ControlNet Ex

Media
1797-series

Planning and Installation

Manual
Important User Information Solid state equipment has operational characteristics differing from those of
electromechanical equipment. Safety Guidelines for the Application,
Installation and Maintenance of Solid State Controls (Publication SGI-1.1
available from your local Rockwell Automation sales office or online at
http://www.ab.com/manuals/gi) describes some important differences
between solid state equipment and hard-wired electromechanical devices.
Because of this difference, and also because of the wide variety of uses for
solid state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is
acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for
indirect or consequential damages resulting from the use or application of
this equipment.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with
any particular installation, Rockwell Automation, Inc. cannot assume
responsibility or liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to
use of information, circuits, equipment, or software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without
written permission of Rockwell Automation, Inc. is prohibited.
Throughout this manual, when necessary we use notes to make you aware of
safety considerations.

Identifies information about practices or circumstances

WARNING
that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property
damage, or economic loss.

Identifies information that is critical for successful

IMPORTANT
application and understanding of the product.

Identifies information about practices or circumstances

ATTENTION
that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
• identify a hazard
• avoid a hazard
• recognize the consequence

SHOCK HAZARD Labels may be located on or inside the equipment (e.g.,

drive or motor) to alert people that dangerous voltage may
be present.

BURN HAZARD Labels may be located on or inside the equipment (e.g.,

drive or motor) to alert people that surfaces may be
dangerous temperatures.
 Table of Contents
Preface What’s in This Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Abbreviations and Symbols . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Common Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Chapter 1
Overview of the ControlNet Ex What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 1-1
Media System Understand the ControlNet Ex Media System . . . . . . . . . . . 1-2
Understand ControlNet Ex Components . . . . . . . . . . . . . . . 1-4
Nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Trunk Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Cable Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Trunk Terminator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tap Terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Segments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fiber Repeater Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Insulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
ControlNet Ex System Installation Requirements . . . . . . . . . 1-9
Certified Equivalent ControlNet Ex System Components 1-10
UL, cUL I/O Entity Parameters and Requirements . . . . . 1-11
European Community Directive Compliance . . . . . . . . . 1-12
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Ex Directive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
What Is Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2
Plan a ControlNet Ex Media What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 2-1
System Determine How Many Taps You Need. . . . . . . . . . . . . . . . 2-2
Connect Programming Devices in Safe Areas . . . . . . . . . . . 2-3
Coax Cable Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Fiber Media Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Determine Trunk Cable Section Lengths. . . . . . . . . . . . . . . 2-4
Determine Trunk Cable Section Length When
You Use a FLEX Ex Redundant ControlNet
Barrier Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Estimate Fiber Media Lengths . . . . . . . . . . . . . . . . . . . . . . 2-7
Determine How Many Trunk Terminators You Need . . . . . 2-7
Determine What Type of Connectors You Need . . . . . . . . . 2-8
Use Redundant Media in a Hazardous Area . . . . . . . . . . . . 2-10
Application Considerations . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Understand Conductor Categories. . . . . . . . . . . . . . . . . 2-13
General Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . 2-14
Ferrite Beads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Required Ferrite Beads . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Add Ferrite Beads . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

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Table of Contents ii

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

General Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Plan a Segment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Plan Your Network . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
What Is Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

Chapter 3
Install a ControlNet Ex Media What This Chapter Contains . . . . . . . . . . . . . . . . . . . . . . . 3-1
System Install the Trunk Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Wire External to Enclosures . . . . . . . . . . . . . . . . . . . . . 3-1
Wire Inside Enclosures. . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mount the Taps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Select Where to Mount the Taps . . . . . . . . . . . . . . . . . . 3-2
Mount the Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Install Fiber Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Installation in Zone 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Electrostatic Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Select a Fiber Repeater Hub Mounting Location . . . . . . 3-8
Mount the Fiber Repeater Hub . . . . . . . . . . . . . . . . . . . 3-9
Connect the Fiber Repeater Hub to a ControlNet
Ex Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Install Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Collect Your Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Strip the Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Test for Electrical Shorts and Continuity Between the
Center Conductor and the Shield . . . . . . . . . . . . . . . . . 3-19
Attach the Connectors to the Cable. . . . . . . . . . . . . . . . 3-20
Test for Electrical Shorts and Continuity Between the
Connector Body and Pin . . . . . . . . . . . . . . . . . . . . . . . 3-24
Connect Cable Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Terminate Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Connect Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Install the 1797-BCNR Module . . . . . . . . . . . . . . . . . . . . . . 3-28

Appendix A
Mounting Dimensions What This Appendix Contains . . . . . . . . . . . . . . . . . . . . . . A-1
Tap Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Universal Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . A-2

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 Table of Contents iii

Appendix B
Adjust the Cable Strip Tool What This Appendix Contains . . . . . . . . . . . . . . . . . . . . . . B-1
Calibrate the Cutting Blades. . . . . . . . . . . . . . . . . . . . . . . . B-1
Reverse and Replace the Cutting Blades. . . . . . . . . . . . . . . B-3
Change the Memory Blade Holder . . . . . . . . . . . . . . . . . . . B-5

Appendix C
Protect Your System Against
Electrostatic Discharge

Index

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 Preface

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

This manual targets the configurion of a ControlNet Ex system.

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

Some configurations on a standard ControlNet system may not be

possible within a ControlNet Ex configuration. Many of the installation
methods and equipment for the ControlNet Ex system is the same as
those available for the ControlNet system. However, some differences
do exist. As you use this manual, note these differences.

The following tables describe where specific information is found in

this manual.

For See Chapter

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

For See Appendix

Mounting dimensions (taps, universal mounting A
bracket, and repeater)
Adjusting the cable strip tool B
Protecting your system against electrostatic discharge C

ATTENTION You must have fundamental knowledge about

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

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Preface 2

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

This Means
PVC cable polyvinyl chloride cable
FEP cable fluorinated ethylene propylene cable
PLC processor Allen-Bradley programmable logic controller
network continues (other nodes not shown)

Common Techniques We use the following conventions throughout this manual:

• bulleted lists indicate information, not procedural steps

• numbered lists indicate sequential step

TIP This symbol identifies helpful tips.

For More Information For more information, refer to the following:

• Electronic Data Sheets:

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

• RSNetWorx and RSLinx Software Demos and Tutorials

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 Chapter 1

Overview of the ControlNet Ex Media System

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

For Information On See Page

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

This system is an intrinsically-safe system specifically designed for use

in hazardous areas.

TIP For information on installation requirements for

hazardous areas, refer to NFPA 70 (National Electrical
Code NEC), Article 500.

TIP This publication describes how to plan and install a

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

• CNET-IN002, ControlNet Coax Media Planning

and Installation Manual

• CNET-IN001, ControlNet Fiber Media Planning

and Installation Manual

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

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

For information on installing ControlNet media in a hazardous area,

refer to the ControlNet Coax Media Planning and Installation Manual,
publication CNET-IN002.

Use the following figures and term definitions to understand the

ControlNet Ex media system

Figure 1.1 ControlNet Coax to Fiber system for FLEX Ex

Safe Area Hazardous Area

Coax Segment Coax Segment

T T T T T T T T T
Trunk Cable
Trunk Cable H H
N N N N N N N
Network
Coax (1786) Fiber Hubs
Ex (1797) Fiber Hubs
Fiber Segment

41326

Term Means
Network • A collection of connected nodes
• A collection of nodes with unique addresses in the range of 1-99
• The connection paths between any pair of devices may include repeaters and bridges.
Segment • Trunk cable sections connected via taps with terminators at each end and with no
repeaters.
Trunk Cable • The bus or central part of a media system
Trunk Cable Section • A length of a cable between any two taps
Fiber Repeater Hub • Consists of a fiber repeater and fiber adapter
H • The components reconstruct and retransmit all traffic on one fiber or coax segment
side to another coax or fiber segment side.
Tap • The connection between any device and the ControlNet Ex or ControlNet media
system
T

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Term Means
Node • Any physical device connecting to the ControlNet Ex or ControlNet media system that
requires a network address to function on the network
N
• A network may contain a maximum of 99 nodes
• This address must be in the range of 1...99 and be unique to that network.
Trunk Terminator • A 75 Ω resistor mounted in a BNC plug

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

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

Repeater • A device that connects two or more segments together

You can also use the 1797-BCNR FLEX Ex Redundant ControlNet

Barrier Module to interconnect between ControlNet coax and
ControlNet Ex networks. This module provides an alternative to
installing ControlNet Ex fiber repeater hubs.

Figure 1.2 ControlNet Coax barrier system for FLEX Ex

1797-BCNR
Safe Area Hazardous Area
Coax Segment Coax Segment

T T T B T T T T T
Network Trunk Cable
Trunk Cable
N N N N N N N

41326

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

information.

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1-4 Overview of the ControlNet Ex Media System

Understand ControlNet Ex The ControlNet Ex media system is comprised of these components:

Components • Nodes
• Taps1
• Trunk cable1
• Cable connectors1
• Terminators1
• Segments
• Fiber repeater hubs (option)1
• Tap terminator
• Network
• Insulators
• Coax barrier (option)1
1
For information about purchasing these components see the Allen-Bradley ControlNet Media
Component List, publication AG-PA002.

Nodes

Nodes are defined as physical devices connected to the ControlNet Ex

media system that require a network address to function on the
network.

T T T T

N N N N

40953

Taps

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

T T T T

N N N N

Drop Cable 40944

1 m (39.6 in.)

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 Overview of the ControlNet Ex Media System 1-5

There are four styles of taps available with:

• T or Y placement of BNC connectors

40955
T-tap Y-tap

• Straight or right-angle connector on the drop media

Straight Right-angle 40956

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

See page 2-2 for detailed information on taps.

Trunk Cable

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

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

ATTENTION
You must use either of these types of ControlNet Ex
trunk cable:
• 1797-RG6, Belden 3092A
• Belden 3092A blue quad-shield RG-6 type coax
cable

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Cable Connectors

Use a cable connector (cat. no. 1786-BNC) to attach coax trunk cable
sections to the tap’s BNC connector.
T T T T

Trunk Cable
N N N N 40957

Optional Connectors

Rockwell Automation also offers optional cable connectors for use in

your network configuration. See page 2-8 for available connectors.

Trunk Terminator

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

each end of a segment.
T T T T

Trunk Cable
N N N N
40958

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

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 Overview of the ControlNet Ex Media System 1-7

Tap Terminator

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

taps.

Segment
1797-TCAP T T T T
Trunk Cable

N N N

40959

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

Segments

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

terminators.
Segment

T T T T

Trunk Cable
N N N N
40959

The total allowable length of a segment depends upon the number of

taps in your segment and the coax cable type used.

See page 2-1 for detailed information.

Fiber Repeater Hubs

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

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1-8 Overview of the ControlNet Ex Media System

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

Safe Area Hazardous Area

Coax Segment Coax Segment

T T T T T T T T

Trunk Cable H H
N N N N N N

Coax (1786) Fiber Hubs Ex (1797) Fiber Hubs 41327

Fiber Segment

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

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

Network

A ControlNet network is the collection of connected segments, fiber

repeater hubs, and nodes.

Insulators

The ControlNet Ex media system must maintain isolation from ground.

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

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

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 Overview of the ControlNet Ex Media System 1-9

Two insulator kits are available:

• Catalog number 1797-BOOT provides standard BNC trunk cable

insulators.
• Catalog number 1797-INS provides a variety of the preformed
boots and insulators used with the ControlNet Ex system
products.

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

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

Catalog Catalog Name Description

Number
1797-RPA ControlNet Ex Represents one ControlNet Ex
Modular node and must be connected to a
Repeater Adapter coax trunk cable by
1797-TPx
1797-RPFM ControlNet Ex Allows connection of a maximum
Fiber Repeater of two devices per 1797-RPA and
Module, Medium is powered directly by 1797-RPA
Distance
1797-ACNR15 Redundant Represents one ControlNet Ex
Media node and must be connected to a
ControlNet Ex coax trunk cable by
Adapter 1797-TPx -each one with two
redundant output channels that
are connected to different
ControlNet Ex networks (coax
cables and 1797-TPx)
1797-BCNR FLEX Ex Galvanic isolation barrier for
Redundant signal between the non-intrinsic
ControlNet ControlNet system an
Barrier Module intrinsically-safe ControlNet Ex
system.
1797-TCAP ControlNet Ex Represents one ControlNet Ex
Tap (Dummy) node and is a simple capacitor
Terminator (56pF) with a coax connector
1797-TPx ControlNet Ex Four types of connections
Coax Tap available: S (straight T-tap), R
(right angle T-tap), YS (straight
Y-tap), and YR (right angle Y-tap) -
a maximum of 48 taps can be
connected by coax trunk cable
1797-XT ControlNet Ex Simple resistor (75 Ω) with coax
Trunk Terminator connector that must be on each
end of the ControlNet Ex coax
trunk for termination

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Catalog Catalog Name Description

Number
1786-RG6 Quad-Shield, Maximum (functional) length
RG-6 75Ω Coax between two 1797-TPx is 3280ft
Trunk Cable (1000m) - each 1797-TPx reduces
the (functional) coax cable length
by 16.3 m (53.4 ft)
1786-BNCP, Standard Coax Standard cable couplers
-BNCJ, BNCJI Trunk Cable BNC
Couplers
1797-BOOT FLEX Ex Boot Replacement insulators
Insulator Kit

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

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

ATTENTION You must isolate all metallic parts during the

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

Certified Equivalent ControlNet Ex System Components

You may use these items as equivalents for system components.

Component Catalog Number Source

Coax Trunk Cable 1797-RG6 Rockwell Automation
3092IS 1
Belden Wire & Cable Co.
3092A with blue jacket Belden Wire & Cable Co.

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

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 Overview of the ControlNet Ex Media System 1-11

UL, cUL I/O Entity Parameters and Requirements

TIP For more information on UL and cUL installation

requirements, refer to publication 1797-RM001, FLEX
Ex System Certification Reference Manual.

Terminals Vt (V) It (mA) Groups Ca (µF) La (µH)

Male Bus Connector 5.8 400 A-G 3.0 3.0

The entity concept allows interconnection of intrinsically-safe

apparatus with associated apparatus not specifically examined in
combination as a system when the approved values of Voc and Isc or Vt
and It of the associated apparatus are less than or equal to Vmax and
Imax of the intrinsically-safe apparatus and the approved values of Ca
and La of the associated apparatus are greater than Ci + Ccable and Li +
Lcable respectively for the intrinsically-safe apparatus.

Wiring methods must be in accordance with the National Electric

Code, ANSI/NFPA 70, Article 504 and 505 or the Canadian Electric
Code CSA C22.1, Part 1, Appendix F. For additional information refer
to ANSI/ISA RP12.6.

WARNING
Substitution of components may impair the intrinsic
safety of this system.
AVERTISSEMENT: La substitution de composant peut
compromettre la securite intrinseque.

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If fiber optic cable is provided with a metal shield, it must be

connected to a dedicated intrinsic safety ground in the
intrinsically-safe location and isolated in the non-intrinsically-safe
location or be connected to a ground in the hazardous location and
isolated in the intrinsically-safe location.

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

European Community Directive Compliance

The ControlNet Ex System has the CE mark. It is approved for

installation within the European Community or EEA regions. It has
been designed and tested to meet the following directives.

EMC Directive

The ControlNet Ex System is tested to meet the Council Directive

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

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

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

The ControlNet Ex System is intended for use in an industrial

environment.

Publication CNET-IN003A-EN-P - January 2006

 Overview of the ControlNet Ex Media System 1-13

Ex Directive

The ControlNet Ex System is tested to meet the Council Directive 94/9

EC (ATEX 100a) Equipment and Protective Systems Intended for Use
in Potentially Explosive Atmospheres by applying the following
standards:

• EN50014:1992, Electrical Apparatus for Potentially Explosive

Atmospheres
• EN50020:1994, Electrical Apparatus for Potentially Explosive
Atmospheres - Intrinsic Safety “i”
• EN50039:1980, Electrical Apparatus for Potentially Explosive
Atmospheres - Intrinsically-safe Electrical Systems “i”
• pr EN50284:1997, Special requirements for construction, test,
and marking of electrical apparatus of equipment group II,
category 1 G

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

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1-14 Overview of the ControlNet Ex Media System

Notes:

Publication CNET-IN003A-EN-P - January 2006

 Chapter 2

Plan a ControlNet Ex Media System

What This Chapter Contains Read this chapter to determine your network requirements.

For See Page

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

After reading this chapter, consult engineering drawings of your

facility for specific information concerning the best location for
installing your network.

TIP The ControlNet Ex media system is a ground-isolated

network. To help prevent accidental grounding:
• Properly select cable, connectors, and
accessories. Local agencies require use of these
items for instrinsically safe system certification.
• Use the supplied ight-blue intrinsically-safe
insulators and dust caps to cover exposed metal
parts.
• Any accessories should have a dielectric rating of
greater than 500V.
• Use good installation techniques.
• Use blue tape to help prevent metal-to-ground
connections.

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

2-2 Plan a ControlNet Ex Media System

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

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

TIP A disconnected drop cable can cause noise to enter

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

TIP If you are planning future installation of additional

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

Each tap kit contains the following pieces:

BNC Connector Kits

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

Ex Insulator Kit
With Intrinsically-safe ControlNet Ex
Insulators Cable Labels
Universal Mounting Bracket
30394-M
Screws
Dust Cap

For noise suppression, ferrite beads 41329

are molded on the drop cable.

TIP We provide the light-blue intrinsically-safe insulators

and dust caps to cover exposed metal parts. Use
these items for instrinsically safe system certification
by local agencies.

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 Plan a ControlNet Ex Media System 2-3

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

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

41330
1797-TPS 1797-TPYS 1797-TPR 1797-TPYR

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

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

Programming 1784-KTCX15
Terminal Node

41331

Coax Cable Type You must use 1786-RG6, Belden 3092A, or Belden 3092A blue quad-
shield RG-6 coax cable as the ControlNet Ex trunk cable.

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2-4 Plan a ControlNet Ex Media System

Fiber Media Type Fiber media type specifications are listed below.

• Fiber type 62.5/125µ

• Connector type ST (plastic or ceramic)
• Operating wavelength 1300 nm
• Optical power budge 13.3 dB
You should install all fiber for your ControlNet Ex cable system in
accordance with the regulations contained in applicable country
codes, state codes, and applicable municipal codes (for example,
National Electric Code). All metal connectors must be insulated
from the ground. Use blue ControlNet cable or the ControlNet Ex
Cable Marking Kit (1797-EXMK) to mark cable as intrinsically-safe.
When you use the 1797-EXMK, be certain to place one marker at
every meter of length.

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

IS Insulators
Tap Tap Tap
Trunk Terminator Trunk Terminator
With With
Intrinsically-safe Trunk Cable Section Trunk Cable Section Intrinsically-safe
Insulator Insulator

30094-m

TIP When determining the length of trunk cable sections,

measure the actual cable path as it is routed in your
network. Consider vertical dimensions as well as
horizontal dimensions. You should always calculate
the three-dimensional routing path distance when
determining cable lengths.
Cover all exposed metal on connectors with either
the intrinsically-safe insulators or other forms of
insulation.
Select the shortest path for routing the cable to
minimize the amount of cable you need. The specific
details of planning such a cable route depends upon
the needs of your network.

The total allowable length of a segment containing standard RG-6

quad-shield cable depends upon the number of taps in your
segment. There is no minimum trunk cable section length

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 Plan a ControlNet Ex Media System 2-5

requirement. The maximum allowable total length of a segment is

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

IMPORTANT The derating curve is applicable only when the cable

meets ControlNet attenuation specifications.

Figure 2.2 ControlNet Single Media Derating Curve

Segment Length m (ft)

1000 (3280)
Maximum Allowable Segment Length 750 (2460)
for FLEX Ex on ControlNet =
500 (1640)
1000 m (3280 ft) - 16.3 m (53.4 ft) X 250 (820)
[Number of Taps - 2]

2 16 32 48
Number of Taps
30014-m

EXAMPLE If your segment requires 10 taps, the maximum

segment length is:
1000m (3280 ft) - 16.3 m (53.4 ft) x [10 - 2]
1000m (3280 ft) - 130.4 m (427.7 ft)= 869.6 m
(2852.3 ft)

An allowable total length of RG-6 cable segment in your application

can be determined by using the equation below. Each additional tap
decreases the maximum length of the segment. The maximum
number of taps allowed on a segment is 48. Each additional tap
decreases the maximum length of the segment.

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

Maximum Allowable Segment Length of Cable =

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

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

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

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2-6 Plan a ControlNet Ex Media System

EXAMPLE If your segment requires 3 taps using 1786-RG6

cable, the maximum segment length is:
([20.29 db - 3*.32 db] / 5.99 db] * 304)
(19.33 db / 5.99 db) * 304 = 982 m (3227 ft)

IMPORTANT The total trunk cable length or number of taps can

be increased by installing a repeater hub on the
segment. This creates another segment.

For redundant media, decrease the number of taps by half, as shown

in the derating curve.

Figure 2.3 ControlNet Redundant Media Derating Curve

Segment Length m (ft)

1000 (3280)
Maximum Allowable Segment Length 750 (2460)
for FLEX Ex on ControlNet =
500 (1640)
1000 m (3280 ft) - 16.3 m (53.4 ft) X 250 (820)
[Number of Taps - 2]

2 8 16 24
Number of Taps
30014-m

Determine Trunk Cable Section Length When You Use a FLEX Ex

Redundant ControlNet Barrier Module

When you use a FLEX Ex Redundant ControlNet Barrier Module

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

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 Plan a ControlNet Ex Media System 2-7

500 m
(1640 ft)

Segment Length m (ft)

250 m
(820 ft)

2 20

Number of Taps With One FLEX Ex Redundant ControlNet Barrier Module

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

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

1.5 dB/km.

IMPORTANT Avoid joining cable with connectors as much as

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

Determine How Many Trunk You must use 75 Ω trunk terminators equipped with intrinsically-safe
insulators (cat. no. 1797-XT) at the end of each segment in the
Terminators You Need ControlNet Ex cable system.

1797-XT

Intrinsically-safe Insulator

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2-8 Plan a ControlNet Ex Media System

After you have determined the number of segments in your network,

multiply this number by two to determine how many terminators you
need for your network.

IMPORTANT To comply with intrinsic safety standards, be sure to

cover the exposed metal with the intrinsically-safe
insulator provided with each terminator.

Determine What Type of Use the following table to determine what type of connectors you need.
Connectors You Need

Use This BNC Connector To Cat. No.

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

Use This Optional BNC Connector To Cat. No.

Bullet (Jack-to-jack) Reserve a space in the trunk cable for future installation of a 1786-BNCJ
tap or to splice a trunk cable

Barrel (Plug-to-plug) Connect two adjacent taps without a trunk cable section 1786-BNCP
between them

Isolated-bulkhead Go through grounded panel walls while maintaining the shield 1786-BNCJI
(Jack-to-jack) isolation of the trunk cable

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

Right Angle Provide a 90° bend in your cable (prevent bending your cable Refer to the ControlNet
(Jack-to-plug) excessively) Media System
See Chapter 3 for the bend radius specification Component List,
publication AG-PA002 for
the part number

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 Plan a ControlNet Ex Media System 2-9

Cable Enters and Exits

In This Example, ControlNet Ex Panel Wall From the Side
Cable:
Isolated-bulkhead
Connectors
• Enters and exits the panel Bullet Connector
enclosure from the side
using isolated-bulkhead
connectors Barrel
• Contains two adjacent Connector
taps connected by a barrel
connector
• Reserves one future tap
location with a bullet
Taps
Right Angle
Connectors 20091m

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

TIP If you install a bullet connector for future tap

installations, count the bullet as one of the tap
allotments on your segment (and decrease the
maximum allowable cable length by 16.3 m [53.5 ft]).

This helps you avoid reconfiguring your network

when you install the tap.

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2-10 Plan a ControlNet Ex Media System

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

Trunk cables on a redundant cable network are defined by the

segment number and the redundant trunk cable letter.

Actual ControlNet Ex products are labeled with these icons

(the shaded icon represent redundant media).

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

Safe Area Hazardous Area

1786 Fiber 1797 Fiber

Repeater Hub Repeater Hub Trunk Cable A =
. . . .

A-B A-B A-B A-B

Q UALITY Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
1797 - RPA Q UALITY
1797 - RPA

ControlNet Ex ControlNet Ex
ControlNet Ex FIBER MODULE ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER Comm Module REPEATER ADAPTER
Status Status MEDIUM RANGE Status Status MEDIUM RANGE
. .
PWR PWR

. . . .

. .

Chan 1 Chan 2 Chan 1 Chan 2

1 1
1 2 3 4 1 2 3 4
+V -V +V -V +V -V +V -V
Recv Xmit Recv Xmit Recv Xmit Recv Xmit

. .
. .

Coax Trunk Cable A =

Trunk Cable B =

1786 Fiber 1797 Fiber

Repeater Hub . .
Repeater Hub
. .

A-B A-B A-B A-B

Q UALITY Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
1797 - RPA Q UALITY
1797 - RPA

ControlNet Ex ControlNet Ex
ControlNet Ex FIBER MODULE ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER Comm Module REPEATER ADAPTER
Status Status MEDIUM RANGE Status Status MEDIUM RANGE
. .
PWR PWR

. . . .

. .

Chan 1 Chan 2 Chan 1 Chan 2

1 1
1 2 3 4 1 2 3 4
+V -V +V -V +V -V +V -V
Recv Xmit Recv Xmit Recv Xmit Recv Xmit

. .
. .

Coax Trunk Cable B =

Node

41346

Observe the following guidelines when planning a redundant media

system in a hazardous area.

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

• Each node on a redundant-cable network must support

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

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 Plan a ControlNet Ex Media System 2-11

• Install the cable system so that the trunk cables at any physical
device location can be easily identified and labeled with the
appropriate icon or letter. Each redundant ControlNet Ex device
is labeled so you can connect it to the corresponding trunk
cable.

• Both trunk cables (trunk cable A and trunk cable B) of a

redundant-cable network must have identical configurations.
Each segment must contain the same number of taps, nodes and
fiber repeaters. Connect nodes and fiber repeaters in the same
relative sequence on both trunk cables.

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

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

Segment 1 Hazardous Area

Trunk Cable A = A-B

Q UALITY

Comm
Status
Allen-Bradley

Module
Status
.

1797 - RPA

ControlNet Ex
REPEATER ADAPTER
A-B
Q UALI TY Allen-Bradley
.

1797 - RPFM

ControlNet Ex
FIBER MODULE
MEDIUM RANGE
1797 Fiber
.
PWR

.
1 2
+V -V +V -V
3 4
.

Recv Xmit
Chan 1

.
Chan 2

Recv Xmit
.

Repeater Hub

Trunk Cable B = A-B

Q UALITY Allen-Bradley
.

1797 - RPA
A-B
Q UALI TY Allen-Bradley
.

1797 - RPFM

ControlNet Ex
ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER
Status Status MEDIUM RANGE
.
PWR

. .

Chan 1 Chan 2

1
1 2 3 4
+V -V +V -V
Recv Xmit Recv Xmit

.
.

. .

Node1 1797 Fiber A-B

Q UALITY

Comm
Status
Allen-Bradley

Module
Status
1797 - RPA

ControlNet Ex
REPEATER ADAPTER
PWR
.
A-B
Q UALI TY Allen-Bradley 1797 - RPFM

ControlNet Ex
FIBER MODULE
MEDIUM RANGE

Repeater
. .

Chan 1 Chan 2

1
1 2 3 4
+V -V +V -V
Recv Xmit Recv Xmit

.
.

Node1 . .

A-B A-B
Q UALITY Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
1797 - RPA

ControlNet Ex

Node1
ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER
Status Status MEDIUM RANGE
.
PWR

. .

Node1
Chan 1 Chan 2

1
1 2 3 4
+V -V +V -V
Recv Xmit Recv Xmit

.
.

1
Node

Trunk Cable B =

Trunk Cable A = 41683

1
Node Supporting Redundant Media Segment 2

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2-12 Plan a ControlNet Ex Media System

• Avoid connecting a single node’s redundant trunk cable

connections on different segments; this will cause erratic
operation.

Safe Area Hazardous Area

Segment 1 1786 Fiber 1797 Fiber
Repeater Hubs Repeater Hubs
. .

. .

A-B A-B
Q UALITY Allen-Bradley 1797 - RPA
Q UALI TY Allen-Bradley 1797 - RPFM A-B A-B
Q UALITY Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
1797 - RPA

ControlNet Ex
ControlNet Ex FIBER MODULE ControlNet Ex
Comm
Status
Module
Status
REPEATER ADAPTER MEDIUM RANGE
ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER
PWR
.
Status Status MEDIUM RANGE
.
PWR

. .

. . .

.
Chan 1 Chan 2
Chan 1 Chan 2

1
1 2 3 4 1
1 2 3 4
+V -V +V -V
Recv Xmit Recv Xmit +V -V +V -V
Recv Xmit Recv Xmit

.
.
.
.

1797 Node
. .

. .

A-B A-B
Q UALITY Allen-Bradley 1797 - RPA
Q UALI TY Allen-Bradley 1797 - RPFM A-B A-B
Q UALITY Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
1797 - RPA

ControlNet Ex
ControlNet Ex FIBER MODULE ControlNet Ex
Comm
Status
Module
Status
REPEATER ADAPTER MEDIUM RANGE
ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER
PWR
.
Status Status MEDIUM RANGE
.
PWR

. .

. . .

.
Chan 1 Chan 2
Chan 1 Chan 2

1
1 2 3 4 1
1 2 3 4
+V -V +V -V
Recv Xmit Recv Xmit +V -V +V -V
Recv Xmit Recv Xmit

.
.
.
.

1786 Node

Segment 2
41348

A node supporting redundant trunk cable connections will function

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

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

ATTENTION ControlNet Ex products cannot be used in an

intrinsically-safe environment after they have been
exposed to non-intrinsically-safe signals.

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 Plan a ControlNet Ex Media System 2-13

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

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

Understand Conductor Categories

Conductors can be divided into three categories.

Category Includes
1 ac power lines

High-power digital ac I/O lines

High-power digital dc I/O lines

Power connections (conductors) from motion drives to motors

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

Low-power digital ac/dc I/O lines

Low-power digital I/O lines

ControlNet Ex communication cables

3 Low-voltage dc power lines

Communication cables to connect between system components

within the same enclosure

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2-14 Plan a ControlNet Ex Media System

General Wiring Guidelines

Follow these guidelines with regard to noise coupling. Following

intrinsic safety requirements should prevent most or all of these
situations from occurring. These guidelines are provided as a general
reference for wiring.

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

angles.

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

or sources of rf/microwave radiation.

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

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

For more information on general wiring guidelines, see the

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

Wire External to Enclosures

Cables that run outside protective enclosures are relatively long.

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

Cable in a Contiguous Route Your From Noise Sources of This Strength

Metallic Wireway or Cable At Least
Conduit?
Yes 0.08 m (3 in.) Category-1 conductors of less than 20A
0.15 m (6 in.) ac power lines of 20A or more, up to 100 KVA
0.3 m (12 in.) ac power lines greater than 100 KVA
No 0.15 m (6 in.) Category-1 conductors of less than 20A
0.3 m (12 in.) ac power lines of 20A or more, up to 100 KVA
0.6 m (24 in.) ac power lines greater than 100 KVA

Wire Inside Enclosures

Cable sections that run inside protective equipment enclosures are

relatively short. As with wiring external to enclosures, you should
maintain maximum separation between your ControlNet Ex cable and
Category-1 conductors.

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 Plan a ControlNet Ex Media System 2-15

When you run cable inside an enclosure, route conductors external to

all raceways in the same enclosure, or in a raceway separate from
Category-1 conductors.

Route Your Cable At Least From Noise Sources of This Strength

0.08 m (3 in.) Category 1 conductors of less than 20 A
0.15 m (6 in.) ac power lines of 20A or more, up to 100 KVA
0.6 m (24 in.) ac power lines greater than 100 KVA

Surge Suppression

Transient electromagnetic interference (emi) can be generated

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

Inductive loads switched by solid-state output devices alone do not

require surge suppression. However, inductive loads of ac output
modules that are in series or parallel with hard contacts require
surge-suppression to protect the module output circuits as well as to
suppress transient emi.

Ferrite Beads Ferrite beads provide additional suppression of transient emi.

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

Required Ferrite Beads

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

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2-16 Plan a ControlNet Ex Media System

Add Ferrite Beads

Wrap the IS power input cable

two turns around the ferrite bead
before connecting the terminal
block to the adapter.

Five ferrite beads come with the

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

42206

Add ferrite beads on the

ControlNet Ex trunk cable inside the
cabinet wherever the trunk cable
goes into or out of the cabinet.

Ferrite Beads

30890-M

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 Plan a ControlNet Ex Media System 2-17

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

General Planning

The ControlNet Ex cable system is isolated from earth and must be

protected from inadvertent ground connections.

Plan a Segment

Refer to this list when you plan a segment.

• All connections to the trunk cable require a tap

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

• Tap drop-cable length must not be changed

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

RG-6 trunk cable

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

(3280 ft), with 2 taps

• 75 Ω trunk terminators are required on both ends

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

maintenance purposes

• Use BNC bullet connectors at future tap locations

• Do not mix redundant and non-redundant nodes

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

unconnected drop cables

• Avoid high noise environments when routing cables

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

trunk as it enters and leaves control cabinets

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2-18 Plan a ControlNet Ex Media System

Plan Your Network

Refer to this list when you plan your network.

• Maximum of 99 nodes (excluding fiber repeater hubs)

• Fiber repeater hubs require a tap but are not counted as nodes
(they are included in the number of devices allowed per
segment [48])

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

segment

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

network

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

the same

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

network cannot exceed 800 m (2640 ft)

Order Parts

The following table contains a list of ControlNet Ex Components.

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

Item Cat. No. Guidelines Required Quantity1

Taps You need a tap for each connection to the Number of repeaters x 2
Straight T-tap 1797-TPS trunk cable (nodes and repeaters). +
Straight Y-tap 1797-TPYS Number of nodes
Right-angle T-tap 1797-TPR Each tap kit contains: two BNC connector
Right-angle Y-tap 1797-TPYR kits, one dust cap, one universal mounting
bracket, ControlNet Ex cable labels and
two screws
Trunk Terminators 1797-XT You need a terminator for each end Number of segments x 2
(quantity of 50) of each segment.
Trunk Cable Use the ControlNet Ex Media System Follow guidelines on page 2-4
Component List, publication AG-PA002, of this document to determine
to order your required length of cable. cable length
Tap Terminator 1797-TCAP Use the dummy load to plug into drop One for every drop cable that is
cables that are not attached to a node. not attached to a node
(quantity of 5)

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 Plan a ControlNet Ex Media System 2-19

Item Cat. No. Guidelines Required Quantity1

Coax Tool Kit 1786-CTK Use the tool kit to create your trunk cable One
to your specifications.
1
You will need to double your quantities when ordering components for a redundant cable system.
2
The connector kit may be shipped with two ferrules. The smaller diameter ferrule should not be used with ControlNet Ex applications.

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2-20 Plan a ControlNet Ex Media System

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

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 Chapter 3

Install a ControlNet Ex Media System

What This Chapter Contains Follow the instructions in this chapter to install your ControlNet Ex
media system.

For See Page

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

TIP You should read Chapter 2, Plan a ControlNet Ex

Network, before you install your network.

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

Wire External to Enclosures

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

For This Coax The Pull Strength Should Not The Bend Radius Should Not
Cable Exceed Exceed
PVC 42.75 kg (95 lbs) 76.2 mm (3.0 in.)

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3-2 Install a ControlNet Ex Media System

Wire Inside Enclosures

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

For This Coax Cable The Bend Radius Should Not Exceed
PVC 38.1 mm (1.5 in.)
Tap drop-cable 25.4 mm (1.0 in.)

The 1797-EXMK Cable Marking kit is available for clearly marking

drop cables and trunk cables as intrinsically-safe.

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

Select Where to Mount the Taps

There is no spacing requirement between taps; you can install two

adjacent taps if necessary by using a barrel connector (1786-BNCP).

IMPORTANT If the barrel connector (1786-BNCP) is used, use an

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

Be certain that:

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

• the location does not cause any cable bend-radii to exceed the
limits listed on pages 3-1 and 3-2.

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

routing specifications.

• you do not mount the tap in a position that routes the drop
cable over any ac power terminals on nearby modules.

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 Install a ControlNet Ex Media System 3-3

ATTENTION Do not allow any metal portions of the tap, such as

the universal mounting bracket screws or
connectors, to contact any conductive material. This
contact could cause noise on the network.
Also be certain all exposed metal is covered by
either the intrinsically-safe insulators or tape having a
500V dielectric rating.

Mount the Taps

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

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

bracket as an assembly.

• through the body holes in the tap using screws, flat washers,
and a tie wrap.

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

TIP See Appendix A for universal mounting bracket and

tap mounting dimensions.

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3-4 Install a ControlNet Ex Media System

Mount a Tap with a Universal Mounting Bracket

1. Align the universal mounting bracket with the mounting holes

on the tap.

2. Use the screws provided with the tap to attach the tap to the
universal mounting bracket.
Universal Mounting Bracket

Y-Tap

Dust Cap T-Tap

Universal Mounting Bracket

(Provided With Tap)
Dust Cap
20084-M 20080-M

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

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

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

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 Install a ControlNet Ex Media System 3-5

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

mounting surface.

DIN Mounting Rail Another Mounting Surface

Universal Mounting Bracket

Universal Mounting Bracket

Use four screws to attach the universal

mounting bracket to another mounting
surface.
DIN Rail
Suitable Fixture
20081-M 20082-M
Mount the universal mounting bracket on specified Allen-Bradley mounting rails or #3 style symmetrical DIN rails (35 mm X 7.5 mm [1.38 in. x 0.30 in.])

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

A-B rail 1492-N1 DIN rail #3 199-DR1
1492-N22 1492-DR5
1492-N44 1492-DR6
1492-DR7

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

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3-6 Install a ControlNet Ex Media System

Mount a Tap Through the Body Holes

TIP A suitable fixture (mounting surface) can be

conductive or grounded because the mounting holes
are electrically isolated.

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

Tie Wrap Screws and Flat Washers

Screws and Flat Washers

(Not Supplied)
Body Holes
Body Holes
Tie Wrap

41645 You can use a variety of screw types. 41646

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

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

Operating temperature -20 to 70 °C (-4 to 158 °F)

Storage temperature -40 to 85 °C (-40 to 185 °F)
Relative humidity 5 to 95% noncondensing

Install Fiber Hubs Read the following sections before installing a fiber repeater hub.

To Install a Fiber Repeater Hub, You Should See Page

Apply the Installation in Zone 1 and related intrinsically-safe 3-7
warnings and standards
Select where to mount the fiber repeater hub 3-8
Mount the fiber repeater hub 3-9

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 Install a ControlNet Ex Media System 3-7

Installation in Zone 1

The 1797-RPA and 1797-RPFM modules must not be exposed to the

environment. You must install these modules in a metal enclosure.
This repeater hub has a protection factor of IP20.

ATTENTION These modules cannot be used in a hazardous

environment after they have been exposed to
non-intrinsically-safe signals.

Electrostatic Charge

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

Attention! Avoid electrostatic charge.

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

European Community Directive Compliance

If this product has the CE mark it is approved for installation within

the European Community or EEA regions. It has been designed and
tested to meet the following directives.

EMC Directive

This product is tested to meet the Council Directive 89/336/EC

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

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

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

This product is intended for use in an industrial environment.

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3-8 Install a ControlNet Ex Media System

Ex Directive

This product is tested to meet the Council Directive 94/9 EC (ATEX

100a) Equipment and Protective Systems Intended for Use in
Potentially Explosive Atmospheres by applying the following
standards:

• EN50014:1992, Electrical Apparatus for Potentially Explosive

Atmospheres
• EN50020:1994, Electrical Apparatus for Potentially Explosive
Atmospheres - Intrinsic Safety “i”
• EN50039:1980, Electrical Apparatus for Potentially Explosive
Atmospheres - Intrinsically-safe Electrical Systems “i”
• pr EN50284:1997, Special requirements for construction, test,
and marking of electrical apparatus of equipment group II,
category 1 G

Inputs/Outputs

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

When you use an intrinsically-safe electrical apparatus according to

EN50020, the European directives and regulations must be followed.

Select a Fiber Repeater Hub Mounting Location

The fiber repeater hub should be mounted:

• so that air can flow in and out of the air holes on the top and
bottom of the coax repeater.

For proper ventilation, be certain that there is a minimum of 5.1

cm (2 in.) from surrounding equipment.

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

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

ATTENTION Be certain that the adapter and fiber modules are

secured together with DIN-rail anchors. Failure to do
so may result in the loss of communications or cause
damage to the modules.

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 Install a ControlNet Ex Media System 3-9

Mount the Fiber Repeater Hub

Follow this procedure to mount the fiber repeater hub.

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

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

41167

2. Hook the lip on the rear of the adapter onto the top of the DIN
rail, and rotate the module onto the rail.

41166

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

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

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3-10 Install a ControlNet Ex Media System

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

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

41168

5. Remove the adapter backplane connector cover.

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

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

41169

IMPORTANT A DIN-rail end anchor (A-B part number 1492-EA35)

must be used on the left side of the adapter and to
the right side of the fiber module to keep the units
from moving.

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

cover in place.

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

IMPORTANT You can attach only two media modules to the

repeater adapter. If you exceed the module limit, you
may cause damage to the adapter or fiber modules
and void the intrinsically-safe certification.

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 Install a ControlNet Ex Media System 3-11

Connect the Fiber Repeater Hub to a ControlNet Ex Network

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

of the Ex coax tap to the adapter BNC connector.

Intrinsically-safe
Insulator

41170

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

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

IMPORTANT Make note of which fiber is receive and which is

transmit. These fibers must be interchanged at the
opposite end of the cable.

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

A-B A-B A-B A-B

Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM Allen-Bradley Q UALI TY Allen-Bradley 1797 - RPFM
Q UALITY
1797 - RPA Q UALITY
1797 - RPA

ControlNet Ex ControlNet Ex
ControlNet Ex FIBER MODULE ControlNet Ex FIBER MODULE
Comm Module REPEATER ADAPTER Comm Module REPEATER ADAPTER
Status Status MEDIUM RANGE Status Status MEDIUM RANGE
. .
PWR PWR

. . . .

. .

Chan 1 Chan 2 Chan 1 Chan 2

1 1
1 2 3 4 1 2 3 4
+V -V +V -V +V -V +V -V
Recv Xmit Recv Xmit Recv Xmit Recv Xmit

. .
. .

Receive Transmit
Transmit Receive

4131

ATTENTION Use the blue intrinsically-safe insulators on all coax

BNC drop connectors as they are installed.

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3-12 Install a ControlNet Ex Media System

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

adapter through a removable terminal block.

+V -V +V -V

+V -V +V -V

41297

Screw terminals and spring terminals are provided.

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

shows after inserting the wires into position.

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

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

ATTENTION Do not use any unused terminals on this adapter.

Using these terminals as supporting terminals can
result in damage to the module or unintended
operation of your system.
Make certain that you power this adapter with an
intrinsically-safe power supply. Do not exceed the
values listed in the specifications for this adapter.
Do not remove or replace a module when power is
applied. Interruption of the bus can result in
unintended operation or machine motion.

IMPORTANT Be certain that all fiber modules are attached and

secured before you apply intrinsically-safe power to
the adapter. Failure to do so may cause damage to
the adapter and modules.

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 Install a ControlNet Ex Media System 3-13

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

Collect Your Tools

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

ControlNet Media Component List,

Publication AG-PA002

ControlNet Coax Media Planning and Installation

Guide, Publication CNET-IN002

Cable Strip Tool With Two Blade Cassettes

Wire Cutters (One for PVC and One For FEP)

Terminators and Extra Connectors

Crimp Tool

Memory Blade Cartridges (Contains Two Sets of

Memory Blades)
Knife Memory Blade Holder

Calibration/Flare Tool 41902

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

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3-14 Install a ControlNet Ex Media System

Strip the Cable

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

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

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

ATTENTION Be certain to perform the calibration procedure the

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

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

Blade Holder

20165

2. Straighten out the end of the cable.

3. Insert the cable into the cable strip tool’s cutting chamber so that
extra cable, approximately 25.4 mm (1 in.), extends beyond the
edge of the tool.

25.4 mm (1 in.)
Extra Cable

Cable
20073

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 Install a ControlNet Ex Media System 3-15

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

forward until it meets the cable with slight resistance.

20073
This gauge moves two rollers toward the cable and regulates the
depth of the cut.

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

5. Hold the cable in one hand, place the index finger of your other
hand inside the chamber-gauge ring and turn the strip tool 360°
around the cable. Turn four or five full rotations until the strip
tool glides easily around the cable.

20074

Repeat steps 4 and 5, moving the chamber-gauge ring forward one notch
for each time you repeat the steps, until you reach the last notch.

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

IMPORTANT The last time you repeat steps 4 and 5, apply

sufficient pressure on the chamber-gauge ring to be
certain the ring has reached the last stage. The
chamber gauge reads ‘stop’ for the last repetition.

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6. After you have moved the chamber gauge ring to the last
position and turned the strip tool the final time:
a. Move the chamber-gauge ring backward to release the strip
tool and remove it from the cable.
b. Slip the crimp ferrule onto the cable. Push it back to the
sheath area of the cable to keep it out of the way for the
moment.

Crimp Ferrule

41887a
Cable

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

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

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

All Four Shield Layers White Foam Electric
Braid/Tape/Braid/Tape Or 1st Tape, If Tape
Is Bonded
Center
Conductor

8.3 mm (0.33 in.) 4.0 mm (0.16 in.)

3.7 mm (0.15 in.)
20076a

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 Install a ControlNet Ex Media System 3-17

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

All Four Shield Layers White Foam Electric
Braid/Tape/Braid/Tape Or 1st Tape, If Tape
Is Bonded
Center
Conductor

8.3 mm (0.33 in.) 4.0 mm (0.16 in.)

3.7 mm (0.15 in.)
20076a

IMPORTANT If you do not see the three distinct layers of cable or

if the outer braid has been scored or cut, snip off the
exposed end with the wire cutters and repeat the
entire cable-stripping process. It is very important
that the outer braid be intact before you crimp the
connector.

If You Are Go To Step

Using
FEP cable 7
PVC cable 8

7. If you are using plenum FEP cable, cut off an additional 3.1mm
(approximately 1/8 in.) of the outer sheath with the knife from
the toolkit.
All Four Shield Layers
White Insulation Or
Braid/Tape/Braid/Tape
1st Tape

Center
Conductor

Sheath

11.44 mm (0.45 in.) 4.0 mm (0.16 in.)

3.7 mm (0.15 in.)
20076a

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

in length.

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3-18 Install a ControlNet Ex Media System

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

T-Tap 3.7 mm 8.3 mm

(0.15 in.) (0.33 in.)
4.0 mm
(0.16 in.)

PVC Cable
Center Conductor PVC Cable Only

PVC/CL2 FEP/CL2P
PVC/CL2 FEP/CL2P

Calibration/flare Tool

Use this end of the calibration

The center conductor should be exactly 4.0 mm (0.16 in.). If
tool to verify proper
the center conductor is too long, cut off the excess with the
measurements for FEP cable.
wire cutter from the cable kit. If it is too short, repeat the
entire cable stripping process. 41952

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

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

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 Install a ControlNet Ex Media System 3-19

Test for Electrical Shorts and Continuity Between the Center

Conductor and the Shield

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

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

1788-MCHKR

SETUP ENTER

LENGTH
TEST WIRE MAP

OFF

31195-M

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

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

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

and connector body at one end of the cable.
Connector Body

20166

Pin

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

ohmmeter, or continuity tester to test for electrical continuity.

If Resistance Reading Indicates Then

That a short exists Continue to next section
There is no short Use your wire cutters to cut off the
connector, install a new connector
and begin testing again

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3-20 Install a ControlNet Ex Media System

IMPORTANT Replace the trunk cable section if problems persist

with the cable after completing these tests.

Attach the Connectors to the Cable

1. Push the calibration/flare tool onto the cable and with a slight
twisting motion (with sufficient inward pressure) to expand the
braid.

41888

Push the calibration/flare tool gently and

rotate slightly onto the connector while
you apply pressure. This will work the
base of the connector underneath
the wire braid slowly.

41890

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 Install a ControlNet Ex Media System 3-21

2. Place the center pin over the center conductor.

Center
centerConductor
conductor

41889

Sometimes strands of insulation are left on the

center conductor. Be certain that the center
conductor is clean before you install the center pin.
Center
center Pin
pin

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

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3-22 Install a ControlNet Ex Media System

3. With the center pin in place, use the crimp tool to crimp the pin
into place.
The smaller hexagonal crimping notch is
for crimping the center pin onto the
center connector.

41903

Check for braid strands that

could cause a short to center
conductor.

4. Slide the ControlNet connector onto the cable.

Braid and Tape Shields

Connector Base

41896

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 Install a ControlNet Ex Media System 3-23

5. Slide the crimp ferrule over the three outer shields and
connector base until it meets the shoulder on the connector.

20077e

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

The larger hexagonal crimping

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

Crimp Ferrule

IMPORTANT Many network problems are due to improperly

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

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Test for Electrical Shorts and Continuity Between the Connector

Body and Pin

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

the connector body and pin.
Attach the connector end of the
cable to the port on top of the
media checker.
MediaChecker

1788-MCHKR

SETUP ENTER

LENGTH
TEST WIRE MAP

OFF

31195-M

If Resistance Reading Indicates Then

That a short exists Continue to next section.
There is no short Use your wire cutters to cut off the
connector, install a new connector,
and begin testing again.

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

at the opposite end of the cable.

Connector Body

Pin 41686

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 Install a ControlNet Ex Media System 3-25

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

or continuity tester to test for electrical continuity.
Attach the connector end of the
cable to the port on top of the
media checker.
MediaChecker

1788-MCHKR

SETUP ENTER

LENGTH
TEST WIRE MAP

OFF

31195-M

If Resistance Reading Indicates Then

That a short exists Continue to next section.
There is no short Use your wire cutters to cut off the
connector, install a new connector,
and begin testing again.

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

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

To eliminate signal reflections from the ends of the segment, you must
attach a 75 Ω trunk terminator (catalog number 1797-XT) to the first
and last taps on the segment. The terms first and last refer to the
physical location of the node along the trunk cable.

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

20078

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

to cover any exposed metal.

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

Repeat steps 1 and 2 at the other end of

the segment.

1797-XT with
intrinsically-safe
insulator 20079

ATTENTION
Be certain that the intrinsically-safe insulator covers
all metal parts.

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Connect Devices After you terminate your segments, connect your devices.

To Connect a See
Fiber repeater hub Page 3-11
ControlNet Ex adapter Procedure below

1. Remove and save the blue dust cap (on the straight or
right-angle connector).

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

ring.

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

If Your Node Supports Connect the Straight or Right-angle Connector
non-redundant media To the channel A connector on the device (channel B is not
used)1
redundant media From trunk cable A to channel A on your device

From trunk cable B to channel B on your device

1
While both channels are active, we recommend using channel A for non-redundant media.

Publication CNET-IN003A-EN-P - January 2006

3-28 Install a ControlNet Ex Media System

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

Use the 1797-BCNR FLEX Ex ControlNet barrier module in Class I,

Divison 2 or Zone 2 safe areas, as shown in the figure.

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

Barrier Module

Safe Area Hazardous Area

ControlNet Barrier
ControlNet Ex Tap
(1797-TPR)
ControlNet A
.

ControlNet Ex TAP .

(1797-TPR)
.

PA ControlNet Ex
ControlNet B Adapter

ControlNet Ex Tap
ControlNet Ex
(1797-TPR)
Tap (1797-TPR)

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

IMPORTANT For complete installation instructions and

requirements, refer to the FLEX Ex Redundant
ControlNet Barrier Module Installation Instructions,
publication 1797-5.35.

To install the module:

1. Select the appropriate mounting location.

2. Mount the barrier module on Rockwell Automation part number

199-DR1 DIN rail.

Publication CNET-IN003A-EN-P - January 2006

 Install a ControlNet Ex Media System 3-29

3. Ensure the locking tabs snap into place.

IMPORTANT Connect the ControlNet Ex side of the barrier

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

4. Remove the insulator boot from the terminals.

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

In
3 Channel A
1 Out
In
4 Channel B
Out
2

ControlNet Trunk Cables

30502-mdin

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

connector (1).
b. Connect the redundant ControlNet trunk cable to the Channel
B output connector (2).
c. Connect the ControlNet trunk cable to the Channel A input
connector (3).
d. Connect the redundant ControlNet trunk cable to the Channel
B input connector (4).

6. Install a direct ground wire with a minimum diameter of 4 mm2

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

IMPORTANT Do not connect terminal 5 or the DIN rail to a

standard earth ground connection in the safe area.

Publication CNET-IN003A-EN-P - January 2006

3-30 Install a ControlNet Ex Media System

Notes:

Publication CNET-IN003A-EN-P - January 2006

 Appendix A

Mounting Dimensions

What This Appendix Use these mounting dimensions to mount your taps, universal
mounting brackets, and repeaters.
Contains

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

Y-Tap
T-Tap

35.66 mm 30.23 mm
(1.40 in.) (1.19 in.)
15.24 mm 15.24 mm
(0.60 in.) (0.60 in.)

25.44 mm
(1.00 in.)
33.02 mm
(1.30 in.)
31.37 mm
(1.235 in.)
39.37 mm
(1.55 in.)

127 mm (5/16 in.)

Mounting Holes

127 mm (5/16 in.)

Mounting Holes

20168
20169

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

A-2 Mounting Dimensions

Universal Mounting
Bracket
58.42 mm
(2.30 in.)

49.53 mm
(1.95 in.)

15.47 mm
(0.609 in.)

30.94 mm 19.05 mm
(1.128 in.) (0.75 in.)
9.53 mm
(0.375 in.)

20170-m

Publication CNET-IN003A-EN-P - January 2006

 Appendix B

Adjust the Cable Strip Tool

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

Calibrate the Cutting Use the following procedure to calibrate your cable strip tool to cut
FEP or PVC cable.
Blades
1. Turn the three screws outward to back the blades out. This
prevents the calibration tool from bottoming out.

2. Place the calibration tool into the cable strip tool with the
narrow end installed and facing forward for FEP cable (use the
wider end for PVC).

Calibration Tool PVC

FEP
41892

Adjusting Screws To Turn The Screw

Increase the cut depth Clockwise
Decrease the cut depth Counterclockwise
2088-m

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

locked in place.

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

When aligned properly, the grooves of the calibration tool

should align with the blades.

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

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

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

B-2 Adjust the Cable Strip Tool

6. Retract the handle of the cable strip tool.

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

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

8.3 mm 3.7 mm 4.0 mm

(0.33 in.) (0.15 in.) (0.16 in.)

30030-m

First Cut: All Four Shield Second Cut: White Third Cut: Center Conductor
Layers-braid/tape/braid/tape Insulation Or 1st Tape
The second cut should cut the The third cut should cut all layers
The first cut should cut the
sheath, three outer shields, and of the cable down to the center
outer sheath without cutting
possibly the inner tape shield. The conductor. This cut should not
the outer wire braid. If the
insulation can be scored slightly, score the center conductor. If the
braid is frayed, scored, or cut
but should not have a deep cut. blade leaves a mark on the
by the blade, adjust the blade
conductor, adjust the blade slightly
outward slightly to eliminate
so to eliminate marking the
the fraying.
conductor.

The first and second cut adjustments need to be precise. Adjustments

as small as 1/12 to 1/8 of a turn can make the difference between a
perfect and an imperfect cut.

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

Publication CNET-IN003A-EN-P - January 2006

 Adjust the Cable Strip Tool B-3

Reverse and Replace the To reverse or change the cutting blades:

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

20182-m

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

20183-m

If You Are Go To
Reversing the memory blade cartridge The next step
to use the second set of blades
Replacing the memory blade cartridge Step 4

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

Publication CNET-IN003A-EN-P - January 2006

B-4 Adjust the Cable Strip Tool

30031-m

Go to step 5.

4. Align the memory blade cartridge (the side with the raised
notches) to the raised area on the inside of the strip tool and
slide the new memory blade cartridge in.

Raised Notch

Raised Area

30031a-m

TIP The blades should be on top as you slide the

cartridge in.

5. Swing the memory blade holder closed.

20069-m

Publication CNET-IN003A-EN-P - January 2006

 Adjust the Cable Strip Tool B-5

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

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

20182-m

2. Snap the memory blade holder off the rod and

remove it from the strip tool.

20070-m

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

snap the holder into place.

4. Swing the memory blade holder closed.

20069-m

Publication CNET-IN003A-EN-P - January 2006

B-6 Adjust the Cable Strip Tool

Notes:

Publication CNET-IN003A-EN-P - January 2006

 Appendix C

Protect Your System Against Electrostatic

Discharge

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

Post these labels or something similar beside each module to protect

the system against electrostatic charge.

Attention: Avoid electrostatic charge.

Attention: Avoid electrostatic charge.

Attention: Avoid electrostatic charge.

Attention: Avoid electrostatic charge.

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

C-2 Protect Your System Against Electrostatic Discharge

Notes:

Publication CNET-IN003A-EN-P - January 2006

 Index

A redundant media 2-10

abbreviations and symbols 1-2 repeater 1-2, 1-7, 2-8
segment 1-7, 2-17
about this manual 1-1
stripping trunk cable 3-14
application considerations 2-13 surge suppression 2-15
tap 1-2, 1-4, 2-2, 2-18
B mounting dimensions A-1
terminating segments 3-25
barrel connector 2-8
terminator 2-18
BNC cable connectors 1-6, 2-8 terminators 1-3, 2-7
installing 3-13 testing for electrical continuity 3-19,
bridge 1-2 3-24
bullet connector 2-2, 2-8 trunk cable 1-2, 1-5, 2-18
testing 3-19, 3-24
C wiring 2-14
wiring external to enclosures 2-14
cable connectors 1-6, 2-8 wiring inside enclosures 2-14
barrel 2-8 trunk cable section 1-2, 1-5, 2-4
bullet 2-8 wiring guidelines 2-14
installing 3-13 ControlNet Coax Toolkit
isolated bulkhead 2-8 crimp tool 3-22
right-angle 2-8 knife 3-17
categories of conductors 2-13 strip gauge 3-18
coax cable 2-3 strip tool 3-14
Collect Your Tools 3-13 adjusting the cutting blades B-1
continuity tester 3-19 changing the memory blade holder
ControlNet cable system B-5
application considerations 2-13 crimp tool 3-22
cable connector
bullet 2-2
cable connectors 1-6, 2-8 F
optional 1-6 FEP cable 1-2
Coax Toolkit 3-13 ferrite beads 2-15
component definitions 1-2 flare tool 3-13
connecting cable sections 3-25
connecting devices 3-27
determine I
cable needed 2-3 installing cable connectors
number of repeaters 2-8 stripping the cable 3-17
number of taps 2-2 stripping trunk cable 3-14
number of terminators needed 2-7 isolated bulkhead connector 2-8
trunk cable section lengths 2-4
type of cable connectors needed
2-8 L
ferrite beads 2-15 link
installing planning 2-17
cable connectors 3-13
trunk cable 3-1
link 2-17 M
mounting taps 3-2 media
network 1-2 redundant 2-10
node 1-4 guidelines 2-10
ordering components 2-17 mounting dimensions
planning guidelines 2-17 tap A-1

Publication CNET-IN003A-EN-P - January 2006

2 Index

N changing the memory blade holder B-5

NetLinx Media Checker 3-19 support
node 1-4 questions or comments about manual
1-2
technical product assistance 1-2
O surge suppression 2-15
ohmmeter 3-19
ordering components 2-17 T
tap 1-2, 1-4, 2-18
P determine number needed 2-2
programming terminals mounting 3-2
ways to connect to a ControlNet link 2-3 to a universal mounting bracket 3-4
publications using the body holes 3-6
mounting dimensions A-1
1770-4.1 2-14
selecting where to mount 3-2
AG-PA002 1-4, 2-8
techniques used in the manual 1-2
CNET-IN001 1-1
CNET-IN002 1-1 terminators 1-3, 2-7
PVC cable 1-2, 3-1, 3-17 trunk cable 1-2, 1-5
bend radius 3-1
installing 3-1
R pull strength 3-1
redundant media 2-10 stripping 3-14
guidelines 2-10 terminating 3-25
repeater 1-2, 1-7, 2-8 testing for shorts and continuity 3-19,
selecting where to mount 3-8 3-24
RG-6 cable 2-3, 3-1 wiring external to enclosures 2-14, 3-1
right-angle connector 2-8 wiring inside enclosures 2-14, 3-2
trunk cable section 1-2, 1-5, 2-4, 3-25

S W
segment 1-7
wiring
planning 2-17
terminating 3-25 external to enclosures 2-14, 3-1
strip tool inside enclosures 2-14, 3-2
wiring guidelines 2-14
adjusting the cutting blades B-1

Publication CNET-IN003A-EN-P - January 2006

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Pub. Title/Type ControlNet Ex Media Planning and Installation Manual

Cat. No. 1797-series Pub. No. CNET-IN003A-EN-P Pub. Date January 2006 Part No. 957208-04

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Installation Assistance

If you experience a problem with a hardware module within the first 24

hours of installation, please review the information that's contained in this
manual. You can also contact a special Customer Support number for initial
help in getting your module up and running:

United States 1.440.646.3223

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Outside United Please contact your local Rockwell Automation representative for any
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Publication CNET-IN003A-EN-P - January 2006 5 PN 957208-04

Copyright © 2006 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.