CL6300 Series Intrinsically
Safe I/O Card, Termination
Panels, and I/O Modules
October 1990
This bulletin describes the CL6300 Series of intrinsically
safe products which form an integral part of the
PROVOX® plus serial input/output system.
Bulletin BU4.2:CL6300
This product series consists of:−
The PROVOX plus serial input/output (I/O) system
provides reliable, high throughput communications
between analog and discrete field devices and
associated controllers in both intrinsically safe (I.S.) and
non-intrinsically safe (non-I.S) environments.
it offers a full range of analog (CL6800 Series) and
discrete (CL6700 Series) l/O files, cards and termination
panels in addition to I.S signal conditioning and safety
modules (CL6300 Series).
Full integration of both I.S and non I.S products within the
same subsystem is permitted providing I.S and non-l.S
wiring is correctly segregated.
Both non-l.S and I.S products use the same cables,
configuration, 1/0 card files and Cable interface Panels
thus reducing spares costs and simplifying l/O
configuration.
In all cases, the customer may select the appropriate
termination panel and I.S or non-l.S signal conditioning
modules to match his analog or discrete l/O
requirements.
Type CL6301 I.S Discrete l/O Termination Panels.
Type CL6302 I.S Discrete Input Isolating Modules.
Type CL6303 I.S Discrete Output Isolating
Modules.
Type CL6321 I.S Analog Input Termination Panel.
Type CL6322 I.S Analog Input High-level Isolating
Modules.
Type CL6323 I.S Analog Input Low-level Isolating
Modules.
Type CL6324 I.S Analog Input RTD Isolating
Modules.
Type CL6325 I.S Analog Input Thermocouple
Isolating Modules.
Siting/location of control l/O card file and termination
panels may be outside the control room, closer to the
control process devices thus achieving savings in cable
costs.
Type CL6331 I.S Analog Output Termination Panel.
Redundancy back-up is provided in the control l/O
subsystem
Type CP7042 I.S Termination Panel Cabinet.
PROFLEX, PROVOX, and ENVOX are registered trademarks of Fisher Controls International, Inc.
Type CL6332 I.S Analog Output Isolating Modules.
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Functional Descriptions
I/O cards
The l/O cards contain a microprocessor, RAM, ROM and
peripheral circuits. Peripheral circuits include a
watchdog
timer,
redundancy
switchover,
analog-to-digital (ADC) converter interface plus input
multiplexing and output drivers for the Analog card, serial
bus interface, parallel l/O interface and cable
integrity/redundancy switchover interface. Output
changes occur on demand, whilst input signals are read
at 20 millisecond intervals for analogs and 5 millisecond
intervals for discretes. Readback tests are performed on
each configured output channel every 250 milliseconds.
Readback circuitry verifies that a termination panel is
connected and that all configured l/O card outputs are
within self-test tolerance or are in the desired active or
inactive state.
When the discrete card is configured for the Pulse Count
Input (PCI) function, only eight channels are used and
when the analog card is configured for outputs, it
provides eight outputs through a 25-pin D-shell
connector. Analog inputs and discrete inputs and outputs
are connected through a 37-pin D-shell connector.
Termination Panels
The I.S termination panels provide 16 channels for
Discrete l/O, Analog input and Analog Output and 8
channels for PCI inputs. The Analog Output Termination
panel connects to 2 Analog I/O cards configured for
outputs. The range of panels is equipped for both
simplex and redundant operation.
The I.S discrete input/output termination panel allows
interfacing between the field devices and the discrete I/O
card. It is available in two options:
a) to accommodate up to sixteen l/O signal conditioning
modules.
b) to accommodate eight pulse count input channels.
The I.S analog input termination panel provides an
isolated interface between field inputs and the analog l/O
card. The termination panel allows installation of up to
sixteen signal conditioning modules that convert various
input signals to an isolated 1-5 volt dc signal.
The I.S analog output termination panel provides an
interface between the field device (for example: valve,
relay, step-motor) and the analog l/O card. Any of the
sixteen 4-20mA current output channels may be
converted to voltage output (1 to 5 volts dc) by the
installation of a 250 ohm resistor.
I/O Modules
The range of I.S l/O modules handle both analog and
discrete signals in both directions.
Signal conditioning catering for high level, millivolt,
thermocouple, pulse count and RTD inputs is provided,
as well as the appropriate output channel conditioning for
such output devices as valves, relays and stepper
motors.
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Redundancy
All I.S Termination Panels have redundant capability.
Redundancy operates at I/O card level ie. CL6721 for
discretes, CL6821 for analog, and the interconnecting
cables.
Two levels of redundancy are supported by all
termination panel types:
1:1 Redundancy
1 :N Redundancy.
1:1 Redundancy at l/O Card Level
(Figure 4)
in this situation, one back-up l/O card supports one
primary I/O card. if a primary l/O card failure is detected
such that l/O data is not corrupted when inputs are
reported and/or outputs are driven, both input and output
values will be held at their last levels. Switchover is
bumpless for both inputs and outputs and normal input
reporting and output driving continues after switchover is
complete. Switchover from failure detection will be no
more than 250 milliseconds and typically less than 1 00
milliseconds. When a switchover of analog outputs
occurs, reporting of current input value is delayed 750
milliseconds to allow input filters to stabilize.
If a failure is detected such that l/O data is corrupted
when inputs are reported and/or outputs are driven, a
bump of inputs and/or outputs at switchover is possible.
1 : N Redundancy at l/O Card Level
(Figure 5)
in 1 :N redundancy, one backup card may support as
many as eight primary I/O cards of the same type,
discrete or analog. Figure 5 shows 1 :N redundant l/O,
where N=2, using the Type CL6741 , CL6841 or CL6842
Cable Interface Panels. These panels are not required
for 1:1 redundancy. The backup i/O card can be located
in any slot in the control l/O card file. it does not have to
be located in the same card file as the primary card.
When redundant (backup) control l/O cards are used, it
is recommended that redundant communications also
be used between the control l/O card file and the 20
Series or SR90 Controller.
Redundancy at Discrete or Analog l/O
Panel
Discrete or Analog l/O termination panel redundancy is
achieved using a redundant analog or discrete l/O
termination panel containing panel mounted relays for
switchover between the primary and redundant
operation cables.
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Simplex Operation (Figure 6)
In simplex applications where backup support is not
needed, the same termination panels are used, but the
backup I/O cards and the associated interconnecting
cables are not required.
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Input/Output Capability and
Configuration
I/0 Channel Types for I.S Termination
Panels
Types CL6301, CL6302, CL6303
Capability
The input/output capability for I.S products is shown
below. The products require either the discrete l/O card
(CL6721) or the analog l/O card (CL6821) in conjunction
with the appropriate termination panel.
16 discrete channels (individually configurable as
inputs or outputs)
16 isolated analog input channels
16 analog output channels
8 pulse count input channels
Configuration
There are particular requirements which have to be
observed when configuring discrete and analog l/O
cards for both inputs and outputs.
Specific 1/O channel types and ratings determine the
appropriate termination panel for each discrete and
analog l/O card and which I.S modules are to be used.
l/O card channels are configured from a PROFLEX® or
ENVOX® workstation to match the termination panel
input and output signals. The configuration procedure is
common to both I.S and non-l.S control l/O channels.
The Type CL6301 I.S Discrete l/O Termination Panel is
suitable for both simplex and redundant applications.
There are two options for this panel. CL6301 -3 is used
for Discrete inputs and outputs and CL6301-4 is used for
Pulse count inputs only.
CL63O1-3 accommodates 16 discrete l/O channels.
Each channel can have any of the following I.S Modules.
CL6302-1 I.S Module Dry Contact or Namur
Proximity Switch input with debounce.
CL6302-2 I.S Module Proximity Switch input. 3 wire
with debounce.
CL6303-1 I.S Module Solenoid Driver output, 24V
dc 35mA
CL6303-2 I.S Module Solenoid Driver output, 1 5V
dc 65mA
CL6303-3 I.S Module Relay Output module, for I.S
signal.
The Type CL6301-4 accommodates 8 pulse input
channels and uses the following I.S modules.
CL6302-1 I.S Module. Option for FAST input
1OkHz max.
CL6302-2 I.S Module. Option for FAST Input
1OkHz max.
CL6302-3 I.S Module Pulse Count input mA (35V
dc Max). 10kHz Max frequency. Option for voltage
input
Types CL6321, CL6322, CL6323, CL6324, CL6325
The Type CL6321-2 I.S Analog Input Termination Panel
is suitable for both simplex and redundant applications.
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This panel accommodates 16 Analog input channels.
Each channel can have any of the following I.S Modules.
CL6322-1 I.S Module
High-level current input, 4 - 20mA with
Transmitter power
CL6322-2 I.S Module
High-level current input, 4 - 20mA without
Transmitter power
CL6323-1 I.S Module
Low-level voltage input, -10 to 70mV
CL6324-1 I.S Module
RTD input. -168 to 60_C, Coeff.
0.00385 ohm/ohm/_C
Types CL6331, CL6332
The Type CL6331 -2 I.S Analog Output Termination
Panel is suitable for both simplex and redundant
applications. This panel accommodates 16 analog
output channels. It therefore requires two Type CL6821
Analog I/O cards to service its full simplex capacity and
either four Type CL6821 or two Type CL6821 and two
ports of a CL6842 Analog Output Cable Interface Panel
to service its full Redundant capability. It uses the
following I.S Module only.
CL6332-1 I.S Module
Analog output 20mA.
CL6324-2 I.S Module
RTD input. -100 to 10_C, Coeff.
0.00385 ohm/ohm/_C
CL6324-3 I.S Module
RTD input. -73 to 315_C, Coeff.
0.00385 ohm/ohm/_C
CL6324-4 I.S Module
RTD input. 0 to 200C, Coeff.
0.00385 ohm/ohm/_C
CL6324-5 I.S Module RTD input.
0 to 600_C, Coeff.
0.00385 ohm/ohm/_C
CL6324-6 I.S Module
RTD input. 38 to 260_C,
Coeff. 0.00385 ohm/ohm/_C
Cabinet
The Type CP7042 I.S Termination Panel Cabinet is
designed to accept CL6300 Series Termination Panels
with both front and rear access. This cabinet will also
accept CP6701 Card files and CL6700 and CL6800
Series non-l.S Termination panels, subject to
compliance with I.S and non-l.S wiring segregation rules.
This cabinet will not accept Type CL6620 Controller files.
An option is provided to permit cable marshalling at the
rear of the cabinet
CL6325-1 I.S Module
Thermocouple input. -100 to 760_C, Type J High
CL6325-2 I.S Module
Thermocouple input. -51 to 338_C, Type J Low
Cables
CL6325-3 I.S Module
Thermocouple input. -100 to 1350_C, Type K High
The coaxial cable connecting the advanced controller to
the control l/O card file is identical for all products within
the PROVOXpIus serial l/O system. This cable length
can be as long as 5000 ft (1524 m). To order this cable
and associated connectors refer to Bulletin 4.
l0:DH7060, DH7080 Series Data Highway Products.
CL6325-4 I.S Module
Thermocouple input. -18 to 538_C, Type K Low
CL6325-5 I.S Module
Thermocouple input. 0 to 1 750_C, Type R
CL6325-6 I.S Module
Thermocouple input. -184 to 315_C Type T
CL6325-7 I.S Module
Thermocouple input. -73 to 871_C, Type E
CL6325-8 I.S Module
Thermocouple input. 0 to 1800_C, Type B
CL6325-8 I.S Module
Thermocouple input. 0 to 1750_C, Type S
A multi-twisted pair cable with D-connectors connects
the control I/O card to the applicable termination panel.
The maximum length of this cable is 200 ft (61 m). The
50 ft, 100 ft and 200 ft cable options include one extra
cable connector which can be installed after routing
through cable trays or conduit. The customer can also
specify that Fisher chooses the appropriate length of
cable when the termination panels are mounted in the
same or an adjoining cabinet as the card file.
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Ordering Information
l/O Card
For each Discrete l/O or Analog Input Termination Panel,
one of the following l/O cards is required. For Analog
Output Termination Panels equipped for more than 8
channels, two Analog l/O cards are needed.
Type CL6721 Discrete l/O Card
Type CL6821 Analog l /O Card
Cable Interface Panels
For 1 to N (N=2 to 8) redundancy in inputs or outputs,
one of the following cable interface panels is required.
Type CL6741
Type CL6841
Type CL6842
Discrete Cable Interface Panel
Analog input Cable Interface
Panel
Analog Output Cable Interface
Panel
Type CL6323-1 −10 to 70 millivolt Input
Type CL6324 RTD Input Modules
100 ohm Platinum,Temp. Coeff.0. 00385 ohm/deg C
Type CL6324-1
−168 to 60_C
Type CL6324-2
−100 to 100_C
Type CL6324-3
−73 to 315_C
Type CL6324-4
0 to 200_C
Type CL6324-5
0 to 600_C
Type CL6324-6
38 to 260_C
Type CL6325 Thermocouple Input Modules
Type CL6325−1
−100 to 760_C Type J High
Type CL6325-2
−51 to 338_C Type J Low
Type CL6325-3
−100 to 1350_C Type K High
Type CL6325-4
−18 to 538_C Type K Low
Type CL6325-5
0 to1750_C Type R
Type CL6325-6
−184 to 315_C Type T
Type CL6325-7
−73 to 871_C
Type E
Type CL6325-8
0 to 1800_C Type B
Type CL6325-9
0 to 1750_C Type S
Type CL6332 4 to 20 mA Output Module
I.S Termination Panels
Type CL6301-3
Type CL63O1-4
Type CL6321-2
Type CL6331-2
Discrete l/O I.S Termination Panel
Pulse Count Input I.S Termination
Panel
Analog Input I.S Termination
Panel
Analog Output I.S Termination
Panel
I.S Cabinet
Type CP7042 I.S Termination Panel Cabinet
Cables
Cables are specified as:
5 feet
I.S Modules
10feet
Discrete I.S Modules
Type CL6302-1
Type CL6302-2
Type CL6302-3
Type CL6303-1
Type CL6303−2
Type CL6303-3
Dry contact/Namur Proximity
Switch Input
3 Wire Proximity Switch input
Pulse Count Input
Solenoid Driver, 24V, 35 mA
Output
Solenoid Driver, i5V, 65 mA
Output
Relay Output
Analog I.S Modules
Type CL6322-1 4 to 20mA Input with transmitter power
Type CL6322-2 4 to 20mA Input without transmitter
power
20 feet
Fisher-specified cable lengths of 5,10 or 20 feet
50-foot cable with 2 moulded connector ends and
one extra connector end shipped loose
100-foot cable with 2 moulded connector ends and
one extra connector end shipped loose
200-foot cable with 2 moulded connector ends and
one extra connector end shipped loose
Note that two cables are required for analog input and
discrete I.S Termination Panels supporting redundancy,
and four cables for analog output I.S Termination Panels
supporting redundancy.
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I.S Design Recommendations
Recommendations for Intrinsically Safe Systems and
installations
1. References
CENELEC Standards:EN50 014 - General Requirements
EN50 029 - Intrinsic Safety - ’i’
EN50 039 - Intrinsically Safe System - ’i’
National legal regulations and standards
2. Certified System (In most countries an
‘ia’ system MUST be certified)
The system is documented by the System Designer
and includes:
Schematic Diagrams
List of equipment, components, cables etc. with their
electrical parameters
Description of environmental conditions
A ”System Certificate” is given by a local approved
Laboratory/Certifying Authority, ie. PTE in Germany,
BASEEFA in U.K., CERCHAR or LCIE in France
The system will be labelled with:
Type of certification
Certifying Authority/laboratory name
Number of certificate
eg. [EEx ia] llC T6 LCIE SYST 88.1253.
All subsequent modifications must be submitted to the
certifying authority/laboratory.
3. Non Certified System (applicable to ‘ib’
systems)
The system has also to be documented in the same way,
but all calculations may be done by the system designer
himself, if he is able and if there is no ambiguity about
safety coefficients. If such ambiguities exist, it will be
necessary to refer the system to a certifying authority/
approved laboratory for the country in which the system
is to be installed to obtain a certificate.
All calculations and design considerations must be
written- up and included in the descriptive document,
including the safety coefficients. Each subsequent
modification must be reappraised, calculated, written up
and appended to the ”System Description” document,
which must be available for any audit required by a
governmental authority.
This type of system must be labelled with the reference
of the ”System Description” and should state ”NON
CERTIFIED SYSTEM” and give the name of the
designer’s company.
4. Intrinsically Safe Design
Recommendations
Each system must be calculated and fully
documented.
With Galvanically Isolated Barriers, grounding is not
necessary from an I.S point of view.
If grounded shields are necessary, for example to
eliminate EMI effects care should be taken to avoid
difference of potential at ground points and consequent
circulating currents.
If shields are to be grounded, they should be terminated
either in the hazardous area at the signal source or in the
control/equipment room. At the remote ends of the
cables, the shields must be carefully isolated from local
ground.
The cables must be either:
Type A −
with individual shields for each I.S
circuit (2 or 3 wires). Mechanical
protection would not be necessary.
Type B −
without individual shields. Mechanical
protection is necessary (ducts, conduit
or cable trays).
I.S wiring routes must be clearly identified and separated
from the non-I.S routes.
The total installation must reach at least IP2O
environmental protection level. The CP7O42 cabinet
provides this level of protection with the doors closed.
It is necessary to know the environmental conditions to
determine what minimum level of protection is needed.
eg. Nature of the flammable atmosphere (l IA, llB or llC)
Ignition Temperature (T1 to T6) Zone of Installation
(Zone O: only ”ia” is permitted) (Zone or 2: either ”ia” or
”ib” can be used) Note: ”ia” certified apparatus or
modules can be used in an ”ib” system.
Calculations must be made in designing an I.S system.
Data on distances within the plant, all certificates and
documentation, apparatus characteristics, cables etc. to
be used in the system need to be available.
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For more information, FAX (612) 895-2244
While this information is presented in good faith and believed to be accurate,
Fisher-Rosemount Systems, Inc., does not guarantee satisfactory results from
reliance upon such information. Nothing contained herein is to be construed as a
warranty or guarantee, express or implied, regarding the performance,
merchantability, fitness or any other matter with respect to the products, nor as a
recommendation to use any product or process in conflict with any patent.
Fisher-Rosemount Systems, Inc., reserves the right, without notice, to alter or
improve the designs or specifications of the products described herein.
©1993 Fisher-Rosemount Systems, Inc. All rights reserved.
Printed in USA.