) are available for both the 6 Amp and 10 Amp relays. Choose the right output for your needs based on required current, available panel size and your budget. Relay for 6 Amp REL-MR-24DC/21 Input Data (Coil side) Nominal Input Voltage 24 VDC Typical Input Current 7mA Typical response Time 5ms Typical Release Time 2.5ms Coil resistance at 20C 3390 Ohms +/-10% Output Data Contact Type Single Contact, 1 PDT Contact Material AgSnO Max Switching Voltage 250 V AC/DC Min Switching Voltage 12 V AC/DC Continuous Current 6 A Max Inrush Current N/A Min Switching Current 10 ma Max Pwr Rating, Ohmic Load 250VAC, 1500 VA Min Switching Pwr. 120 mw PLC V8L (10 Amp Relays) Specifications Dimensions PLC-V8 (6 Amp Relays) PLC-V8L w/ 8 10A relays 112mm(w) X 80.3mm(H) X 91.25mm(D) PLC-V8L w/ 8 10A relays 4.4 in. (w) X 3.16 in. (H) X 3.59 in. (D) PLC-V8 w/ 8 6A relays 49.6mm(w) X 80.3mm(H) X 91.25mm(D) PLC-V8 w/ 8 6A relays 19.6 in. (w) X 3.16 in. (H) X 3.59 in. (D) Relay for 10 Amp REL-MR-24DC/21-HC Input Data (Coil side) Nominal Input Voltage 24 VDC Typical Input Current 17mA Typical response Time 7ms Typical Release Time 3ms Coil resistance at 20C 1440 Ohms +/-10% Output Data Contact Type Single Contact, 1 PDT Contact Material AgNI Max Switching Voltage 250 V AC/DC Min Switching Voltage 12 V AC/DC Continuous Current 10 A Max Inrush Current 30A (300ms) Min Switching Current 100 ma Max Pwr Rating, Ohmic Load 250VAC, 4000VA Min Switching Pwr. 1.2W The relays are shipped complete in the DIN Rail mounting package and are ready to snap onto the DIN Rail. 8 relays are jumpered together with the adapter providing an integrated cable assembly and an easy installation. The relays are modules that can be replaced in the DIN Rail package. The 10 Amp relays use a Plug-in Bridge to Jumper Field Power. This jumper option allows the full 10 Amps per relay continuous output at 250 VAC when used with the 10 Amp Mechanical Relay. Phoenix Miniature Series Relays Part No. Model Number Description PLC-RSC-24DC/21-HC 10 Amp Mechanical Relay 14mm(8 requir PLC-OSC-24DC/24DC/2 3 Amp Solid State Relay (8 required) PLC-RSC-24DC/21 6 Amp Mechanical Relay 6.2mm(8 Requi PLC-V8L/FLK 14/OUT Large 8 Relay Cable Adapter (10 Amp) PLC-V8/FLK 14/OUT 8 Relay Cable Adapter (6 Amp) FLK 16/14/DV OUT/100 1m 16 to 14 position cable FLK 16/14/DV OUT/200 2m 16 to 14 position cable FBST 14-PLC BK Plug-in Bridge 2 Position for 14mm PLC All relays Assemblies meet the following Certifications Hazardous Area FM Approved Class I, Div 2, Groups A, B, C & D Approvals Atex 3 G IIC T4 UL US and Canada

152

Railbus isolator Railbus isolator 8922-RB-IS provides galvanic isolation between Railbus sections prevents fault-voltage invasions protects IS field wiring modules MODULE SPECIFICATION See also

153 Railbus isolator Railbus isolator 8922-RB-IS provides galvanic isolation between Railbus sections prevents fault-voltage invasions protects IS field wiring modules MODULE SPECIFICATION See also System Specification MECHANICAL Dimensions (approx.) (w) x 160 (h) x 42 (d) mm Weight g (typ.) HAZARDOUS AREA APPROVALS Location of module......class 1, Div 2, Group A, B, C, D hazardous location or...zone 2, IIC T4 hazardous area Safe area Railbus...U m = 250 V Isolated Railbus...U n = 18 V POWER SUPPLIES Safe area Railbus supply current*.50 ma 12 V IS Railbus supply current*...60 ma 12 V Power dissipation within module W (max.) * Note: DC power for the Railbus Isolator is required from both sides of the galvanic interface. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June2004

Power supplies General Good power supply management is at the heart of the 8000 system. AC and DC power supply units are available to suit the available resources.

154 Power supplies General Good power supply management is at the heart of the 8000 system. AC and DC power supply units are available to suit the available resources. All units are designed to endure the harsh environmental conditions that are frequently found in process plants and, naturally, they meet rigorous EMC and electrical safety standards. Power supply connections are minimised and simplified to ensure that power provision requires the minimum of wiring effort 8000 series power supplies are designed to support redundancy when required. Most have health signal outputs for early warning of problems. DC system power supply The 8910-PS-DC DC input power supply provides a regulated A output from a DC input voltage range of 18.5 up to 36V. This input voltage range accommodates the typical 24 V DC supplies available on process plants worldwide. This power supply is designed to mount directly on 8711-CA-NS or 8712-CA-NS node services carriers or on a 8717-CA-PS power supply carrier. On the node services carriers mentioned here, two positions are provided. This enables a second power supply to be mounted, under conditions where the user wants to provide additional power, or where a redundant power supply is required to provide maximum system availability. DC IS module supply Power Supply module 8920-PS-DC mounts on its own carrier (8724-CA-PS) and accepts a locally available 24V dc (nominal) supply and converts it to 12V dc for powering 8000 I/O modules that have intrinsically safe field wiring. Its 5A output is capable of powering between six and twenty I/O modules, depending on the module types and their mix. A number of 8920-PS-DC modules may be used together, within an 8000 node, in a load-sharing arrangement. Where power supply redundancy is required an additional supply module may be added in an n+1 arrangement. Failure of any power supply is signalled to the Bus Interface Module. AC power supplies The 8913-PS-AC and 8914-PS-AC supplies produce DC output power from a wide range of AC inputs. Both can be mounted in a Zone 2 or Division2 hazardous area which means that they can be used for a broad range of applications including supplying power to 8000 series modules. System power The 8913-PS-AC is a dual output supply capable of producing 12 V and 24 V DC outputs of approximately 5 A. For 8000 series products, the 12 V output can be used to supply system power to the node and also provide 24 V to power field devices via the field power bussing facilities on the 8000 series carriers. Field power The 8914-PS-AC has a single 24 V DC output with a 10 A capacity. This is ideal for powering a wide range of field devices. With 8000 series products, it is normally distributed via the field power bus (see below). Load sharing A load sharing diode is built in to the 12V output of the 8913-PS-AC power supply and the 24V output of the 8914-PS-AC. This enables one or more of the same power supply type to be connected in parallel to share the load requirements. Power health signalling The 8913-PS-AC and the 8914-PS-AC supplies provide power health signals that can be routed to the BIM to warn of possible imminent power failure. The 8913 provides the power health signal from its 12 V DC output. Bussed field power (2/2 modules/carriers only) In addition to the system power supply, an 8000 node may need to be supplied with additional field power. Conventional systems require field power supplies to be wired in at the field terminals or via additional patching connectors. This adds complication to the field wiring and can be a source of confusion during maintenance work. The 8000 system overcomes this complication with a system for bussing power on the carriers. Each carrier can bus an external power supply to modules so that they can energise the field wiring. In the case of the 4-20mA Analog Input and Output modules, the bussed field power is also used to energise the field interface circuits. The connection for the bussed field power is located at the top of the carrier and uses a two-part removable connector. Individual bussed field power supplies connect to two modules. If an adjacent pair of modules require the same power supply voltage the connector can be wire-linked to provide it, otherwise a different supply voltage (AC or DC) can be connected. EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Power supplies System power supply 8910-PS-DC power for 2/2 (general purpose) node 12 V DC output 18.5-36V DC input 4.

155 Power supplies System power supply 8910-PS-DC power for 2/2 (general purpose) node 12 V DC output V DC input 4.9 A capacity supports redundancy with second supply MODULE SPECIFICATION HAZARDOUS AREA APPROVALS Location of node...safe area or...class 1, Div 2, Groups A, B, C, D T4 hazardous location or...zone 2, IIC T4 hazardous area Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations ELECTRICAL EMC compliance... To EN and EN generic emission/immunity standards Electrical safety. EN :1993 and Amendment A2:1995 OUTPUT Output voltage...12 V dc ± 5% Output current A Input-output isolation...50 V ac rms, 720 V dc...(continuous working to EN , Pollution Degree 2,...Installation Category 2) Hold-up (on i/p supply failure)...7 ms...( 40 C, full load and 22V input) Thermal protection...protected against output s/c Supply health indicator...led (fed from final output) Power-fail signal to BIM (o/p threshold) ± 2 V INPUT Input voltage V dc Efficiency (at full load) 20 V input at 3.6 A % 24 V input at 3.1 A % 36 V input at 2.1 A % Input connection...two-part, screw terminal...each connection duplicated, 2.5 mm2 max. cable cross-section Input protection...fuse + supply reversal diode Power-fail signal to BIM (i/p threshold) ± 0.5 V ENVIRONMENTAL Operating temperature (no forced ventilation) (60% of full load) C to + 70 C Optimum orientation (full load) C to + 55 C Worst case orientation (full load) C to + 50 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration Hz to BS EN and BS part 2.1 Shock...10 g, 11 ms pulse width, to BS EN C external ambient...80,000 hrs Ingress Protection...IP20 to IEC 529/BS EN (tested on power supply carrier with all supply connectors in place) Corrosive atmospheres To withstand gaseous corrosion level G3 as defined by ISA Standard SP71.04:1995, when protected by a suitable field enclosure. MECHANICAL Dimensions (approx.)...42 (w) x 110 (h) x 160 (d) mm Carrier mounting...types 8711-CA-NS or 8712-CA-NS Weight g EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

Power supplies IS module power supply 8920-PS-DC power for 2/1 (IS) modules 12 V DC output 24 V DC (nominal) input 5 A capacity supports load sharing for redundancy MODULE SPECIFICATION HAZARDOUS

156 Power supplies IS module power supply 8920-PS-DC power for 2/1 (IS) modules 12 V DC output 24 V DC (nominal) input 5 A capacity supports load sharing for redundancy MODULE SPECIFICATION HAZARDOUS AREA APPROVALS Location of power supply...safe area or...class 1, Div 2, Group A, B, C, D hazardous location...zone 2, IIC T4 hazardous area Output...Galvanically isolated...voltage clamped; Un = 18 V Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations Factory Mutual Research Co., Class No for Class I, II, III, Division 1, Groups A - G hazardous locations (IS circuits) EN 50020:1994 Electrical apparatus for potentially explosive atmospheres, intrinsic safety i EC Directive 94/9/EC (ATEX) ELECTRICAL EMC compliance... To EN and EN generic emission/immunity standards...en :1995 EN :1995 Electrical safety. EN :1993 and Amendment A2: and EN :1994 OUTPUT Output voltage...12 V dc ± 5% Output current...5 A Input/Output isolation 250 V ac rms(tested at 1500 V ac rms) ENVIRONMENTAL Operating temperature (no forced ventilation) (60% of full load) C to + 70 C Optimum orientation(full load) C to + 55 C Worst case orientation C to + 50 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration Hz to BS EN and BS part 2.1 Shock...10 g, 11 ms pulse width, to BS EN C external ambient...80,000 hrs Ingress Protection...IP20 to IEC 529/BS EN (tested on power supply carrier with all supply connectors in place) Corrosive atmospheres: To withstand gaseous corrosion level G3 as defined by ISA Standard SP71.04:1995, when protected by a suitable field enclosure. MECHANICAL Dimensions (approx.)...84 (w) x 110 (h) x 160 (d) mm Carrier mounting...type 8724-CA-PS Weight g INPUT Input voltage V dc Efficiency (at full load) 18.5 V input at 4.1 A...76% 24 V input at 3.3 A...78% 36 V input at 2.1 A % Input connection...2-part screw terminal, each duplicated Cable size mm2 (max.) EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: June 2004

157 Power supplies System Power - dual voltage 8913-PS-AC system & field power for 8000 Process I/O 12 V 5 A for system power 24 V 5 A for auxilliary power input voltage V ac or V dc Zone 2 / Div 2 mounting supports parallel connection for redundancy MODULE SPECIFICATION See also System Specification Location of power supply...safe area or...zone 2, IIC T4 hazardous area or...class 1, Div 2, Groups A, B, C, D T4 hazardous location ELECTRICAL EMC compliance...to EN ,3,4,5,6,11...EN 55011/22, EN Electrical safety...to EN INPUT Input voltage (AC) V ac Input frequency (AC) Hz Input voltage (DC) V dc Efficiency...up to 87 % Connections (Fig. 2)...2-part pluggable connector Input protection...slow-blow fuse and VDR* OUTPUTS Output V dc ± 10% Output V dc ± 5% Output 1 current (see Fig. 1)...5 A (nom.) Output 2 current...5 A Connections (Fig. 3)...2-part pluggable connector Input-output isolation V dc Hold-up time (at full rated load)...15 ms (typ.) Thermal protection...reduced output power Supply health indicator...led ENVIRONMENTAL Operating ambient temperature to +70 C Maximum operating case temperature C Storage temperature to +100 C Relative humidity...93 %, 40 C for 56 days MECHANICAL Dimensions (see Fig 4) (w) x 138 (h) x (d) mm Mounting methods...35 mm x 7.5 mm T-section DIN rail (see also Accessories overleaf) Weight g Figure 1 - Output current de-rating (24 V output only) 4 A 60 C ambient (optimum attitude - free air) 5 A POWER-FAIL SIGNALLING - Output 2 only Threshold to trigger "power-fail" signal V (max.) (min.) Power-fail signal output (open collector) Power supply "OK"...Low impedance to ve of o/p 2 Power supply "failure"...high impedance to ve of o/p 2 (Up to 8 power fail signals can be monitored by the 8510-NS- MO module when it is fitted on the 8718-CA-NS carrier.) internal load-sharing diode on 12V output only * voltage dependent resistor 3.75 A C ambient (optimum attitude - free air) Input voltage V AC Input voltage V AC A EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

Power supplies System Power - dual voltage 8913-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Figure 4 - Outline and fixing dimensions 1 2 3 Figure 2 - AC input power Terminal

158 Power supplies System Power - dual voltage 8913-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Figure 4 - Outline and fixing dimensions Figure 2 - AC input power Terminal Des. Description 1 Protective earth 2 N Input neutral 3 L Input live Output connector screw terminals ±1 Figure 3 - DC output power Terminal Des. Description 1 Protective earth 108 ± Output 1 + ve 3 + Output 1 + ve 4 Output 1 ve 24 V DC 5 Output 1 ve Output 2 + ve 7 + Output 2 + ve 8 Output 2 ve 12 V DC 9 Output 2 ve 10 Aux. Power fail signal 11 Protective earth ACCESSORIES Heavy duty DIN rail mounting kit fk-dn Surface panel mounting kit fk-su For larger amplitude vibration environments APPROVALS Authority Standards Certificate No. FM No. 3600/ TÜV EN50021 TÜV01ATEX1774X CSA Applicable standards: Factory Mutual Research Class No. 3600/3611 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Directive 94/9/EC Category 3 - II 3 G CENELEC standard EN50021:1999 EEx n A II T4 CSA International - Class EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

159 Power supplies Field power 8914-PS-AC power for wide range of Zone 2/Div 2 mounted equipment field power for 8000 Process I/O 24 V 10 A for field power input voltage V ac or V dc Zone 2 / Div 2 mounting supports parallel connection for redundancy MODULE SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of power supply...safe area or...zone 2, IIC T4 hazardous area or...class 1, Div 2, Groups A, B, C, D T4 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 for Zone 2 ELECTRICAL EMC compliance...to EN ,3,4,5,6,11...EN 55011/22, EN Electrical safety...to EN INPUT Input voltage (AC) V ac Input frequency (AC) Hz Input voltage (DC) V dc Efficiency...up to 87 % Connections (Fig. 2)...2-part pluggable connector Input protection...slow-blow fuse and VDR* OUTPUT Output...24 V dc ± 10% Output current (see also Fig.1)...10 A (nom.) Connections (Fig. 3)...2-part pluggable connector Input-output isolation V DC Hold-up time (at full rated load)...15 ms (typ.) Thermal protection...reduced output power Supply health indicator...led POWER-FAIL SIGNALING Threshold to trigger "power-fail" signal V (max.) V (min.) Power-fail signal output (open collector) Power supply "OK"...Low impedance to ground Power supply "failure"...high impedance to ground (Up to 8 power fail signals can be monitored by the 8510-NS-MO module when it is fitted on the 8718-CA-NS carrier.) ENVIRONMENTAL Operating ambient temperature to +70 C Maximum operating case temperature C Storage temperature to +100 C Relative humidity...93 %, 40 C for 56 days MECHANICAL Dimensions (see Fig 4) (w) x 138 (h) x (d) mm Mounting methods...35 mm x 7.5 mm T-section DIN rail (see also Accessories overleaf) Weight g Figure 1 - Output current de-rating 8 A 7.5 A 60 C ambient (optimum attitude - free air) C ambient (optimum attitude - free air) 85 Input voltage V AC 165 Input voltage V AC A 10 A *voltage dependent resistor EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

Power supplies Field power 8914-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Figure 4 - Outline and fixing dimensions 1 2 3 Figure 2 - AC input power Terminal Des.

160 Power supplies Field power 8914-PS-AC continued TERMINAL ASSIGNMENTS Input connector screw terminals Figure 4 - Outline and fixing dimensions Figure 2 - AC input power Terminal Des. Description 1 Protective earth 2 N Input neutral 3 L Input live Output connector screw terminals ±1 Figure 3 - DC output power Terminal Des. Description 1 Protective earth 108 ± Output + ve 3 + Output + ve 4 Output ve 5 Output ve Output + ve 7 + Output + ve 8 Output ve 9 Output ve 10 Aux. Power fail signal 11 Protective earth ACCESSORIES Heavy duty DIN rail mounting kit fk-dn Surface panel mounting kit fk-su For larger amplitude vibration environments APPROVALS Authority Standards Certificate No. FM No. 3600/ TÜV EN50021 TÜV01ATEX1774X CSA Applicable standards: Factory Mutual Research Class No. 3600/3611 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Directive 94/9/EC Category 3 - II 3 G CENELEC standard EN50021:1999 EEx n A II T4 CSA International - Class EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Jul 2005

Power Supplies Node Services Power Supply Monitor for 8521 Controllers 8410-NS-PS power supply status monitoring signals supply failure(s) monitors all 2/2 and 2/1 power supplies Zone 2/Div 2

161 Power Supplies Node Services Power Supply Monitor for 8521 Controllers 8410-NS-PS power supply status monitoring signals supply failure(s) monitors all 2/2 and 2/1 power supplies Zone 2/Div 2 mounting mounts on 8750-CA-NS carrier The Power Supply Monitor can monitor the health of supplies powering an 8000 node and signal the controller/ebim in the event of one, or more, of them failing. The module can receive power supply status signals from up to six external supplies and can also monitor the status of 8920-PS-DC supplies which power the intrinsically safe (2/1) I/O modules. Where power supply redundancy is employed, the module enables failed power supplies to be identified and replaced without interference to the process. The module itself may be removed and replaced in a Zone 2/ Div 2 hazardous area without gas clearance. MODULE SPECIFICATION See also System Specification HAZARDOUS AREA APPROVALS Location of monitor module...safe area or...zone 2, IIC T4 hazardous area...or Class 1, Div 2, Groups A, B, C, D T4 hazardous location Applicable standards: Factory Mutual Research Co., Class No for Class I, Division 2, Groups A, B, C, D hazardous locations CSA Std C22.2 No. 213 for Class I, Division 2, Groups A, B, C, D hazardous locations ATEX Category 3 (for Zone 2 installation) to EN50021:1999 protection type n ENVIRONMENTAL Ambient temp Operating, C to + 70 C Storage C to + 85 C Relative Humidity...5 to 95% RH (non-condensing) Vibration and Shock...See System specification MECHANICAL Mounting method...(captive x2) screw fixing Weight (approx.)...75 g DIMENSIONS (MM) INPUTS (VIA CARRIER) Number of inputs From external 2/2 power supplies...6 Via Railbus from 8920-PS-DC power supplies...1 Power supplies "OK"...low impedance to ground Power supply "failure"...high impedance to ground ELECTRICAL Railbus (12V) current...5 ma (typ.)...10 ma (max.) LED INDICATOR PWR (i.e. Railbus supply present) 89 Power ON indicator EUROPE (EMEA) Tel: +44 (0) Fax: +44 (0) AMERICAS Tel: Fax: ASIA PACIFIC Tel: Fax: enquiry@mtl-inst.com Web site: Feb 2003

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163 PAC8000 Workbench Configuration Guide

164 Contents PAC8000 Workbench Overview...3 Basics for Quoting the PAC8000 Workbench...3 Choose the Controllers... 3 I/O Points Required... 4 Serial BIMs...5 Disaster Recovery... 5 GlobalCare...5 PAC8000 Workbench Part Numbers...6 PAC8000 Workbench without GlobalCare

165 Title 1 PAC8000 Workbench Overview The PAC8000 Workbench is the configuration and programming software for the PAC8000 Controllers and Ethernet Bus Interface Modules (EBIMs). It provides our customers with the software necessary to configure the I/O modules, build control logic in process function blocks as well as the IEC languages, and then download and troubleshoot the logic in either a process simulator or the controller hardware. The PAC8000 Workbench is sold based on I/O counts. More details on I/O count definitions will be given later in this guide. The Workbench can also be sold as either a standalone component or as part of a PPS system. Basics for Quoting the PAC8000 Workbench To quote the PAC8000 Workbench there are some basic things you will need to know about your customer s application. The key information is the type of controllers that will be used as well as the amount of I/O that will be included in the project. Note that a project may contain more than one controller and the Workbench can be used for multiple projects, so you need to understand the size of the maximum project the customer will want to configure in the Workbench. Choose the Controllers The PAC8000 Workbench supports different controller types: The Hybrid Controller allows the customer to write logic in both Advanced Function Blocks (PID and Motor Control) as well any of the IEC languages. The Process Controller allows the customer to write logic in Advanced Function Blocks (PID and Motor Control) but NOT the IEC languages. The Logic Controller allows the customer to write logic in the IEC Languages, but NOT the Advanced Function Blocks (PID and Motor Control). The EBIM is a remote I/O interface and supports no programming languages. The SafetyNet controller is SIL2 certified and support writing logic in a reduced set of the IEC languages. 3

166 Thus, the languages supported by the various controller types are: Controller Type Languages Supported Adv. Function Blocks IEC Hybrid X X Process X Logic X Ethernet BIM SafetyNet X Workbenches licenses exist for each of the above controller types. Note, though, that a Hybrid Workbench can be used to configure any controller type EXCEPT SafetyNet while a SafetyNet and Hybrid Workbench can configure any controller type. A Process Workbench can only configure Process Controllers. Similarly a Logic Workbench can only configure Logic Controllers and an Ethernet BIM Workbench can only configure EBIMs. However, any Workbench type can be used to configure the EBIM. The types of Workbenches and the controllers they can be used to configure/program are as follows: Workbench Type Supported Controller Types Hybrid Process Logic EBIM SafetyNet Hybrid X X X X Process X X Logic X X Ethernet BIM X SafetyNet Logic X X SafetyNet Logic & Hybrid X X X X X Runtime Edition DL DL DL DL DL where DL indicates download only capability. I/O Points Required The Workbench is sold based on the maximum number of I/O points that will be configured in a project (one or more controllers). Three (3) different I/O count options are offered: 3000, 5000, and Note that this I/O point count DOES NOT apply to SafetyNet only Workbench. However, there are versions of the Workbench that include SafetyNet as well as an I/O count limited version of the standard Workbench. The definition of an I/O point in the Workbench is a physical I/O point wired to an 8000 Process I/O module; internal and other non-i/o module tags are not counted. 4

167 Serial BIMs If the customer requires a serial BIM, then a configuration cable is required in addition to the standalone I/O Configuration software that is included on the PAC8000 Workbench CD. The cable can be ordered separately, or as part of a bundle that includes both the software and the cable. In terms of the I/O counts, a serial BIM does not count toward the total I/O used in a project. Note also that if only serial BIMs are required, there is no need to buy the Workbench. In such cases the 8000 Process I/O Configuration Software is sufficient. Disaster Recovery There is a Workbench available to program each controller type; however, there are times when a customer may not possess the Workbench. This is usually when an integrator has created and installed the application for the customer and does not want the customer making changes. However, the customer may need to troubleshoot logic or download an existing program if problems arise. The Workbench Runtime Edition is available to fill this need. GlobalCare GlobalCare is automatically added to the quote/order by the system based on the customer s current GlobalCare contract. 5

168 PAC8000 Workbench Part Numbers PAC8000 Workbench without GlobalCare Part Numbers Part Description I/O Configuration Software 8455-SW-CF 8000 Process I/O Configuration Software (Serial cable included) 8456-SW-CF 8000 Process I/O Configuration Software (Software only) 8460-CA-CF 8000 Process I/O Configuration Cable Hybrid Workbench 8459-HC-30 Hybrid Workbench 3000 I/O 8459-HC-50 Hybrid Workbench 5000 I/O 8459-HC-00 Hybrid Workbench I/O Process Workbench 8459-PC-30 Process Workbench 3000 I/O 8459-PC-50 Process Workbench 5000 I/O 8459-PC-00 Process Workbench I/O Other Workbench 8459-LC-MT Logic Workbench 8459-EB-MT Ethernet BIM Workbench 8459-RT-MT Workbench Runtime Edition SafetyNet Workbench 8841-LC-MT SafetyNet Logic Workbench 8841-HC-30 Hybrid Workbench 3000 I/O plus SafetyNet 8841-HC-50 Hybrid Workbench 5000 I/O plus SafetyNet 8841-HC-00 Hybrid Workbench I/O plus SafetyNet 6

170

171 GE Intelligent Platforms PAC8000 Hybrid Workbench Powerful software for advanced control strategies PAC8000 Strategy Builder for process control applications IEC software for logic control applications Project management tools Network configuration & administration Tagname-based configuration - simplifying system configuration Auto-tagname generation Control strategy development and simulation tools Online configuration and reconfiguration Peer to peer communications Remote data table for mapping Modbus devices Import/export utilities and reports Project back-up and restore 8459-HC-MT Overview The PAC8000 Hybrid Workbench is an integrated project development environment used to create executable program files for download to a PAC8000 Hybrid, Process or Logic Controller, or to configure an 8000 Process I/O Ethernet BIM (EBIM). It is the most comprehensive of all of the Workbench tools as it combines the full functionality of the PAC8000 Process Control and PAC8000 Logic Control Software in a single development tool. The Workbench is used to centralize project engineering by enabling a user to create an instrument index, coordinate I/O database configuration and control strategy development. It configures the control logic and generates an export database to create the operator (HMI) database. It also provides a clientserver implementation that enables multiple engineers to work on the same project. PAC8000 Process Control PAC8000 Process Control software is an open, easy-to-use process control engineering and management solution that delivers comprehensive, distributed control functionality. PAC8000 Process Control is a fully integrated advanced process control and instrument engineering system offering configuration tools, modeling, simulation, troubleshooting utilities, project drawing management and self-documentation. It is a robust solution that provides the flexibility to configure control systems ranging from a few loops to thousands of points. A flexible, scalable design allows cost effective system expansion. In addition, the system's extensive use of industry standards simplifies integration with other applications. PAC8000 Logic Control PAC8000 Logic Control software is the complete tool kit for creating IEC programs. The Workbench fully supports the five IEC automation languages - Ladder Diagram (LD), Sequential Function Chart (SFC), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL) - plus Flow Chart and is used to develop, download, simulate, debug, monitor, and edit application programs. PAC8000 Logic Control lets you mix programming languages in the same project. Its true Windows interface will guide you through development of your project. The Workbench Simulator will test your programs before startup. Then use the Workbench to dynamically view programs as they run in real-time and make changes on-the-fly. PAC8000 Ethernet BIM (EBIM) In a PAC8000 Control system, an Ethernet BIM (EBIM) system can be used as remote I/O to a PAC8000 system controller. In this case, all remote EBIM nodes would be configured as if part of a local I/O system, providing a single integrated configuration of all I/O nodes in the system, whether local or remote. In keeping with its ability to maintain operations on a continuous basis, a redundant EBIM is also capable of receiving a firmware upgrade while in the field. The Workbench provides all the necessary tools to support the PAC8000 Ethernet BIM. I/O Configurator The I/O Configurator is a flexible tool that can communicate directly with the I/O modules. It has a number of functions, ranging from updating the module firmware, through providing the user with indepth information about the hardware, to setting up the conditions the user will require of the system if the equipment has to go into failsafe mode. Microsoft Windows Environment Designed using a Microsoft Windows Explorer paradigm, the Workbench provides a powerful and flexible framework that significantly reduces project implementation and maintenance costs. In addition to working with an easy-to-use hierarchy of objects and folders, capabilities such as drag-and-drop, right mouse click support and context sensitive help inherent within the Workbench make developing, testing and maintaining automation projects easy and straightforward. The Workbench also provides system-wide security allowing for multiple levels of access to the control system.

PAC8000 Hybrid Workbench The PAC8000 Hybrid Workbench is an integrated project development environment that centralizes and coordinates project engineering including instrument index, I/O database

172 PAC8000 Hybrid Workbench The PAC8000 Hybrid Workbench is an integrated project development environment that centralizes and coordinates project engineering including instrument index, I/O database configuration and control strategy development. It is a clientserver implementation allowing multiple engineers to work on the same project. In addition to the extensive control software, the Workbench also provides significant tools for your control system, including I/O Configurator, Program Compiler, Downloader, Remote Data Table Builder for Modbus, Tag Builder, Network Configurator and a Peer-to-Peer table builder. With this extensive range of tools, the Workbench is much more than a development system, it also provides overall system management. Comprehensive tools The PAC8000 Hybrid Workbench provides process and IEC programming for regulatory and discrete control HC-MT Applied Systems Technologies' Cornerstone Software or Emerson's Asset Management Software. Network configuration tool The Workbench's Network Configuration Tool can be used to configure your entire plant network, setting up and maintaining TCP/IP addresses for all devices on the network. After the network is setup, the Workbench is used to monitor and maintain the devices on the network. Each controller, including redundant controllers, needs IP addresses, MAC addresses and node numbers. If the MAC addresses are unknown, they can be found through the Network Configuration tool. Then the Network Configurator can be used to manage the assignment of IP addresses to the controllers. It also provides additional information about each controller that has been configured, such as whether it is a single or redundant controller and the status of both Ethernet LANs. Tagname based system All variables are referred to by tagname, providing a descriptive reference to all variables throughout the system, replacing the need to reference register addresses. The Logic Workbench models a process system input/output with the assignment of module and point destinations. Using a predetermined template, this task is accomplished as a simple "fill in the blanks" procedure and builds the project I/O configuration database. Tag import utility The Tag Import Utility can be used to import a tag list that is already defined in a spreadsheet format. The utility imports a.csv, tab or space separated file directly into the Workbench, saving the need to manually recreate this information if it already exists. The Workbench configures the control strategy or logic and generates an export table that is used to create the operator interface database for all popular HMI packages. The system eliminates expensive, laborious and sometimes error-prone manual engineering work typically required during control projects. Manual generation of bill of materials, control strategy diagrams, and operator interface requirements are abolished. Repetitive programming of control strategies for advanced control is no longer necessary. Similarly, eliminating the repetitive input of system information significantly reduces errors and configuration time. All Workbench activity is centered on a project(s) that is created to address a control need. Controllers are selected and assigned to the project after it has been created. PAC8000 Hybrid Control enables you to remotely manage HART based field instruments. PAC8000 controllers can pass HART information from smart field devices to a separate PC workstation running asset management software, such as Peer to peer capability The peer-to-peer capability allows data from a controller to be used on the network. This takes advantage of the high-speed peer-to-peer communications of the Ethernet network, resulting in more efficient control processing. Peer-to-peer data is setup with tag name assignment, with the tag names being available to all controllers on the network. Assigning peer-to-peer data is easy, all you need to do is simply drag and drop Tagnames from another project or controller to the current controller. Standardized reports All databases are MSDE (Microsoft Data Engine) databases, which are fully SQL compliant and can be readily shared throughout the system. This design enables many standardized reports to be readily generated, including a list of Assigned I/O, Available I/O, Unassigned Points, Factory Acceptance Test status, Point Overview report that lists transducer information for all the tags in the systemtagname for HMI (which returns the information located on the HMI tab of the Project Tags window) and Tagname Index (which returns the information located on the I/O Definition tab of the Project Tags). These reports simplify the overall management of the project.

173 PAC8000 Hybrid Workbench I/O Configurator I/O modules connected to a controller must be configured to permit operation. The controller needs to be told the identity of each I/O module fitted and values of relevant parameters. Modules are added by a simple drag and drop process. Each module has its own set of parameters and these appear with default values when the module is first added to the system. These can then be edited individually to specify the required values and then tagnames are assigned to each I/O point. Failsafe values can be defined to assure that the modules operate safely if there is a system interruption HC-MT Dynamic data Real-time data is available on-screen. The viewable data includes primary variables as well as status parameters. This can be refreshed continually or when the operator requires a screen refresh. Configuration upload Configuration data already contained in a controller can be uploaded to the Workbench. This can be saved as a PC file and copied to other Controllers. PC files that were created for earlier reversions of the controller firmware can also be opened and edited for use with the latest versions of the controller. Simple tabbed pages The right hand side of the screen contains information on any item that is highlighted in the navigation tree to the left. For example, with the network icon selected, three tabbed pages of information are available. These pages define and describe the network protocol, the controllers that are attached to the network and the details of the project contained in the overall configuration file. Remote data table builder for Modbus import The remote data table is used for connecting to remote Modbus master or Modbus slave devices. Tagnames are assigned to these devices, which are then included in the control strategy. An example of a remote Modbus device is a Modbus TCP compliant H1 Linking device that could be used to bring Foundation Fieldbus H1 data into the control system. The Control System Each downloaded application is a complete distributed application running on the target controller. Multiple applications, running on separate controllers, can be linked together using the peer-to-peer tool, which identifies tagnames for use across the network. This data exchange mechanism provides a very efficient way of sharing information between multiple controllers. Project backup and restore You can create a backup file of your project at any time. This useful feature enables you to save your application in a known state, and if necessary, restore the project to that state. You can import and export resources from one project to another, enabling you to re-use prior work. If the results of importing or exporting resources are unsatisfactory, you can choose to restore the project. Downloader The Workbench Downloader is used to download the firmware and control strategy to the controller. With Redundant Controllers, strategy changes can be downloaded to a backup controller without disrupting control in the primary controller. When the download is complete, the backup controller will take over control and update the primary controller with the changes. Control can revert back to the primary controller after these changes are incorporated. Downloading to a simplex controller can be done on-line and without initializing data, the new strategy starting on the next execution cycle.

PAC8000 Hybrid Workbench PAC8000 Process Control Software PAC8000 Process Control Software consists of two integrated components; the Instrument Index and the PAC8000 Strategy Builder.

174 PAC8000 Hybrid Workbench PAC8000 Process Control Software PAC8000 Process Control Software consists of two integrated components; the Instrument Index and the PAC8000 Strategy Builder. Instrument Index The Instrument Index is used to model the process system s input/output by assigning controller, module and point destinations. Using a predetermined template, this task is accomplished as a simple "fill in the blanks" procedure. The Instrument Index uses this information to build the I/O configuration data file. This data file will subsequently be used to cross-link the point attributes to the algorithms on the process control diagrams. PAC8000 Strategy Builder Process control logic diagrams are developed using the PAC8000 Strategy Builder. The control strategy is built by selecting the appropriate blocks, assigning symbolic tags, and then connecting the blocks with analog or digital lines, using standard drawing forms and commands. SAMA style drawings define all the functions and parameters that generators, pulse controllers, sequencers, bumpless transfers, PID and other standard function blocks. To further reduce development time template diagrams can be created and reused within the current project or another future project. For example, a cascade loop can be created and saved for repetitive use to generate additional control loops. When the drawing model is completed, the project diagrams are cross-linked with the I/O database to create: Comprehensive control system engineering documentation. Advanced control strategies. Operator interface database, alarms and faceplates. System maintenance tools. There is no need to review function block codes, re-enter tags, generate spare parts listings, or match control logic to the operator interface. This allows the user to concentrate on designing control strategies and eliminate the repetitive tasks. Project Components In addition to these key design features, PAC8000 Process Control has a wealth of tools and features that simplify the 8459-HC-MT management of the project and provide easy to use interfaces for the user. Comprehensive Self-Documentation PAC8000 Process automatically generates as-built system documentation including I/O configuration reports, cross reference analysis, bill of materials, instrument index, system start-up, maintenance information, and wiring diagrams. The instrument index provides instrument details such as manufacturer, model number, group number, shift and day log, panel wiring information including panel in/out terminal block and panel in/out position, and field wiring information including cable color, size and type. Advanced Control Strategies The system automatically configures control solutions from straight-forward single loops to advanced control strategies. PAC8000 Process Control algorithms provide the logic and analytic functions for complex control strategies such as feed forward, cascade, and multivariable control. Functions are provided for easily configuring biased multi-output loops as found in steam and water header pressure control. The system automatically accounts for different device capacities, devices in service, and devices in automatic mode. Adaptive tuning functions for PID control is supported. Two and three state device drivers provide the functionality for motor and valve operations with failure alarms, local and remote operation, and interlocks. Sequential step functions with interlocks and first out functionality are easily configured. The system provides I/O and point alarm status. On-line Maintenance, Tuning and Troubleshooting Savings in time and system costs are not limited to initial development and start-up. The system provides suggestive tuning capabilities, on-line and off-line control configuration, and intelligent control schematics from which the system can be modified and tuned. PAC8000 Process Simulator The PAC8000 Process Simulator allows the animation of control diagrams with either simulated data or live, real-time process data. The Simulator is also used for tuning and operator control purposes. I/O diagnostic tags are provided for the operator interface for troubleshooting assistance. Verification of control loop integrity and troubleshooting loop problems can be accomplished quickly and efficiently.

PAC8000 Hybrid Workbench PAC8000 Logic Control Software IEC 61131-3 languages PAC8000 Logic Control Software is 32-bit software for distributed control applications.

175 PAC8000 Hybrid Workbench PAC8000 Logic Control Software IEC languages PAC8000 Logic Control Software is 32-bit software for distributed control applications. It supports all five IEC languages: Ladder Diagram (LD), Structured Text (ST), Instruction List (IL), Sequential Function Chart (SFC) and Function Block Diagram (FBD), plus the Flow Chart (FC) language. The workbench is used initially to create and edit the control code and may also be used later for simulation, debugging and on-line monitoring. The code created in the workbench is then downloaded to the PAC8000 Controller HC-MT The Flow Chart is an easy to read decision diagram where actions are organized in a graphic flow. The Flow Chart Editor has full support for connectors and sub-programs. Function Block Diagram (FBD) is a graphical language which allows the user to build complex procedures by taking existing function blocks from the Workbench library, and wiring them together on screen. The FBD editor allows manual input of variables. The diagrams can be zoomed to view the whole diagram or specific areas in more detail. User can mix LD and FBD programming in the same chart. The development process begins with the division of a project into several PLC Loops, also called Resources, identifying their host hardware platforms, and defining the links between them. The physical division of a project is represented by configurations and communications networks. A Configuration represents a hardware platform which contains a single resource. Language options The Ladder Diagram (LD) is one of the PAC8000 familiar methods of representing logic equations and simple actions. Contacts represent input arguments and coils represent output results. Each block in the selection list has a description text. Program development process A resource contains several programming units called Program Organization Units (POUs). POUs can be programs, functions or function blocks. Programs can be described in any of the five IEC languages plus Flow Chart. Linking variables to I/O channels Before defining the project code, the I/O is defined in the Workbench in the form of a tag database, which identifies the I/O channels and their respective field devices. Once a device is selected, a simple mouse-click 'connects' a variable to a channel. The Build To validate the project, the project code must be built. This step is also very useful for syntax checking; all detected errors can be easily located with a simple mouse-click. The generated code is fully publicly documented supported. The code generator produces the code for each resource. The Structured Text (ST), is a high level structured language with a syntax similar to Pascal but more intuitive to the automation engineer. This language is mainly used to implement complex procedures that cannot be easily expressed with graphical languages. The ST text editor guides the user to the correct syntax and punctuation and provides the best validation and programmer assistance facilities. The Sequential Function Chart (SFC) language divides the process cycle into a number of well-defined steps, separated by transitions. The Workbench fully supports graphical Function Chart programming, which is familiar to many engineers. The Instruction List (IL) is a low-level language, similar to the simple textual PLC languages. IL is a register-level programming language. PAC8000 Logic Control has a set of more than 60 IEC functions and function blocks. Users can enlarge this set by writing functions and function blocks in the LD, FBD, ST, and IL languages. Logic Control Strategy Simulation Simulation enables the project code to be tested without the need for any hardware to be attached. Each resource can be executed cycle by-cycle, and various system variables, such as the cycle time, can be monitored or forced. For debugging with real platforms, or to perform maintenance operations on 'live' systems, changes can be downloaded on-line without stopping the running resources. During the testing phase I/O devices can be set as virtual, if the PAC8000 Controller is not completely ready or is unavailable to the programmer. Function block instances can be directly debugged from editors. The configuration manager and virtual machine are launched and a Simulate I/Os panel is displayed. The Simulation Mode can be started from the Project Manager or from a programming language editor. The workbench is intuitive and user-friendly, but to further assist the user, an HTML-based cross-referenced on-line help system is provided, which includes a complete language reference. The Workbench also offers a document generator. Project items are shown as a tree, the table of contents of the project documentation can be customized by a simple click on each item.

GE Intelligent Platforms PAC8000 RTU

GE Intelligent Platforms PAC8000 RTU A ruggedized, reliable RTU PAC8000 Remote Terminal Unit (RTU) thrives in the desert heat of the Arabian Peninsula and the arctic cold of Siberian oil fields delivering