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Instrumentation Systems
Installation Manual
PN1:006
Revision C — October 1995
D3P00691302
ENVOX, microPROVOX, and PROVOX are marks of one or more of the Fisher-Rosemount group of
companies.
All other marks are the property of their respective owners.
The contents of this publication are presented for informational purposes only, and while every effort
has been made to ensure their accuracy, they are not to be construed as warranties or guarantees,
express or implied, regarding the products or services described herein or their use or applicability. We
reserve the right to modify or improve the designs or specifications of such products at any time without
notice.
Your Evaluation Please . . .
Job Responsibility:
Please indicate your evaluation of PN1:006 (Revision C — October 1995). Attach extra sheets if needed.
1. How and when do you use this manual? V Read entire manual before attempting task
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2. How well is the manual’s content V Excellent — parallels product’s operation,
organized? Please explain. very usable
V Good — representative of the product’s
operation, usable
V Average — usable but can be improved
V Fair — not very usable, should be improved
V Poor — not usable, must be improved
V No Opinion
Understandable Applicable
3. Is the manual’s content understandable V V Excellent — very easy to understand,
and applicable to the product’s operation? very applicable
Please explain. V V Good — easy to understand, applicable
V V Average — applicable but some sections
not easy to understand
V V Fair — not very understandable/applicable,
should be improved
V V Poor — not understandable/applicable,
must be improved
V V No Opinion
4. How well do the manual’s illustrations V Excellent — very easy to understand, extremely
convey product information? usable
Please explain. V Good — easy to understand, very usable
V Average — fairly easy to understand, usable
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improved, not very usable
V Poor — cannot understand, must be improved,
totally unusable
V No Opinion
5. Describe the amount of usable information V Too much information — not all required to
in this manual including tables. perform task
Please explain. V Proper amount provided — not too much nor
too little
V Too little information — needed additional
information to perform task
V No Opinion
Sections Index
Documentation Map
This map shows manuals used to plan the installation of a PROVOXr Process
Management System. The number, title, and binder location are shown for each
document, identifying where specific information is located. See the descriptions
on the back of this map for more information.
PN1:006
PROVOX
PN1:002
Planning and Installation
PN1:003
AC and DC Power and Ground Wiring
PN1:004
Signal Wiring and Highway System
Guidelines
PN1:005
Preventing Electrostatic Discharge
PN4:007
Lightning Protection Guidelines for
Instrumentation Systems
PN1:008
Site Evaluation
Contents
Section/Title Page
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 CE Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Structure of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.6 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.7 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.8 Excellence in Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Section/Title Page
Appendixes
Section/Title Page
Glossary
Index
Tables
3-1 Ambient Temperature and Humidity Limits for Category A . . . . 3-2
3-2 Ambient Temperature and Humidity Limits for Category B . . . . 3-2
3-3 Ambient Temperature and Humidity Limits for Category C . . . . 3-2
4-1 Shock and Vibration Limits for All Environmental Categories . . 4-1
5-1 Electromagnetic Field Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
6-1 Copper Reactivity Rates (Angstroms of Film Formation per
30 Day Exposure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Classification of Chemically Active Contaminants in
cm3/m3 (ppm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Guidelines for Environmental Characterization by Visual
Changes in Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Interpreting Humidity Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
8-1 Constant Percentage (C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
A-1 Environmental Classifications of PROVOX Instrumentation . . . A-1
Index 13
Index
Figure 1-Table 1
1 Introduction 1
1.2 CE Statement
If you intend to have your PROVOXr system certified for compliance to
appropriate European Union directives, the following CE statement is
extremely important to your ability to achieve that compliance.
J Acronyms and Abbreviations — Terms are spelled out the first time
they appear in text. Thereafter, only the acronym or abbreviation is
used. In addition, the glossary defines the acronyms and
abbreviations.
J Revision Control — The title page lists the revision level and the
printing date of this manual. When the document is revised, the
revision level and the printing date is changed.
Warning
All warnings have this form and symbol.
Do not disregard warnings. They are
installation, operation, or maintenance
procedures, practices, conditions,
statements, and so forth, which if not
strictly observed, may result in personal
injury or loss of life.
Caution
All cautions have this form and symbol. Do
not disregard cautions. They are
installation, operation, or maintenance
procedures, practices, conditions,
statements, and so forth, which if not
strictly observed, may result in damage to,
or destruction of, equipment or may cause
a long term health hazard.
Note
Notes have this form and symbol. Notes contain
installation, operation, or maintenance
procedures, practices, conditions, statements,
and so forth, that alert you to important
information which may make your task easier or
increase your understanding.
Figure 2-Table 2
2 Importance of Environmental
Considerations 2
The importance of considering the site environment can not be
understated. Whether installing a new system in a new plant, a new
system in an existing plant, or expanding an existing system,
environmental conditions must be considered; both in the immediate
area, and in surrounding areas, also.
Figure 3-Table 3
Ambient Relative 35 & 45% 20 & 80% 20 & 80% 20 & 80%
Humidity,
Non-Condensing
Maximum 6% ¤ hr 6% ¤ hr 6% ¤ hr
Relative Humidity --------------------
Variation
Warning
Both ac-line power and 24 volt dc power
with large current capability are supplying
power to installed equipment. To avoid
personal injury and damage to equipment,
exercise extreme caution when making
temperature measurements.
Caution
Preventing condensation is extremely
important. Corrosive vapors dissolving in
condensation turn it into acids that begin
to erode conductive lands, component
leads, connector pins, and other metal on
electronic equipment. The equipment can
become damaged beyond repair.
In most cases, there are two sources of heat within instrument cabinets or
enclosure systems. The first source is heat from the instruments; the
second source is ambient heat around the cabinet or enclosure system.
The second source may be a heat gain or a loss, depending upon the
temperature difference between the inside and the outside of the cabinet.
Further equations given below allow for calculating heat transfer through
the walls.
For the Types CP6101 and CP6102 System Power Supplies, dissipated
power is typically 225 watts, with a maximum of 385 watts (depending on
power supply load regulation requirements). For the Type CP6103
System Power Supply Unit, dissipated power from the 600 Watt unit is
typically 200 watts and from the 1200 Watt unit is 400 watts. Dissipation is
fairly stable for either unit over the typical range of output power. In
consoles, multiply the power consumption of the instruments by 1.4 to
allow for power supply heat losses.
where:
qs = 0.33(qr )
where:
The resultant cooling load measurement units are BTU per hour. Convert
the load to tons of refrigeration by dividing by 12,000.
Example
A group of cabinets in a rack-room contain various combinations of
instruments. What is the required cooling load?
First, add the electrical current drawn by the equipment in each cabinet.
For this example, the assumption is 270 Amps at 24 Vdc total for all
cabinets.
3 Next, apply the equation and determine the BTU per hour cooling
required:
The above example covers the cooling requirement for the electronic
equipment only; it does not cover additional heating from lighting, other
room equipment, personnel, and so forth.
qs = (U)(A)(Dt)
where:
Example
Assume a cabinet with 36 ft2 exposed metal surface and a temperature
that averages 40° F hotter than the desired temperature inside the
cabinet. The net heat gain is:
where:
CFM = cubic feet per minute of air flow. Refer to subsection 8.3
for the air flow equation.
Dt = the desired inside temperature minus the incoming air
temperature of the pressurizing system.
Example
Assume a NEMA 12 enclosure that is 4 ft by 4 ft by 1.5 ft and the
desired internal temperature is to be maintained at 75° F. For proper
pressurization, the volume of incoming air is the cabinet volume
(4 x 4 x 1.5) times 0.05 (the percentage constant for NEMA 12 cabinets)
= 1.2 CFM. The incoming air temperature is 70° F.
Figure 4-Table 4
4
Note
The limits noted in the table apply to infrequent
happenings. Equipment continuously exposed to
vibration or shock conditions may require
additional mounting considerations. Consult your
Fisher-Rosemount Systems representative or
sales office for more information.
Figure 5-Table 5
5 Electromagnetic Effects
In most plant sites, maintenance personnel use hand-held, two-way
radios for routine maintenance procedures. The use of such radios
imposes design requirements on process control instrumentation and its
installation to make it compatible with the radio signals. Two paths exist
from a transmission source which must be considered for electromagnetic
compatibility (EMC). One path goes directly to an affected instrument 5
from the radio antenna. The other path goes indirectly by way of the
signal and power lines connected to an affected instrument. In the latter
case, the signal and power lines act like a receiving antenna.
Near field signals consist of a radiation field and an induction field from
the radio antenna. In the near field area, both the radiation field and the
induction field are important. At a distance equal to the wavelength
divided by 2p, or slightly less than l/6, the radiation field and the induction
field have equal intensity.
Significant errors can occur if the measuring instruments are setup too
close to the antenna. And, in a near field area, radio signal field strength
cannot be calculated or tested in a repeatable manner.
E = (1.6/d)Öp, if d ³ l/2p
Caution
5
Magnetic media is especially sensitive to
EMI. To prevent loss or corruption of
stored data, never use radio
communication near magnetic media.
Figure 6-Table 6
The Class G1 through GX ratings used in the tables are taken from
Instrument Society of America (ISA) Standard S71.04, Environmental
Conditions for Process Measurement and Control Systems: Air-Born
Contaminents. The standard contains rating definitions and application
information. Fisher-Rosemount Systems uses this standard as a guide for
product design and environmental measurement.
Table 6-2 lists the gas concentration levels for reference purposes. They
approximate the copper reactivity levels listed in Table 6-1, if the relative
humidity is less than 50 percent. For a given gas concentration, the
severity level increases by one level for each 10 percent increase in
relative humidity above 50 percent, and also increases by at least one
level for a relative humidity rate of change greater than 6 percent per
hour.
Caution
Damage by corrosive atmospheres occurs
to most instrumentation systems during
initial installation and during maintenance
shut-downs. Also, if the system is stored in
a harsh environment or exposed to
corrosive vapors when the environmental
control system is not operational, damage
will occur.
When low relative humidity is indicated, it implies that very little moisture
condensed onto the coupons either because the atmosphere inherently
contained little moisture or the moisture was well controlled. The low
humidity may have caused the copper sulfide film formation to have been
attenuated. Additional testing of the environment is recommended.
When little humidly effects are indicated, relative humidity conditions
present during the test period are considered not to have had any
unusual effect on the copper sulfide film formation.
When high relative humidity is indicated, substantial moisture was
condensing on the coupons. The humidity may have caused the copper
sulfide film formation to accelerate. Consideration should be given to
controlling the humidity in this environment.
6
This page intentionally left blank.
Figure 7-Table 7
See Section 8 for further description of dust control. The section provides
information about selecting the dust control system that provides the
amount of protection needed. Of course, once the selection is
implemented, properly maintaining the dust control system by renewing
filters periodically and keeping all dust control equipment operating
properly is necessary.
Figure 8-Table 8
Note 8
Engineering a proper environment requires
qualified and proven environmental experts who
can provide a total-system approach. Experience
indicates that a casual approach to environmental
control normally does not bring about the expected
results.
All pipes, cables, and conduit passing through the walls, floors, and
ceilings require sealing to maintain positive air pressure. Open pipes and
conduit must be capped or plugged to prevent air passage. Additionally,
cooking, eating, and smoking activities must be excluded from the room
once the instrumentation system is installed.
Caution
The importance of maintaining the
environmental control system can not be
overemphasized. Failure of the
environmental system has a direct effect
on the reliability of the process control
system. Once corrosion begins on process
control equipment, the damage caused by
corrosion is normally not reversible!
8
The usual item not regularly maintained is air filters. Yet, clogged air filters
directly contribute to early instrument failure by disrupting proper
instrument cooling. Clogged or used up chemical filters allow corrosive
contaminants to surround the instruments. Damaged air-lock seals and
air-lock doors propped open allow contaminants to enter otherwise
protected rooms or enclosures.
Figure I-Table I
Appendix A
A Environmental Classification of
PROVOX Instrumentation
Table A-1 below indicates the environmental classification for PROVOXr
instruments. The classifications follow the definitions of the Instrument
Society of America (ISA) Standard S71.04, Environmental Conditions for
Process Measurement and Control Systems: Air-Born Contaminants.
Figure J-Table J
Appendix B
It should be pointed out that atmospheric dust varies considerably in particle size as well as
constituents. In the above sample there were very few particles noted which were in excess of 30
microns in average diameter. With this as an upper limit, the particles were divided into six size
ranges as indicated, with Column (2) indicating the average particle size for each group. For
example the largest group consisted of those particles ranging between 30 and 10 microns — or
an average of 20. In this particular size range it will be noted that the number of particles present
is indicated as 1000 as shown in Column 3. This represents the proportionate quantities by count
and simply indicates the relative number of particles in each size range based upon 1000 particles
for the average 20 micron size. X00559:006--0
Figure K-Table K
Appendix C
X00560:Envirn--0
C
Glossary
American National Standards CCITT
Institute (ANSI) Acronym: Comite Consultatif International
A technical organization that develops pour Telephonie et Telegraphie, or
standards for the compatibility of International Consultative Committee for
industrial equipment. This organization Telephony and Telegraphy. [See
consists of users and manufacturers of International Consultative Committee for
such equipment. Telephony and Telegraphy]
decibel
The relative difference between two
American Wire Gauge (AWG) signal levels expressed logarithmically.
The usual system of wire size
measurement in the United States. A
decibel millivolt
14 AWG wire has a cross-sectional area A measure of signal strength that is
of 2.08 mm; a 000 AWG wire has a calculated by using the following formula:
cross-sectional area of 85.02 mm. Note dBmV = 20 log (signal voltage÷1 millivolt)
that the smaller the AWG value, the
larger the wire. digital volt meter (DVM)
A test instrument that measures voltage,
current, or resistance, and gives
numerical readings.
British Standards Institute (BSI)
An independent organization that defines
Electronic Industries Association Glossary
Glossary
Glossary
Index
A E
air-born contaminates, 6-1, 7-1 electromagnetic interference, 5-1,
5-3, 5-4
air-inlet filter, 7-1
environmental classification, class
ambient, 3-1 G1, class G2, class G3, 6-4
antennas, 5-3
F
C far field signals, 5-1
category A, 2-2
category B, 2-2 G
category C, 2-2 gas concentration, 6-2
CE mark, 1-1 ground loop, 5-3
chlorides, sulfides, 6-2
circuit degradation, 5-1 H
class G1, environmental hot spots, 3-3
classification, 6-4, 8-2
humidity, environmental conditions,
class G2, environmental relative, 2-1, 6-2, 8-1, 8-2
classification, 6-5, 8-2 Index
HVAC, 8-1, 8-3
class G3, environmental
classification, 6-5, 8-2
class GX, environmental M
classification, 6-5
mechanical influence, 4-1
compliance, European, 1-1, 5-2
copper reactivity, 6-1, 6-3
N
corrosive vapors, environmental
conditions, 2-1, 3-3, 6-1, 6-4, 8-1 near field signal, 5-1
normal operating limits, 2-2
D
O
dust, environmental conditions, 2-1,
7-1, 8-1, 8-2 operative limits, 2-2
Index
Notes
Notes
PN1:006