PROCESS AUTOMATION

Wiring and Installation Guide

FOR FOUNDATION FIELDBUS

AND
 With regard to the supply of products, the current issue of the following document is applicable:
The General Terms of Delivery for Products and Services of the Electrical Industry, as published by
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Table of Contents

1 Technical overview .................................................................................. 3

1.1 Introduction ............................................................................................................. 3
1.2 Terms ....................................................................................................................... 4
1.3 FOUNDATION Fieldbus in automation hierarchy ................................................ 6
1.4 Topology of the H1 bus .......................................................................................... 6
1.5 Physical layout of the H1 bus ................................................................................ 7
1.6 Use of the FOUNDATION Fieldbus in hazardous areas ...................................... 9
1.6.1 The FISCO model ................................................................................................... 10
1.6.2 The Entity model ..................................................................................................... 11
1.6.3 The FNICO model ................................................................................................... 12
1.6.4 Summary ............................................................................................................... 13

2 Planning and designing a FOUNDATION Fieldbus application ......... 15

2.1 Dimensioning of a FOUNDATION Fieldbus H1 segment .................................. 15
2.1.1 Current calculation .................................................................................................. 15
2.1.2 Voltage calculation and line length ......................................................................... 16
2.2 FOUNDATION Fieldbus standard application .................................................... 19
2.2.1 Power feed concepts of standard FOUNDATION Fieldbus applications ................ 20
2.2.1.1 FOUNDATION Fieldbus power supply .................................................................... 20
2.2.1.2 The FOUNDATION Fieldbus Power Conditioner..................................................... 20
2.2.2 Power Repeater ...................................................................................................... 22
2.2.3 Junction box ........................................................................................................... 24
2.2.4 Segment Protectors ................................................................................................ 25
2.2.5 Terminating the trunk with a fieldbus terminator. .................................................... 26
2.3 Use of FOUNDATION Fieldbus in hazardous areas .......................................... 27
2.3.1 Installation in accordance with European standards .............................................. 27
2.3.1.1 Installation in Zone 2 of a hazardous area............................................................... 27
2.3.1.2 Installation in Zone 1 or 0 ........................................................................................ 28
2.3.1.3 Dimensioning of a fieldbus segment with FieldBarriersTM...................................... 33
2.3.2 Installation in accordance with North American standards ..................................... 33
2.3.2.4 Installation in Division 2 of a hazardous area .......................................................... 33
2.3.2.5 Installation in Division 1 of a hazardous area .......................................................... 35
2.4 Fieldbus Process Interfaces ................................................................................ 39
2.5 Fieldbus terminators ............................................................................................ 40
2.6 Fieldbus cable ....................................................................................................... 40
2.7 Grounding and shielding of a fieldbus application ........................................... 41
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1
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Table of Contents
Date of issue 17.12.2003

2
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

1 Technical overview

1.1 Introduction

One of the arguments cited most frequently for using fieldbus systems is savings of
hardware in the form of cables, cable ducts, terminals and input/output cards in the
control system, etc.
Fieldbus systems also have other advantages, for example
• simplified wiring through the use of parallel wiring with a 2-wire fieldbus transmissi-
on line. The main savings potential in this case is the time required for installation,
• Simplified documentation,
• space savings in the switching area, control room, marshalling area,
• simplified asset management.
Additional savings potentials are evident if the overall lifetime of a system is conside-
red. In this case, field devices with a fieldbus interface offer significantly greater func-
tionality than conventional field devices using 4 to 20 mA technology.
• The "busmaster“ detects missing field devices automatically
• In some circumstances, the nature of the error is reported (for example lead brea-
kage, short circuit, etc.)
• Defective field devices can be replaced during operation without the need to turn
off the system.
• Many field devices also support pre-fault indication, i.e. they provide information
about maintenance tasks that are due and problems before the field device actually
fails.
All this information helps in preventive maintenance and is designed to prevent failu-
res as much as possible.The potential for savings in this case consists in reducing
down times.
The following requirements are made for fieldbus system in or within process auto-
mation applications:
• Uniform, manufacturer-independent application profiles. This means that field de-
vices with the same function can be operated in identical ways independently of the
manufacturer.
• Interoperability, i.e. it must be possible to operate fieldbus components of different
manufacturers on the same transmission segment without problems.
• Data and power transmission on a shared 2-conductor lead.
• Intrinsic safety for applications in hazardous areas.
• Simple interface between the hazardous area and the safe area.
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

These requirements are currently met by only 2 fieldbus systems:

• the FOUNDATION Fieldbus
• the PROFIBUS MBP.

More recent documentation also refers to PROFIBUS MBP in connec-

tion with PROFIBUS PA. MBP stands for Manchester Bus Powered.
PROFIBUS PA and PROFIBUS MBP are identical. The following sec-
tion refers only to the term PROFIBUS MBP that has just been introdu-
ced.
PROFIBUS MBP-IS refers to the intrinsically safe version of the PRO-
FIBUS MBP.

This manual is designed to provide an overview of how to plan a FOUNDATION Field-

bus application and then install it.

1.2 Terms

Anyone who becomes involved with understanding fieldbus technology will be con-
fronted by a large number of technical terms. The following section is intended to ex-
plain the most frequently used terms:
Fieldbus termi- To avoid reflections, a fieldbus transmission line must be termina-
nator ted with a fieldbus terminator on both ends. Fieldbus terminators
can be included in the field devices or junction boxes, or they can
be external mounted.
Fieldbus power Supply device with an active design. FOUNDATION Fieldbus
supply or power supplies are directly connected to the transmission line of
power supply the H1 bus and must include a filter for decoupling data.
The supply device can consist of a power supply, a Power Con-
ditioner or a Power Repeater.
Junction box A connecting element (dividing box) between the trunk and the
spur. A junction box always has at least one input and one output
for the trunk and can have 1, 2, 4, 6 or 8 connections for spurs.
FieldBarrierTM A special form of the junction box through which intrinsically safe
field devices can be connected to a non-intrinsically safe trunk
Fieldbus Pro- An interface between simple standard field devices such as val-
cess Interface ves, proximity switches or temperature measurement sensors and
(FPI) the fieldbus.
Host: A device that makes one or more fieldbus interfaces available.
The host generally represents the "central switching point" of a
fieldbus system. Generally this involves a card that is integrated
into a programmable logic controller (PLC), a distributed control
system (DCS) or a personal computer (PC). The data transfer for
field devices is initiated and controlled by the host. In addition, the
transferred data are processed or forwarded to a higher-level sys-
Date of issue 17.12.2003

tem.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

Linking Device: In the case of a FOUNDATION Fieldbus, the host can be connec-
ted to both the H1 bus and the H2 bus (High Speed Ethernet,
HSE). In the second case, the Linking Device connects the host
that is connected to the HSE with the field devices that are con-
nected to the H1 bus. The Linking Device can have either one or
more H1 bus interfaces, but only one HSE interface.
Power Conditi- Supply device with a passive design. Power is supplied to the
oner Power Conditioner on the input of a standard power supply and
the output is connected to the transmission line of the H1 bus. A
redundant power supply can be implemented with Power Conditio-
ners.
Power Repea- The term repeater refers to an amplifier that receives the data sig-
ter nal on one side and then sends the processed signal on the other
side. This amplification function works in both directions, i.e. both
from the host to the field device and from the field device to the
host. At the same time, Power Repeaters make the power supply
available on the field device side (field side for short).
Segment Pro- A junction box that has short circuit current protection on the out-
tector puts of its spurs.
Splice Spur, which is shorter than 1 m.
Spur A short fieldbus transmission line through which field devices can
be connected to the trunk.
Trunk Main line of a fieldbus system. Field devices will be connected via
a short spur to the trunk.
Table 1.1: Definitions of terms
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

1.3 FOUNDATION Fieldbus in automation hierarchy

When FOUNDATION Fieldbus is arranged in the automation hierarchy, the following

structural view emerges:
Factory level

Ethernet TCP/IP

Process level

H2 bus (High Speed Ethernet; HSE)

Host Host
(Linking Device)
Field level
H1 bus segment H1 bus segment H1 bus segment

Fig. 1.1: FOUNDATION Fieldbus in automation hierarchy

The following section describes planning and layout for the H1 bus. For the following
topics related to the H2 bus, please refer to available specialised literature regarding
fast Ethernet/high-speed Ethernet.

1.4 Topology of the H1 bus

A topology is the way and means by which communication interfaces of individual bus
stations are connected with each other. Basically, the following topologies are possib-
le:
• Line topology, also called bus topology
• Tree topology, an extension of line topology
• Ring topology
• Star topology
Line topology can occur as simple line topology or as line topology with spurs.

The H1 bus of the FOUNDATION Fieldbus uses the line topology with
Date of issue 17.12.2003

spurs.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

The layout of a line topology of this type with spurs is as follows:

Fieldbus terminator
Dividing box
Trunk Junction box

FT
FT
Fieldbus
terminator

Spur

Fig. 1.2:Line topology

To avoid reflections on the line ends, the H1 bus must be provided with a fieldbus ter-
minator on both ends. These terminators are identified in Fig. 1.2 by FT. These termi-
nators
• can be connected as a separate component or
• can be integrated in a field device or in the junction box.
In the second case, it must be ensured that the fieldbus terminators on the first and
last stations are turned on.

1.5 Physical layout of the H1 bus

The physical layout of the H1 bus is defined in standard IEC 61158-2 of the Internati-
onal Electrotechnical Commission and ISA S50.02-1992 of the International Society
of Measurement. This standard specifies, among other things that
• the data is Manchester encoded and is transmitted at a transfer rate of 31.25 kBd.
• power for the field devices is accessed through the bus.
Care must be taken that the power consumption of connected fieldbus stations
(field devices + host) is less than the amount of power provided by the supply de-
vice.
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

The H1 bus of the FOUNDATION Fieldbus supports the following options of

IEC 61158-2:
Options of the H1 bus physical layout
Interface Voltage Voltage Voltage
Transfer rate 31.25 kBd 31.25 kBd 31.25 kBb
Bus supply No Yes (DC) Yes (DC)
Intrinsic safety No No Yes
Max. number of devices
per segment
32 12a 10b

a.This is the maximum number of devices per bus segment in accordance with IEC 61158-2. Supply devices are now
available that allow for a greater number of field devices.
b.The maximum number of devices per bus segment for intrinsically safe applications depends on various factors. For
more detailed information, please refer to chapter 2.1.1.

Table 1.2: Physical options of the H1 bus for the FOUNDATION Fieldbus

• It is absolutely essential for proper communication that an input voltage equal to or

greater than 9 V to be applied to each device. This must be calculated as a function
of the topology, the cable that is used, the supply voltage and the resulting current.
Various software tools are available for this purpose.
The trunk of the H1 bus cannot be designed to any arbitrary length. Depending on the
type of cable used, the maximum cable length can be up to 1900 m.
Cable type A Cable type B Cable type C Cable type D
Cable struc- Twisted wire Single or mul- Multiple twis- Multiple non-
ture pair, shielded tiple twisted ted wire pairs, twisted leads,
pairs, com- not shielded complete
plete shiel- shielding
ding
Wire cross 0.8 mm² 0.32 mm² 0.13 mm² 1.25 mm²
section (#18 AWG) (#22 AWG) (#26 AWG) (#16 AWG)
Max. cable 1900 m 1200 m 400 m 200 m
length
Table 1.3: Fieldbus cable types and max. lead length

The lead lengths specified above apply only to applications outside a

hazardous area. For information on permissible cable lengths within a
hazardous area, please refer to chapter 1.6.

The total cable length is the sum of the trunk cable length plus the sum
of all spur lengths!
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

The maximum length of a spur is limited to 120 m. The permissible spur length de-
pends on the number of field devices operated on a fieldbus segment and the number
of field devices per spur. Permissible spur lengths are shown in table 1.4:.
The number of Maximum safety length for safe applications
fieldbus
stations per 1 device per 2 devices per 3 devices per 4 devices per
spur spur spur spur
segmenta
1 to 12 120 m 90 m 60 m 30m
13 to 14 90 m 60 m 30 m 1m
15 to 18 60 m 30 m 1m 1m
19 to 24 30 m 1m 1m 1m
25 to 32 1m 1m 1m 1m
a.All devices that receive data must be taken into consideration as fieldbus stations. Any hosts or Power Repeaters that are present
must be included in the count.

Table 1.4: Permissible spur lengths

Information regarding cable lengths in table 1.3 and table 1.4 do not
apply for applications in hazardous areas. For more detailed informa-
tion, please refer to chapter 1.6.1 and chapter 1.6.2.

1.6 Use of the FOUNDATION Fieldbus in hazardous areas

If the FOUNDATION Fieldbus is used in hazardous areas, explosion protection

measures must be applied. The measures to be taken depend on the following fac-
tors:
• In what country will the system be installed?
- If the fieldbus will be installed inside Europe, European standards must be ap-
plied.
- If the fieldbus will be installed inside North America, North American standards
must be applied.
- If the fieldbus will be installed in other regions, for example in Asia, European
standards are generally used as the basis. It may happen, however, that an in-
stallation based on North American standards is required.

If a fieldbus application is planned in a hazardous areas, it should be

found out in advance which explosion protection standards, setup
requirements and installation guidelines applied in this country.

• In what zone/division of a hazardous area will the fieldbus be installed?

Date of issue 17.12.2003

It is important to design a network that allows the replacement of a fieldbus station

during ongoing operation even when the fieldbus is used in hazardous areas, i.e. it
should be possible to disconnect the field devices from the transmission line or to re-
connect them.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

The following options are available:

• Intrinsic safety explosion protection method
• The nonincendive explosion protection method. However, this is only permitted for
installation in accordance with North American standards and for use in the follo-
wing areas:
- Class I Division 2
- Class II Division 2
- Class III Division 1 and 2
The different topologies that are possible in this case are illustrated in chapter 2.3.
Regardless of whether the intrinsically safe or Nonincendive explosion protection me-
thod is used, verification must be provided that the general conditions of the explosion
protection concept in question are maintained.
To make this verification as simple as possible, three different models have been de-
veloped, the FISCO model, the Entity model, and the FNICO model.
These three models will be briefly explained in the following section.

1.6.1 The FISCO model

FISCO stands for Fieldbus Intrinsically Safe COncept.
The Physical-Technical Federal Institute (Physikalisch Technische Bundesanstalt,
PTB) developed the FISCO model and published it in Report PTB-W-53 "Examination
of intrinsic safety in fieldbus systems“. It is preferred for applications in Europe.
This concept is based on the observation that a cable represents distributed induc-
tance and capacitance. The following system requirements apply to the FISCO mo-
del:
1. To transmit power and data, the bus system uses the physical configuration defined
by IEC 61158-2. This is true for the H1 bus of the FOUNDATION Fieldbus.
2. Only one active source is permitted on a bus segment (here the Power Repeater).
All other components work as passive current sinks.
3. The basic current consumption of a bus station is at least 10 mA.
4. It must be ensured for each bus station that
Ui of each field device > Uo of the Power Repeater
Ii of each field device > Io of the Power Repeater
Pi of each field device > Po of the Power Repeater.
5. Each bus station must fulfill the following requirement:
Ci < 5 nF
Li < 10 µH
6. The maximum permissible line length for EEx ia IIC applications is 1000 m.
7. The maximum permissible spur length for Ex applications is 30 m per spur. The
definition of the spur must be observed in this regard.
Date of issue 17.12.2003

8. The transmission line that is used must conform to the following cable parameters:
Resistance: 15 Ω/km < R’ < 150 Ω/km
Inductance: 0.4 mH/km < L’ < 1 mH/km
Capacitance: 80 nF/km < C’ < 200 nF/km (including the shield)

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

Taking the shield into consideration, the capacitance is calculated as follows:

C’ = C’conductor/conductor + 0.5 * C’conductor/shield if the bus line is potential-free or
C’ = C’conductor/conductor + C’conductor/shield, if the shield is connected with a pole of
the Power Repeater.
9. The bus segment must be terminated on both ends of the line with a fieldbus termi-
nator. A fieldbus terminator is integrated into the Power Repeater so that an exter-
nal terminator is only required on the other end. According to the FISCO model the
fieldbus terminator must conform to the following limits:
90 Ω < R < 100 Ω
0 µF < C < 2.2 µF
Given the prerequisite that Items 1 to 9 must all be satisfied, proof of intrinsic safety
has been provided by means of the FISCO model. Items 1, 3 and 5 are automatically
satisfied if a product is certified in accordance with the FISCO model.

The prerequisite for being allowed to bear the proof of intrinsic safety in
accordance with the FISCO model is that the Power Repeater and all
fieldbus stations connected to it must be certified in accordance with-
FISCO.
Generally, a separate declaration of conformity is required for the field-
bus terminator. In addition, the cable must meet the requirements of the
FISCO model, but they do not need to be certified.

1.6.2 The Entity model

The Entity model is preferably used for intrinsically safe applications in the North Ame-
rican area. It is based on the observation that the cable represents concentrated in-
ductance and capacitance. The result is that less electrical power can be transmitted
into the hazardous area when compared with the FISCO model. The values for Power
Repeaters are 10.6 V and 70 mA. A further result of this is that theoretically only 6
field devices (as opposed to 10 field devices for the FISCO model) can be operated
on a bus segment.
Items 1 through 4 enumerated in chapter 1.6.1 as well as Item 9 also apply to the En-
tity model.
According to the Entity model, the internal inductance of a field device must be less
than 20 µH.
In contrast to the FISCO model, the Entity model provides no specifications in terms
of permitted inductance or capacitance of the fieldbus transmission line. The result of
this is that inductances and capacitances must also be taken into consideration for
the proof of intrinsic safety. A proof of intrinsic safety requires the following compari-
sons or calculations:
Ui of each field device > Uo of the Power Repeater
Ii of each field device > Io of the Power Repeater
Pi of each field device > Po of the Power Repeater
Lcable + Σ Li field devices < Lo of the Power Repeater
Ccable + Σ Ci field devices
Date of issue 17.12.2003

< Co of the Power Repeater

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

This means that in addition to comparing the voltages, currents and power levels, the
total of all input capacitances and inductance must be formed. To this is added the
capacitance or inductance of the lead. The result must be less than the maximum per-
missible capacitance or inductance of the Power Repeater that can be connected.

Fieldbus stations that are certified in accordance with the FISCO model
described in chapter 1.6.1 can be operated on Power Repeaters that
are certified in accordance with Entity model.

Fieldbus stations that are certified in accordance with the Entity model
can not be operated on supply devices that are certified in accordance
with the FISCO model.

There are no additional restrictions for the Entity model in terms of the permissible
lead or spur lengths.

1.6.3 The FNICO model

FNICO stands for Fieldbus NonIncendive COncept.
The Nonincendive explosion protection method is only permitted in North America
and countries that base their standards on North American standards.
Just as for the intrinsic safety explosion protection method, the basic principle of the
Nonincendive explosion protection method is based on limiting the maximum amount
of power that is made free in the form of voltage, current, power and surface tempe-
rature.
The Nonincendive explosion protection method can only be used in areas where no
potentially explosive atmosphere is present under normal conditions. This only occurs
in the event of failure. Specifically, these are:
• Class I Division 2
• Class II Division 2
• Class III Division 1 and 2
Proof that the limit values have been observed must also be provided for the Nonin-
cendive explosion protection method. This is very similar to the proof of intrinsic safe-
ty.
The FNICO model was developed to simplify this proof. Just like the FISCO model,
the FNICO model specifies general conditions in terms of
• input inductances/capacitances
• maximum cable and spur length
• of cable rating values.
These general conditions are identical to those of the FISCO model (Refer to chapter
Date of issue 17.12.2003

1.6.1 on page 10).

The following applies, just as for the FISCO model:
• If a Power Repeater is used in accordance with the FNICO model and

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

• only field devices in accordance with the FNICO model are used and
• the cable meets the requirement for limit values in accordance with chapter 1.6.1
then the proof is reduced to the following comparision:
Vmax of each field device> Voc of the Power Repeater
Imax of each field device> Ioc of the Power Repeater
Pmax of each field device> Poc of the Power Repeater

Since the FNICO model can only be used in areas where a potentially explosive at-
mosphere occurs only in event of failure, more supply current can be fed into the ha-
zardous area than for the FISCO or Entity model. Commonly available Power
Repeaters make a supply current of 215 mA available.

1.6.4 Summary
If wiring is laid for the H1 bus of the FOUNDATION Fieldbus in a hazardous area, ex-
plosion protection measures must be taken.
To make it possible to replace field devices in ongoing operation, the fieldbus appli-
cation in the hazardous area must be designed according to the intrinsic safety or No-
nincendive explosion protection method.
There are 3 ways to do this:
1. The system is designed to be intrinsically safe in accordance with the FISCO model
2. The system is designed to be intrinsically safe in accordance with the Entity model.
3. The system is designed to be intrinsically safe in accordance with the Nonincendive
explosion protection method.

Observe national requirements for explosion protection. This specifies

which types of considerations can be used.

The following table shows the serious differences:

FISCO Entity FNICO
Max. overall cable length in the hazar- 1000 m 1900 m 1000
dous area
Max. spur length in the hazardous 30 m 120 m 30 m
area
Max. number of stations (theoretical) 10 6 21
Consideration of cable inductances No Yes No
and capacitances
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Technical overview

Table 1.5: Comparison of FISCO/Entity/FNICO models

Values in the table 1.5 are theoretical values. For real applications,the
number of stations on an intrinsically safe fieldbus segment in accor-
dance with the FISCO model range from 6 to 8 stations and for the
Entity model about 4 - 5 stations.
For more detailed information, please refer to chapter 2.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

2 Planning and designing a FOUNDATION Fieldbus application

In considering a FOUNDATION Fieldbus application, a large number of other compo-

nents are required in addition to the host (Linking Device; Link Active Scheduler, Con-
troller) and the field devices:
• Power supplies, Power Repeaters or Power Conditioners
• FieldBarriers
• Junction boxes or Segment Protectors for connecting fieldbus-capable field
devices
• Fieldbus process interfaces for connecting conventional field devices to the
fieldbus
• Fieldbus terminators
• Cables and Cord sets
The following section is designed to explain when to use these products and how to
dimension or structure an H1 bus segment.

2.1 Dimensioning of a FOUNDATION Fieldbus H1 segment

A Power Repeater create at the field side a new H1 bus segment.

A Power Conditioner or power supply could be connected anywhere at a H1 bus seg-
ment. In case of a fieldbus terminator is switched on or mounted externaly this indica-
tees the beginning of a H1 bus segment.
It is assumed in the following section that a Type A cable as described in chapter 1.3.
is used.

If a different type of cable is used, only the corresponding cable resis-

tance needs to be replaced.

2.1.1 Current calculation

Fieldbus stations receive power via the bus and work as current sinks. The current
consumption of each station from the bus line must be at least 10 mA for Ex applica-
tions. There are no restrictions for safe area applications. However, these also gene-
rally receive power from the bus line.
Supply devices have always a current limitation. The amount of the current value de-
pends on whether the devices is a safe supply device, a Power Repeater in accor-
dance with the FISCO model or a Power Repeater according to the Entity model. The
following values apply in individual cases:
• Power Conditioner: Iout < 1 A
• Standard Power Repeater (safe), power supply Iout < 400 mA
• Nonincendive Power Repeater, power supply Iout < 215 mA
Date of issue 17.12.2003

• Power Repeater, intrinsically safe in accordance with the FISCO model

Iout < 100 mA
• Power Repeater, intrinsically safe in accordance with Entity model Iout < 70 mA

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

It has to be ensured that the current consumption of all connected fieldbus stations is
less than the current the supply device is capable of providing. The following applies:
Ifrom_supply_device > Σ Iinto_field_devices
The current consumption of the field devices determines the maximum number of sta-
tions per fieldbus segment. For example, if field devices with a higher current con-
sumption are used, the maximum number of fieldbus station that can be connected is
reduced.
If a fieldbus segment is dimensioned so that the current consumption of the fieldbus
station is close to the maximum output current of the supply device, this may be criti-
cal. In the event of failure (defect in a fieldbus station), it may happen that this station
draws a higher current from the bus line than the basic specified current. Under worst
case conditions, it may happen that the entire fieldbus segment is brought down, af-
fected by one defective slave.
To avoid this, some fieldbus devices offer the Fault Disconnect Electronic (FDE). This
is an electronic current limit that restricts additional current consumption of a defective
slave in a failure case. This IFDE can also vary between fieldbus stations. For details,
see the relevant data sheet. If an error case is included in the current calculation, the
situation described above changes as follows:
Ifrom_supply_device > IFDE + Σ Iinto_field_devices
This means that if one fault occurs, current limiting will not be active and thus only the
defective slave will fail.
The highest IFDE present on a fieldbus segment is recommended here as the basis.

2.1.2 Voltage calculation and line length

The distribution of stations on the fieldbus segment can have a negative effect on the
maximum possible line length under certain circumstances. The following example is
intended to clarify this point:

imax RL
in
i1 i2
Supply UL
Uoff >9V
device

RL = Line resistance of line segment x

Ix = Current consumption of fieldbus station x

Fig. 2.1:Worst case of a fieldbus structure

All stations are connected on the end of the fieldbus segment for a fieldbus applicati-
on. The result of the current calculation was that a maximum direct current of 400 mA
Date of issue 17.12.2003

flows, including IFDE. Type A cable with a resistance coating of 44 Ω/km is used.
A requirement for problem-free functioning of a fieldbus station is that the input volta-
ge on the bus line be at least 9 V. The following therefore applies to the maximum

16
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

permissible voltage drop over the lead:

ULmax = Uout - 9 V
For example Uout is at least 24 V (24 V ... 26 V) for Power Repeater KLD2-PR-1.IEC1.
24 V must be assumed for Uout for the worst case consideration, which results
in ULmax of 15 V.
Since all stations are connected at the end of the lead, the maximum permitted lead
resistance is 37.5 Ω (UL/imax). With a resistance coating of 44 Ω/km, this corresponds
to a lead length of 852 m. Although the lead length for an H1 segment can
theoretically be 1900 m, it can only be 852 m long in this case.
The following points must be noted in this example:
• The example under consideration is a "worst case" application. This means that all
other distributions of field devices on the fieldbus transmission line will result in less
of a voltage drop along the cable than the example above.
• In a real application, the field devices are never connected only at the end of the
transmission line. In actual practice, this results in a lower voltage drop along the
transmission line than in the example above.
• The result of this is that theoretically, for lead lengths less than 852 m, there should
never be problems with voltage drop along the lead.
In actual practice, however, it must also be taken into consideration that
1. there may be fluctuations in temperature and
2. junction boxes or terminals may result in additional transition resistances that
cause additional voltage drop.
However, these effects are compensated by the fact, that the field devices are
distributed along the fieldbus transmission line. They are never connected "concen-
trated at the end of the cable.
The following table provides an overview of where, depending roughly on the type of
supply device used, the limit values lie for the "worst case application" described
above:
Min. output max. Max. line
voltage Output cur- length for the
rent "worst case
application
Standard application
Power Conditioner 24 V 1A 340 m (1115 ft)
Power supply/Power Repeater 24 V 400 mA 852 m (2794 ft)
Ex application
Power Repeater, nonincendive 12.3 V 215 mA 348 m (1144 ft)
Power Repeater in accordance with
12.8 V 100 mA 863 m (2832 ft)
the FISCO model
Power Repeater in accordance with
Date of issue 17.12.2003

10.6 V 70 mA 519 m (1702 ft)

the Entity model
Table 2.3: "Maximum lead length for a "worst-case application"

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

There is no need to calculate precisely whether the application can

function until the cable length of the fieldbus transmission line is longer
than the limiting values specified in table 2.3.
If the cable is shorter, there are no problems in terms of voltage drop
along the cable.

If the actual cable length is longer than what was calculated for the worst-case appli-
cation, then
• an (additional) Power Repeater must be included in the planning or
• a cable with reduced resistance coating must be used or
• more precise calculations must be performed.
The more precise calculations are shown below. Since in practice the stations are not
all connected compactly at the end of the transmission line, the resulting structure is
as follows:
ln

l2

l1

RL1 RL2
Supply i1 i2 in
device Uout >9V

RLx = Lead resistance of lead segment x

Ix = Current consumption of bus station x

Fig. 2.2:Real structure of a fieldbus application

Each station causes a voltage drop on the segment length through which its power
supply current flows. For the first station, this would be:
URL1 = i1*RL1 or URL1 = i1 * l1 * R’; with R’ = resistance of the cable (e. g. 44 Ω/km)
For the second station, this appears as follows:
URL2 = i2* (RL1 + RL2) or URL2 = i2 * l2 * R’
In general, the equation for Ex applications is then as follows:
n
URL = R’ * Σ (ix * lx) < Uout - 9 V
x=1
Date of issue 17.12.2003

If the condition described above is not satisfied

1. a Power Repeater must be used to increase the length of the line or
2. the line must be shortened or

18
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

3. a line with reduced resistance load per unit must be used.

If the opposite approach is selected, i.e. it has to be determined whether the input vol-
tage Uin for a specified application is still sufficiently high on the last station, the follo-
wing equation must serve as the basis for calculations:
n
Uin = Uout - URL = Uout - R’ * Σ (ix * lx) > 9 V
x=1

2.2 FOUNDATION Fieldbus standard application

fig. 2.3 shows a typical FOUNDATION Fieldbus H1 application:

Host

Power Repeater
H1 Segment A H1 Segment B

FT
FT

FT
FT

Power supply or
Power Conditioner

Fig. 2.3:Use of power supplies on the FOUNDATION fieldbus

The host is connected to a H1 segment. A power supply or Power Conditioner is con-

nected to supply power to the field devices and the host on this segment. As is illust-
rated in chapter 2.1.1, the output current of the power supply/Power Conditioner as
well as the current consumption of the field devices and host are used to determine
how many stations can be operated on this fieldbus segment.

In accordance with IEC 61158-2, the maximum

number of stations that can be operated on a fieldbus segment is 32.
Each field device, each Power Repeater that is connected, and each
host count as one station in this number!

According to this determination, 4 stations are connected in fig. 2.3 on the H1 seg-
ment A (1 host, 1 Power Repeater, 2 field devices; the power supply/the Power Con-
ditioner are not included in the count, since they do not receive any data telegrams).
Date of issue 17.12.2003

Three stations are connected on H1 segment B (1 Power Repeater, 2 field devices).

Each fieldbus segment must be provided with a fieldbus terminator on both ends. This
fieldbus terminator can be

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

• integrated into the fieldbus station. If so, it can be turned on easily,

• integrated into the junction box where it can also be turned on by means of a slide
switch,
• mounted separately and external and then connected.

2.2.1 Power feed concepts of standard FOUNDATION Fieldbus applications

2.2.1.1 FOUNDATION Fieldbus power supply

The power supplies and Power Conditioners are provided for supplying power to non-
intrinsically safe H1 fieldbus segments.

In the case where no field device or other fieldbus station requiring a

power supply from the H1 bus is connected between the host/Linking
Device and the Power Repeater and the H1 connection requires no
external power supply through the H1 bus, there is
no need for the power supply/Power Conditioner.

Pepperl+Fuchs offers the following power supply:

• KLD2-STR-1.24.400.IEC, fieldbus power supply with 400 mA of current.
The following table shows an overview of the most important characteristic values:
KLD2-STR-1.24.400.IEC
Measurement voltage on the field side 24 V ... 26 V
Measurement current on the field side 400 mA
Max. number of bus stationsa 32
a.The actual number of stations on a bus segment depends on the actual current consumption of the slaves and the host. The specified number of stati-
ons is only reached if the current consumption for each station is 10 mA.

Table 2.4: Rating values of the power supply

The power supply has an integrated fieldbus terminator that cannot be turned off. Be-
cause of this, they must always be connected on the end of the trunk.

2.2.1.2 The FOUNDATION Fieldbus Power Conditioner

Power supplies are active elements and currently supply a maximum of 400 mA
supply current. If
• more supply current is required
• redundancy is desired
• an especially low probability of failure is considered important
Power Conditioners can be used. Power Conditioners are passive elements, i.e. po-
wer is supplied to them from a separate power source that does not need to satisfy
the special requirements of the FOUNDATION Fieldbus.
Date of issue 17.12.2003

20
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

to the H1 connections of the

host or Linking Devices

to the H1 fieldbus
segments

Power
Rail

24 V DC 24 V DC
Fault message Fault message
output output

Power Conditioner

Power feed module redundant

or power source Power feed module
or power source

Fig. 2.4:Structure of a Power Conditioner

The KLD2-PL-1.1.IEC Power Conditioner supplies a maximum output current of 1 A.

It makes the impedance adjustment between the power source supplying the power
and the power feed module and disconnects communication of the H1 bus from the
power source.
Power can be supplied to up to 4 Power Conditioners by one power feed module.
Thus in fig. 2.4, power can be supplied to up to four H1 segments.
Any overload that is present on a Power Conditioner (for example because of a short
circuit that is present) can be indicated by a fault signal output.
If a short circuit is present on an H1 bus, this fault is transferred by the Power Condi-
tioners to the Power Feed modules. The Power Feed modules in turn report the fault
by means of a relay on the fault signal output.
During planning, H1 segments should be dimensioned for a maximum of 930 mA per
segment.
In the event of a short circuit on an H1 bus segment, the Power Conditioner limits the
current to 1.2 A. In the event of a short circuit, the current calculation is as follows:
Date of issue 17.12.2003

3*930 mA + 1.2 A = 3.99 A

This prevents the three H1 bus segments that are not affected by the short circuit from
failing.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

If each H1 segment received a load of 1 A, the following case could occur in the event
of a short circuit:
The following current flows through the fuse of the power feed module/power pack
3*1 A + 1.2 A = 4.2 A
and the fuse is tripped. As a result, the other three H1 bus segments fail.
Power supply components can be designed redundantly if they are provided with de-
coupling diodes. Care must be taken in this case that a power feed module/power
source alone is capable of supplying power to the fieldbus segment in the even of a
failure(see fig. 2.4).
Because of their low probability of failure, Power Conditioners themselves do not
need to be designed redundantly. According to calculations performed by an external
source (Exida), the probability of failure is 2*10-4. This corresponds to a MTBF (Mean
Time Between Failure) of approx. 5000 years. The redundancy that is also required
for the power supply is thus reliably ensured.
Power Conditioners are based on the well-tried and tested KF system of
Pepperl+Fuchs. KF modules are supplied with power from the power rail, an
insert component placed in the 35-mm DIN rail. The power supply is
switched by means of power supply modules, the connecting elements between the
separate power source and the Power Rail, or corresponding power source, to the po-
wer rail.
The UPR-03 Power Rail does not have a grid and is delivered together with a carrier
rail 2 meters in length. The UPR-03 can be shortened at any spot. The PR-03 has a
20-mm grid and is an insert component to be fitted onto a DIN rail in accordance with
EN 50022. It is supplied with a length of 50 cm and can be reduced in size at any of
the grid marks spaced at intervals of 40 mm.
Both Power Rails can be used for the Power Conditioner.
If a power feed module fails, this will also be indicated through a fault signal output.

2.2.2 Power Repeater

Power Repeaters combine two H1 bus segments with each other. They are used to
make it possible
• to increase the line length of a bus segment
• to connect more than 32 stations to one Link Active Scheduler (the part of a H1 in-
put card of a PLC or a Linking Device, which controls the communication on the H1
bus).

It has to be ensured, that the Link Active Scheduler can handle so many
field devices and/or function blocks.
Date of issue 17.12.2003

• to convert from a non-intrinsically safe bus segment to an intrinsically safe bus

segment.
Power Repeaters always open a new H1 bus segment. Because of this, they always
have an integrated, non-selectable fieldbus terminator on the field side and a selec-

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

table or switchable fieldbus terminator on the host side. Thus, Power Repeaters can
be connected everywhere on an H1 bus segment.
One opportunity for using the Power Repeater has already been illustrated in fig. 2.3.
The following figure illustrates the same application with a Linking Device:
H2 bus

Linking Device

Power Repeater
H1 Segment A H1 Segment B

FT

FT
FT
FT

Power supply
Power Conditioner

Fig. 2.5:Power Repeaters on a FOUNDATION fieldbus H1 segment

Power Repeaters only supply power to the field side of the H1 bus. In
this example, a power supply/Power Conditioner is required between
the Linking Device and the Power Repeater because the connected
field devices require power.

The Power Repeaters fulfil the following tasks:

• Galvanic isolation between bus segments,
• conditioning the data signal bidirectionally,
• power supply for the connected instruments,
• diagnostics via LEDs.
These functions are always combined in a single housing.

No configuration is required for Power Repeaters. From the point of view of the host,
they are invisible.
Pepperl+Fuchs offers the following Power Repeaters for standard applications:
Date of issue 17.12.2003

• KLD2-PR-1.IEC, Power Repeater with 24 V, 400 mA available.

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

2.2.3 Junction box

Basically, there are two ways to connect fieldbus stations to the fieldbus cable:
1. daisy chaining the data line
2. with junction boxes
Daisy chaining is the most cost effective and is illustrated in the figure below:

to the host
H1 bus transmission line

Station 1
Station 4
Station 2 Station 3
Fig. 2.6:Connection options for transmission lines using daisy chaining

Many fieldbus stations offer a connection option for an "incoming" and an "outgoing"
transmission line in a number of different mechanical designs.
The advantage of this connection method is that no additional junction boxes are re-
quired and there are no spurs.
The disadvantage is that if a station fails or needs to be replaced, other stations can
also be affected. For example, if Station 2 needs to be replaced in fig. 2.6, the H1 bus
transmission line must be interrupted to do so. This interruption generates fault mes-
sages in the host for Station 3 and 4.
This can be avoided by using junction boxes.

Junction box

Trunk

Spurs

Station 3
Station 1 Station 2
Date of issue 17.12.2003

Fig. 2.7:Use of junction boxes

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Junction boxes form a branch of the trunk referred to as a spur. Up to 4 field devices
can be connected on a single spur as described in table 1.4.
Note the connection between the number of stations on a segment, the
stations per spur and the maximum spur length in table 1.4

However, it is especially advantageous if only one fieldbus station is connected. In the

event that a fieldbus station needs to be replaced, it can be isolated from the spur
without any effects on the other fieldbus stations. Short circuit represents an excep-
tion in this case.

2.2.4 Segment Protectors

There are also junction boxes available on the market with an integrated current limi-
tation. these devices are called Segment Protectors
Segment Protectors offer protection in the event a short circuit or defect in a field de-
vice occurs on the spur. This protection prevents any negative effect spreading from
the spur to the trunk and other spurs.
For example if a short circuit occurs in fig. 2.7 in Station 2 or between Station 2 and
the Segment Protector the trunk and thus all other stations will not be negatively af-
fected by this short circuit. Only Station 2 will fail.
Without this protection, the entire H1 segment fails! What fatal consequences this be-
ars are apparent from fig. 2.3 on page 19.
If this fault occurs on H1 Segment B, only H1 Segment B fails. The Power Repeater
has galvanic isolation between the host side and the field side to prevent this fault
from "overlapping". If a fault occurs on H1 Segment A, however, both segments will
fail!
This can be prevented by using Segment Protectors.
There are junction boxes and Segment Protectors with 1, 2, 4, 6 and 8 spur connec-
tions. Specifically, these are the junction box of series
• F2-JBSC-... Segment Protector with 4, 6 or 8 spur connections
• F3-JBSC-... Segment Protector with 2 spur connections
• F4-JBSC-... Segment Protector with 1 spur connection
• R-JBSC-8 Segment Protector with 8 spurs for DIN rail mounting.
• F2-JB-... junction box with 4, 6 or 8 spur connections
• F3-JB-... junction box with 2 spur connections
• F4-JB-... junction box with 1 spur connection
Date of issue 17.12.2003

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

In addition, you can select from among the following options:

• with cable glands or with connectors. In this case,
connectors offer an advantage if pre-configured
cables are used. Installation time is especially short in
this case.
Fig. 2.8 shows examples of pre-configured cables
called cord sets from the product range of
Pepperl+Fuchs.
• Cable glands are available in plastic, nickel-plated
brass and stainless steel. In addition, special cable
glands are available for armored cables.
• Cable glands are also available in nickel-plated brass
and stainless steel with M12 threading or
7/8" threading.

Fig. 2.8:Cordsets

2.2.5 Terminating the trunk with a fieldbus terminator.

Each end of the transmission line of a fieldbus application must be equipped with a
fieldbus terminator.
A fieldbus terminator is integrated into all Pepperl+Fuchs supply devices.
• It is permanently integrated for power supplies,
• in the case of Power Conditioners, it can be turned on and off,
• in the case of Power Repeaters, it can be turned on and off on the host side and is
permanently integrated on the field side.
If Pepperl+Fuchs supply devices are used, the only other terminator required is on the
other end of the segment.
Pepperl+Fuchs field devices have a terminator that can be turned on and off, as do
FieldBarriers. This can be used if the device is the last station on the fieldbus.
Very frequently there is a need for external fieldbus terminators. The advantage of
these is that the users can see where the terminator is connected.
Date of issue 17.12.2003

26
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Fieldbus terminators are available in the IP20

switch cabinet housing or in the IP67 field
housing.
The fieldbus terminator must be mounted in such
a manner as to ensure the longest possible line
length between the power supply/Power
Repeater/Power Conditioner and the fieldbus
terminator. Fieldbus terminator
in the IP20 housing
Fieldbus terminators in the IP67 housing are sui-
table for ignition protection class EEx i for intrinsi-
cally safe fieldbus segments and in ignition
protection class EEx d (Flame proof/explosion
proof enclosure) for fieldbus segments in the ha- Fieldbus terminator
zardous area. They can also be used for safe ap- in the IP67 housing
plications.

Fig. 2.9:Fieldbus terminators

2.3 Use of FOUNDATION Fieldbus in hazardous areas

As already explained in chapter 1.6 the H1 bus of the FOUNDATION Fieldbus can
also be used in hazardous areas.
A distinction is made below depending on whether the installation is made
• in accordance with European standards and directives or
• in accordance with North American standards and directives.

2.3.1 Installation in accordance with European standards

In this type of installation, a distinction must be drawn depending on whether an in-
stallation is made
• in Zone 2 or
• in Zone 1 or 0.
The host is always mounted in the safe area for all of these applications and the H1
bus trunk is directed into the hazardous area.

2.3.1.1 Installation in Zone 2 of a hazardous area

Fig. 2.10 shows how an application can be installed for Zone 2:
Date of issue 17.12.2003

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Hazardous area
Zone 2
Segment Protectors

Segment Protector
or
Junction box
Station 3
Station 1 Station 2

Fig. 2.10:Zone 2 application

Devices that are mounted in Zone 2 of a hazardous area must have (at least) approval
for Zone 2.
This also to both field devices and junction boxes, but not to the fieldbus cable.
Pepperl+Fuchs offers the following Segment Protectors with approval for mounting in
Zone 2:
• F2-JBSC-... Segment Protector with 4, 6 or 8 spur connections
• F3-JBSC-... Segment Protector with 2 spur connections
• F4-JBSC-... Segment Protector with 1 spur connection
• R-JBSC-8 Segment Protector with 8 spur connections
All Segment Protectors are ¬ II 3 G EEx nAL IIC T4 approved. This means that they
can be used:
• in all areas except in mining industry
• in Zone 2
• in a hazardous area with a potentially explosive gas atmosphere
For more detailed information, please refer to the "Explosion protection manual" of
Pepperl+Fuchs.
Based on the approval in accordance with EN 50021 in ignition protection class
EEx n as non-sparking, power limiting equipment, field devices that are also installed
in Zone 2 may be disconnected from or connected to the spur in ongoing operation.

2.3.1.2 Installation in Zone 1 or 0

Date of issue 17.12.2003

The following shows an example of how to set up a FOUNDATION Fieldbus for

applications in hazardous areas:

28
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Hazardous area
Zone 0 or 1
to the host Intrinsically safe junction boxes

Power Repeater
with intrinsically
safe Interface in
accordance with
FISCO model
Station 3
Station 1 Station 2

Fig. 2.11: Structure of an intrinsically safe fieldbus segment

The Power Repeater opens an intrinsically safe H1 segment. The Power Repeater
must be certified in accordance with the FISCO model. The KLD2-PR-Ex1.IEC1
Power Repeater of Pepperl+Fuchs is such a device. Its rating data is shown below:
KLD2-PR-Ex1.IEC1
Measurement voltage on the field
12.8 V ... 13.4 V
side
Measurement current on the field side 100 mA
Measurement voltage on the host
9 V ... 32 V
side
Since the Power Repeater with an intrinsically safe interface always opens a new
intrinsically safe H1 segment, the necessary terminator is permanently integrated on
the field side. The terminator on the host side can be switched on and off.
In addition to the Power Repeater field devices and junction boxes also require
approval for mounting in a hazardous area.
Pepperl+Fuchs offers the following junction boxes for mounting in hazardous areas:
• F2-JB-I-... junction box with 4, 6 or 8 spur connections
• F3-JB-I-... junction box with 2 spur connections
• F4-JB-I-... junction box with 1 spur connection
Note that in the case of intrinsically safe junction boxes no terminator is integrated for
safety reasons. The fieldbus segment in this case must terminated
• by an external fieldbus terminator or
Date of issue 17.12.2003

• by a fieldbus terminator that is integrated in the field device.

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

The disadvantage of this type of layout for intrinsically safe fieldbus segments is that
in accordance with the FISCO model, only a maximum of 10 stations
can (theoretically) be operated on one fieldbus segment. In actual practice, the
maximum number is 6 to 7 stations. If more stations need to be operating, correspon-
dingly more Power Repeaters are required.
The number of field devices actually connected is derived from the current and volta-
ge calculation that was presented in chapter 2.1.1 and chapter 2.1.2.
The total cable length, i.e. the trunk length plus the total of all spurs, must not exceed
1000 m for the FISCO model.
It will prove to be advantageous if the trunk is laid with increased safety EEx e, since
more supply current can then be transmitted into the hazardous area. Conversion to
an intrinsically safe fieldbus segment takes place on site with the aid of the
FieldBarrierTM.

Ex zone
to Zone 1
host
H1 Segment EEx e H1 Segment EEx e

Power Repeater/ FieldBarrierTM

Power Conditioner
without EEx i
Interface

Ex-zone
Zone 0 or 1 H1 Segments EEx ia

Fig. 2.12: Topology with FieldBarrier

At the time when the cable is installed in a the hazardous area, it must be protected
against
• mechanical,
• chemical and
• thermal
damage. For more detailed information, please refer to EN 60079-14.
Date of issue 17.12.2003

These are the requirements of the "increased safety" ignition protection method in
terms of installation. Lines, terminals etc., that are designed with increased safety
must only be opened under very specific conditions (for example when the system is
turned off). For this reason, it is not a good idea for the field device to be connected

30
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

directly to the EEx e transmission line.

It is much better to use an "intelligent junction box". These intelligent junction boxes,
for example the FieldBarriersTM of Pepperl+Fuchs, convert non-intrinsically safe in-
puts to intrinsically safe outputs. Field devices are connected to intrinsically safe out-
puts and can be disconnected from or connected to the transmission line at any time.
The FieldBarrierTM carries out the following tasks:
• Ensuring galvanic isolation between the non-intrinsically safe fieldbus segment
(trunk) and the intrinsically safe fieldbus segment (outputs).

Care must be taken to ensure galvanic isolation between the

intrinsically safe outputs and the non-intrinsically safe input (the trunk).

• Connection of the trunk with a fieldbus terminator if the FieldBarrier is the last
station on the trunk. A selectable fieldbus terminator is integrated into the FieldBar-
rier for this purpose.
• Ensuring intrinsic safety on the outputs (i.e. voltage and current limiting on every
output).
• Power supply of field devices connected to the outputs
For the trunk, this is a non-intrinsically safe fieldbus segment to which up to 32 field
devices can be connected, in accordance with the FOUNDATION Fieldbus
specification, and which can be up to 1900 m long.
Because of the design of the FieldBarrier, the input impedances of the connected field
devices are transformed to the trunk.
As a result of this, with a topology based on fig. 2.12, a total of 32 stations can be ope-
rated on the intrinsically safe outputs of all FieldBarriers.

FieldBarriers do not count as stations

Use in the safe area or in Zone 2 of a hazardous area is also possible with FieldBar-
riers.
Due to the integrated galvanic isolation the output of the FieldBarrierTM represents a
supply source for each connected field device.

From the point of view of the FISCO model, an output of the FieldBarrier
represents the supply source for the intrinsically safe fieldbus segment.
This opens a new, intrinsically safe fieldbus segment.
Date of issue 17.12.2003

From an architecture perspective, a maximum permissible cable length of 120 m per

output is permitted. The outputs operates without fieldbus terminators.

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

The field devices are intrinsically safe powered with 10 V and 40 mA per output.
Each output has a voltage limit and current limit. This offers the advantage of
preventing negative effects on the other outputs and on the trunk if a short circuit oc-
curs on an output, for example.
Using the FieldBarrier offers the following advantages:
• FieldBarrier combines the features of a short circuit protected junction box with an
IS barrier in a field mountable package.
• The FieldBarrier has a MTBF of several hundred years.
• Limiting the short-circuit current on the output means that only the affected output
will fail if there is a short circuit between the FieldBarrier and field device(s). The
fieldbus segment continues working.
• The only required elements are power supplies/Power Repeaters/Power Condi-
tioners. This reduces the number of components.
There are two possible topologies for the non-intrinsically safe trunk in connection
with the FieldBarrierTM. One was presented in fig. 2.12, the other is shown in the
following illustration:
.
Ex zone H1 Segment EEx e H1 Segment EEx e
to Zone 1
host

Power Repeater/ l<1m

Power Conditioner
without EEx i
Interface FieldBarrierTM

Ex-zone
Zone 0 or 1 H1 Segments EEx ia

Fig. 2.13: Topologies of the non-intrinsically safe fieldbus segment

• In fig. 2.12, the trunk is directed into the FieldBarrier through one of the EEx e
cable glands and back out through the second EEx e cable gland.
Date of issue 17.12.2003

32
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

• In fig. 2.13, the FieldBarrier is connected to the trunk via a junction box

If this possibility is selected, the spur between the junction boxes and
the FieldBarrierTM, referred to as the splice, must be shorter than 1 m.

2.3.1.3 Dimensioning of a fieldbus segment with FieldBarriersTM

Dimensioning of a fieldbus segment was described in chapter 2.1.
However, the calculation of maximum permissible line length described there is only
valid if each fieldbus station of a segment has a linear characteristic input curve.

The FieldBarrier has a non-linear characteristic input curve. For this

reason, Pepperl+Fuchs offers a software program for planning support.
This software, referred to as a Segment Checker, is available for
downloading on the www.pepperl-fuchs.com homepage or through
www.fieldconnex.info.

2.3.2 Installation in accordance with North American standards

In this type of installation, a distinction must be drawn depending on whether an in-
stallation is made
• in Class I, Class II or Class III
• in Division 1 or 2
of a hazardous area. The host is mounted in the safe area for all of these applications.
Because of this, the trunk must be directed into the hazardous area.
The only distinction drawn for installations in the following section is Division I or II.
Reference is made in individual cases to whether the type of installation in question
is permissible for Class I, II or III.

2.3.2.4 Installation in Division 2 of a hazardous area

Most applications are made in Division 2 of a hazardous area. There are two ways to
set up a useful fieldbus topology for applications such as these:
• The trunk is directed into the hazardous area in the "Nonincendive" ignition
protection class. Field devices are connected to the trunk via standard junction
boxes or Segment Protectors (see fig. 2.14 on page 34).
• The trunk is directed into the hazardous area with a protection method approved
for Division 2 (Division 2 wiring method). Field devices are connected to the trunk
via Segment Protectors (see fig. 2.15 on page 35).
Date of issue 17.12.2003

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Hazardous area
Class I Division 2
Junction box or
Segment Protectors
to the host

Power Repeaters
Nonincendive
(for example
KLD2-PR-NI1.IEC)
Station 3
Station 1 Station 2

Fig. 2.14: Division 2 application of the Nonincendive ignition protection class

Standard wiring can be used for this type of Division 2 instrumentation.

The Nonincendive Power Repeater has an approval in accordance
with "Nonincendive field wiring". This means that the field devices must also be
designed for the "Nonincendive field wiring" ignition protection class or the "intrinsic
safety" ignition protection class.
In addition, the following proof must be provided for each field device:
Field device Vmax> Voc Power Repeater
Field device Imax > Isc Power Repeater
It must also be proved that:
ΣCi + CCable < Ca
ΣLi + LCable < La
This means that the total of all input capacitances of field devices plus the line
capacitance is less than or equal to the maximum capacitance of the Power Repeater
that can be connected. The same applies analogously to inductances.
In this special case, the nonincendive Power Repeater has also an approval to be
mounted in Class I Division 2. This means that it can also be used inside the hazar-
dous area to extend the lead or to increase the number of stations that can be con-
nected.
Date of issue 17.12.2003

34
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

The following illustration shows another possibility:

Hazardous area
Division 2 Class I Division 2
Wiring
method Segment Protectors
to the host

Power Repeater or
Power Conditioner

Station 3
Station 1 Station 2

Fig. 2.15:Division 2 application the with Division 2 wiring method

A standard Power Repeater or a Power Conditioner is used for this possible solution.
If the trunk is directed into the hazardous area, it must be laid in accordance with a
Division 2 wiring method. More specific details are specified by NEC Article 501.4.
Segment Protectors are used to connect field devices to the trunk. The outputs of the
Segment Protectors are designed for the Nonincendive ignition protection class. Field
devices that are connected must also be designed in this ignition protection class or
in the "intrinsic safety" ignition protection class.
Proof must be provided for the connection between the output of the Segment Pro-
tector and the fieldbus station (for the spur) as is illustrated on page 34.

2.3.2.5 Installation in Division 1 of a hazardous area

If the transmission line of the FOUNDATION Fieldbus is laid in Division 1 of a
hazardous area, it must be designed to be intrinsically safe.
There are two ways to ensure intrinsic safety:
1. A Power Repeater with an intrinsically safe interface is used.
Generally the Entity model serves as the basis in the North American market (refer
to chapter 1.6.2). If the FISCO model is approved in an exceptional case, the
European standards can be followed in this case. You will find this beginning in
chapter 2.3.1.2 on page 28. An example of an intrinsically safe FOUNDATION
Fieldbus topology in accordance with the Entity model is shown in fig. 2.16.
2. Another possibility is to mount the FieldBarrierTM in a Class I Division 2 and to direct
the intrinsically safe outputs of the FieldBarrierTM into Division 1. An example of
this is shown in fig. 2.20.
Date of issue 17.12.2003

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Hazardous area
Class I Division 1 or 2
Class II Division 1 or 2
to the host Intrinsically safe junction box

Power Repeater
with intrinsically
safe Interface in
accordance with
the Entity model
Station 3
Station 1 Station 2
Fig. 2.16: Intrinsically safe FOUNDATION Fieldbus topology

The Power Repeater opens an intrinsically safe H1 segment. The Power Repeater
must be certified in accordance with the Entity model. The KLD2-PR-Ex1.IEC Power
Repeater of Pepperl+Fuchs is such a device. Its rated data is shown below:
KLD2-PR-Ex1.IEC
Measurement voltage on the field
10.6 V ... 10.9 V
side
Measurement current on the field side 70 mA
Measurement voltage on the host
9 V ... 32 V
side
Since the Power Repeater with an intrinsically safe interface always opens a new
intrinsically safe H1 segment, the necessary terminator is permanently integrated on
the field side. The terminator on the host side can be turned on and off.
In addition to the Power Repeater, field devices and junction boxes also require
appropriate approvals.
Pepperl+Fuchs offers the following junction boxes for mounting in hazardous areas of
Class I Division 1 and 2 as well as Class II Division 1 and 2:
• F2-JB-I-... junction box with 4, 6 or 8 spur connections,
• F3-JB-I-... junction box with 2 spur connections,
• F4-JB-I-... junction box with 1 spur connection.
Note that in the case of intrinsically safe junction boxes no terminator is integrated for
safety reasons. The fieldbus segment in this case must terminated
• by an external fieldbus terminator or
Date of issue 17.12.2003

• by a fieldbus terminator that is integrated into the field device.

The disadvantage of this type of layout for intrinsically safe fieldbus segments is that
in accordance with the Entity model, only a maximum of 6 stations can (theoretically)

36
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

be operated on one fieldbus segment. In actual practice, the maximum number is 4

stations. If more stations need to be operating, correspondingly more Power
Repeaters are required. The number of field devices actually connected is derived
from the current and voltage calculation that was presented in chapter 2.1.1 and
chapter 2.1.2.
The advantage, which also applies to larger applications, is that the wiring is very
simple and thus cost effective.
If power needs to be supplied to more stations via a Power Repeater/Power
Conditioner, this can be done as follows:

Hazardous area
to Class I Division 2
host Division 2
Wiring method

Power Repeater or FieldBarrierTM

Power Conditioner

Ex zone
Class I Div. 1 or 2 H1 Segment EEx ia
Class II Div. 1 or 2

Fig. 2.17:Intrinsically safe fieldbus topology with FieldBarrierTM

The FieldBarrier can only be mounted in a hazardous area of Class I Division 2. If the
trunk is directed into this area, an approved Division 2 wiring method must be used.
The FieldBarrier converts from a non-intrinsically safe input to an intrinsically safe
output in accordance with the Entity model. This means that the intrinsically safe out-
put leads can be laid into areas of Class I Division 1 or 2 and/or Class 2 Division 1 or 2.
The field devices must also have the appropriate approval.
The FieldBarrierTM carries out the following tasks:
• Ensuring galvanic isolation between the non-intrinsically safe fieldbus segment
(trunk) and the intrinsically safe fieldbus segment (outputs).
Date of issue 17.12.2003

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Care must be taken to ensure galvanic isolation between the

intrinsically safe outputs and the non-intrinsically safe input (the trunk).

• Connection of the trunk with a fieldbus terminator if the FieldBarrier is the last
station on the trunk. A selectable fieldbus terminator is integrated into the FieldBar-
rier for this purpose.
• Ensuring intrinsic safety on the outputs (i.e. voltage and current limiting on every
output).
• Power supply of field devices connected to the outputs
For the trunk, this is a non-intrinsically safe fieldbus segment to which up to 32 field
devices can be connected, in accordance with the FOUNDATION Fieldbus
specification, and which can be up to 1900 m long.
Because of the design of the FieldBarrier, the input impedances of the connected field
devices are transformed to the trunk.
As a result of this, with a topology based on fig. 2.12, a total of 32 stations can be ope-
rated on the intrinsically safe outputs of all FieldBarriers.

FieldBarriers do not count as stations

Due to the integrated galvanic isolation the output of the FieldBarrierTM represents a
supply source for each connected field device.

From the point of view of the Entity model, an output of the FieldBarrier
represents the supply source for the intrinsically safe fieldbus segment.
This opens a new, intrinsically safe fieldbus segment.

From an architecture perspective, a maximum permissible cable length of 120 m per

output is permitted. The outputs operates without fieldbus terminators.
The field devices are intrinsically safe powered with 10 V and 40 mA per output.
Each output has a voltage limit and current limit. This offers the advantage of
preventing negative effects on the other outputs and on the trunk if a short circuit oc-
curs on an output, for example.
Using the FieldBarrier offers the following advantages:
• FieldBarrier combines the features of a short circuit protected junction box with an
IS barrier in a field mountable package.
Date of issue 17.12.2003

• The FieldBarrier has a MTBF of several hundred years.

• Limiting the short-circuit current on the output means that only the affected output
will fail if there is a short circuit between the FieldBarrier and field device(s). The

38
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

fieldbus segment continues working.

• The only required elements are power supplies/Power Repeaters/Power Condi-
tioners. This reduces the number of components.

2.4 Fieldbus Process Interfaces

Fieldbus Process Interfaces, or FPIs, are used to transfer simple signals via the
FOUNDATION Fieldbus. For example, this includes signals
• of proximity switches
• of temperature sensors (RTDs, thermo couples)
• for valves
An example of such a Fieldbus Process Interface is the 4-channel FD0-VC-Ex4.FF
valve coupler of Pepperl+Fuchs.
Intrinsically safe FOUNDATION
Fieldbus H1 segment

Fig. 2.18: FD0-VC-Ex4.FF valve coupler

In this case, signals are transferred from 4 intrinsically safe valves including their set-
ting feedback. Many functions that previously had to be depicted in the DCS system
can now be taken over directly from the valve coupler. For example, this includes
• Counting functions (full stroke counter)
• Time functions (measurement of the time required for the valve to move from the
closed position to the open position)
These features allow the valve coupler to generate a message if the full stroke counter
has reached a programmed value or if the time exceeds a programmed limit. Among
other things, this saves programming overhead in the process control system. The
adjustable parameters are automatically downloaded to the new station if the valve
coupler is replaced.
For additional information related to valves available for operation and other Fieldbus
Process Interfaces that are available, go to www.fieldconnex.info or
Date of issue 17.12.2003

www.pepperl-fuchs.com.

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

2.5 Fieldbus terminators

Additional external fieldbus terminators are only required if

• no terminators are integrated into the field devices or they are but should not be
used

and/or

• No terminators are integrated into the junction boxes/Segment Protectors/FieldBar-

riers/ Power Repeaters/Power Supplies/Power Conditioners or, if they are, they will
not be used. Note that for many of the devices named here, the fieldbus terminator
is integrated on the field side and cannot be turned off.
If external fieldbus terminators are
required, Pepperl+Fuchs offers the follo-
wing options:
Fieldbus
1. Fieldbus terminator in IP20 for mounting terminator in IP20
in a switch cabinet
2. Fieldbus terminators in IP67 in ignition
protection class EEx d "flameproof
enclosure"
3. Fieldbus terminators in IP67 in ignition
protection class EEx i "intrinsic safety"
Fieldbus
terminator in IP67

Fig. 2.19:Fieldbus terminators

2.6 Fieldbus cable

For a fieldbus application, cable type A (see table 1.3, “Fieldbus cable types and max.
lead length,” on page 8) should be used for the trunk. It is furthermore
recommended to use a non-pre-configured cable, since it must frequently be laid over
great distances in narrow cable shafts.
Pepperl+Fuchs offers such cables in different lengths from 75 m (250 ft) to 1500 m
(5000 ft). A blue cable is also available for intrinsically safe applications.
Use of pre-configured cables with screw-in plugs and/or sockets are recommended
for spurs. This reduces both the installation time and the time required to replace a
field device if it fails.
These spurs are available
• in lengths of 2 m (6.5 ft), 5 m (16.4 ft), 10 m (32.8 ft) or as specified by the customer,
• with an M12 screw connection as "micro extension cables",
Date of issue 17.12.2003

• with a 7/8" screw connection as "mini extension cables",

• in various cable qualities as well as armored cable.

40
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

For more detailed information, please refer to the corresponding data sheets, which
can be downloaded from www.fieldconnex.info or www.pepperl-fuchs.com.

2.7 Grounding and shielding of a fieldbus application

Shielded cables should be used as a fieldbus transmission line (for example cable
type A). In order for the shield to perform its task of protecting against electromagnetic
interference, it must be grounded.
There are 3 possibilities:
1. The shield is connected on one side with potential equalisation, i.e. it is hard
grounded.
2. The shield is hard grounded on one side, while the other end of the shield is
connected with potential equalisation via a capacitor (capacitive grounding).
3. The shield is hard grounded on both sides.
The Fieldbus Foundation recommends Version 1 in its Application Guide for
Intrinsically Safe Systems.

This version is preferred for usage in the North American market.

A possibility is shown in fig. 2.20 on page 42. This illustrates a safe application. Six
field devices that are connected to the trunk via junction boxes are operated on one
Power Repeater. The trunk is represented in bold in the illustration.
The H1 bus from the host is laid via the power feed module to the power rail.
The Power Repeaters are connected via the power rail with the H1 bus on the host
side. Because of this, the fieldbus terminator is also only turned on on the last Power
Repeater.
On the field side, each Power Repeater opens a new H1 bus segment. Because of
this, the fieldbus terminator is continuously available there and cannot be turned off.
Furthermore, the shield of the fieldbus transmission line on the field side is connected
with the potential equalisation of each Power Repeater.
The SCR shield terminals in each junction box for the trunks and spurs are connected
with each other. Thus the screen has approximately ground potential everywhere.
Since the resistance of the shield is negligible, diversion of interfering signals is rather
defective, especially for stations that are far removed from the Power Repeater.

For applications in which heavy electromagnetic interference fields are

present, connecting the shield to the potential equalisation on only one
side offers only inadequate EMC protection.
Date of issue 17.12.2003

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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Date of issue 17.12.2003

Fig. 2.20:Example of one-sided hard grounding of the shield

42
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 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Better protection is offered by version 2, which is shown in fig. 2.21 on page 44.
In this case, the shield is connected to each field device on the potential equalisation.
The shield on the Power Repeater is connected to the potential equalisation via a ca-
pacitor. Because of this, no direct currents can flow through the shield. Such currents
can arise when the ground potential is not equal everywhere in the application.
High-frequency EMC interference pulses are directed away on both ends of the line,
thus via the capacitor as well.
Since the capacitor must be mounted in the safe area in this example, but it is also
connected with a shield that is laid in the area subject to the danger of explosions, it
must satisfy certain requirements. It must
• have a fixed dielectric (for example ceramic)
• have a capacitance C < 10 nF
• be designed for a test voltage between shield and data line > 1500 V.
This method of connecting the shield with the potential equalisation protects the
application better from EMC interference than the first version. However, the best
protection is achieved if the shield is connected directly with potential equalisation on
both sides.
An example of this is fig. 2.22 on page 45. The best possible EMC protection is
achieved in this example. Of course, a potential equalisation conductor is required.

This optimal procedure for electromagnetic compatibility and personal

protection can be used in accordance with EN 60079-14, Section
12.2.2.3 without any restriction in systems with potential equalisation
that is "ensured to a high degree" during the installation of the fieldbus
system as a whole.

This potential equalisation entails a not insignificant amount of effort in practical

cases. Only the user can decide what kind of EMC protection is actually required in
the systems in question. In systems with low "EMC contamination" it may be sufficient
to select the first of the three possibilities. In systems with very heavy "EMC contami-
nation", it may be necessary to use Version 3.

All fieldbus components of Pepperl+Fuchs support each of the 3 EMC

protective measures presented here. For more detailed information,
please refer to corresponding manual or data sheet. They are available
for downloading at www.fieldconnex.info and www.pepperl-fuchs.com.
Date of issue 17.12.2003

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany +49 621 776-0 • USA +1 330 4253555 • Singapore +65 67799091 • Internet http://www.pepperl-fuchs.com 43
 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Date of issue 17.12.2003

Fig. 2.21:Example of capacitive grounding of a shield

44
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany +49 621 776-0 • USA +1 330 4253555 • Singapore +65 67799091 • Internet http://www.pepperl-fuchs.com
 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application
Date of issue 17.12.2003

Fig. 2.22:Example of two-sided hard grounding of a shield

Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany +49 621 776-0 • USA +1 330 4253555 • Singapore +65 67799091 • Internet http://www.pepperl-fuchs.com 45
 Wiring and Installation Guide for FOUNDATION Fieldbus
Planning and designing a FOUNDATION Fieldbus application

Date of issue 17.12.2003

46
Subject to reasonable modifications due to technical advances. Copyright Pepperl+Fuchs, Printed in Germany
Pepperl+Fuchs Group • Tel.: Germany +49 621 776-0 • USA +1 330 4253555 • Singapore +65 67799091 • Internet http://www.pepperl-fuchs.com
 he general terms of delivery for products and services produced or provided by the electrical industry as
published by the Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.
in its most recent edition as well as the supplementary proviso: "Extended property proviso" are applicable.

We at Pepperl+Fuchs feel obligated to contribute to the future;

this publication is, therefore, printed on paper bleached without the use of chlorine.
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