I/O I n t e r f a c e, I n t r i n s i c S a f e t y a n d

ELCON INSTRUMENTS
Solutions

a Pepperl+Fuchs group company

INDEX

ABOUT US

INTRODUCTION TO P.A.M. (PLANT ASSET MANAGEMENT) 4-5 SMART INSTRUMENTATION AND PAM SYSTEMS HIS (HART INTERFACE SOLUTIONS) - A BETTER WAY HIS ARCHITECTURE HIS SOLUTIONS - GENERAL APPLICATION HIS SOLUTIONS - INTRINSIC SAFETY APPLICATION HIS SOLUTIONS - INTRINSIC SAFETY & REMOTE I/O MUX 2700 HART MULTIPLEXER USING OPC WITH HIS ACCESSORIES MORE INFORMATION? 6 7 8-9 10-11 12 13 14-16 17 18 19

ABOUT US

I/O I n t e r f a c e, I n t r i n s i c S a f e t y a n d

ELCON INSTRUMENTS
Solutions

Founded in Milan, Italy during 1970, Elcon Instruments has been the world leader with innovative intrinsic safety Interface (IS) solutions for the process industry. Commencing 2001, Elcon Instruments will join the Pepperl+Fuchs Group of companies with a mission to provide our customers with a diversified range of specialised Intrinsic Safety and general purpose I/O Interfacing products. These products will be supported by the largest international sales and technical support team in our market sector. Innovative Solutions for the Process Control Industry. This catalog highlights the range of HIS (HART Interface Solutions) which have been designed in partnership with the Fisher-Rosemount AMS group. Elcon has designed a range of solutions utilising our unique HART Interface hardware, to enable you to implement F-R market leading AMS (Asset Management Solutions) software. Our HIS brochure aims to provide you with all the knowledge necessary to allow you to implement a cost effective Plant Asset Management strategy, which will simplify and reduce the cost of running your plants assets. If you cannot find a suitable solution for your application within our brochure, please visit our dedicated HIS website www.his.elconinstruments.com to view the latest solutions or to find your nearest AMS expert. Alternatively e-mail us on [email protected].

INTRODUCTION

In all industrial plants significant resources are dedicated to the maintenance of critical plant assets. To reduce and contain the cost of plant maintenance, Plant Asset Management (PAM) systems are instrumental in improving both process efficiency and resource utilization. The savings obtained by implementing an asset management strategy, increases plant availability and contribute directly to improving the bottom line.

PAM systems provide live access to device information, and streamline all activities related to calibration, configuration and maintenance of instrumentation, while automatically recording an instruments complete maintenance and diagnostic history. This information alone simplifies the task of regulatory compliance, and saves hundreds of hours in preparation time.

DCS + HMI Software Plant Wide LAN

DCS, ESD or F&G I/O Blocks

Connector to suit DCS, ESD or F&G I/O cards

HIS Field Termination Panels

BAG

BAG
SHD

RS485

FAULT HART TX

FAULT HART TX

32 Channel Hart Multiplexer

SHD +24 -

32 Channel Hart Multiplexer

2700

2700

SHD +24 -

SHD

SHD

SHD

HART Protocol Field Devices (32 per panel)

SHD +24 -

SHD +24 -

RS485

PWR ON

MUX

PWR ON

MUX

P.A.M. (PLANT ASSET MANAGEMENT)

Asset Management Solutions (AMS) from Fisher-Rosemount, is the leader PAM systems for instrumentation in the market today. AMS requires connectivity to devices in the field in order to communicate live with device and perform maintenance and diagnostic functions. The HART Interface Solution (HIS) family of solutions from Elcon, provides the most sophisticated, elegant and modular means of connecting a PAM system to HART instrumentation in the field.

A PAM system can be implemented as a stand alone system or in conjunction with a distributed control system (DCS). Regardless of the type and size of the installation, Elcon has a solution. In fact, we have a solution for virtually all DCSs in the market today, and hundreds of successful installations worldwide.

PAM SYSTEM Asset Management Software

Standard 4-20 mA connection for Control Signals

Multidrop RS485 HART Communications

Connector to suit DCS, ESD or F&G I/O cards

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

PWR ON

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT STATUS

FAULT HART TX

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 1

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

CH 2

FR-A0-HART-01

MUX

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2000

2700
32 Channel Hart Multiplexer

BAG

FAULT HART TX

32 Channel Hart Multiplexer

SHD

SHD

SHD +24 -

SHD +24 -

Model 2116/HAT/

2700

RS485

PWR ON

MUX

Intrinsic Safety (Exi) Soultion HART Signals from Hazardous Area

SMART INSTRUMENTATION AND PAM SYSTEMS

The Process Control Industrys standarization on the HART communications protocol for field devices has created a market for HART based software and hardware. Attracted by the opportunity most manufacturers have created a wide range of products to serve this industry. Routine maintenance is a very inefficient way of managing plant assets because it tends to ignore the current operating condition of the equipment. In many cases perfectly functioning equipment is repaired because the schedule dictates a repair, while in other cases maintenance of the equipment is ignored, thus compromising availability. An inherent requirement of optimizing plant utilization is the availability of real-time monitoring data about the equipment. The data is used to implement predictive and proactive maintenance programs that rely on the instrumentation to provide self-diagnostics. These programs eliminate the need for routine maintenance as, in effect, field equipment can announce when it needs attention. Evidence of this is given by the recent releases of PAM software from major control system suppliers. Using an asset management software systems coupled with HIS hardware, maintenance or control room staff can continually monitor devices immediately detect and identify problems with field equipment. All of this adds up to significant savings as problems are intercepted before they cause major plant upsets. In the area of device diagnostics, the PAM system via HIS can access or exercise the diagnostics embedded in the HART devices. This allows engineering staff to focus their valuable time on problem instruments, with no time wasted walking out to the marshalling cabinet or to the field.
4 mA

Sine waves of these two frequencies are superimposed on the direct current (dc) analog signal cables to provide simultaneous analog and digital communications.

HART Signal superimposed on 4-20 mA

20 mA

Fig. 1

Digital Signal

1 0

Analog Signal

Time Note: Drawing not to scale.

Simultaneous Analog and Digital Communication Because the average value of the FSK signal is always zero, the 4-20 mA Analog signal is not affected. The digital communication signal has a response time of approximately 2-3 data updates per second without interrupting the analog signal. Minimum loop impedance of 230 Ohm is required for communication. HART Field Device Features

HART Protocol

Introduction HART is an acronym for Highway Addressable Remote Transducer. The HART protocol makes use of the Bell WEVE GOT 202 Frequency Shift Keying (FSK) standard to superimpose digital signals at a low level on top of the 4-20 mA. ABILITY This enables two way communications to take place and makes it possible for additional information beyond just the normal process variable to be communicated to/from a smart field instrument. The HART protocol communicates without interrupting the 4-20 mA signal and allows a host application (master) to get two or more digital updates per second from a field device.
FIELD COMMUNICATIONS PROTOCOL

Whilst new emerging all digital communications such as Foundation Fieldbus and Profibus are starting to gain some acceptance, HART allows users to get many of the benefits of digital communications whilst still maintaining traditional Analog wiring and control architecture. HART offers: Digital Capability Access to all instrument parameters and diagnostics. Supports multivariable instruments. On-line device status. Analog Compatibility Simultaneous analog and digital communications. Compatible with existing 4-20 mA equipment and wiring. Interoperability Fully open defacto standard. Common command and data structure. Enhanced by Device Description Language. Availability Field proven technology with more than 5,000,000 installations. Large and growing selection of products. Used by more smart instruments than any other in the industry. For more information please visit the HART Foundation on www.hartcomm.org

HART has been a protocol adopted by the majority of the major manufacturers of process control field equipment. It is an open standard that is administered by the HART Communications Foundation. As the digital FSK signal is phase continuous, there is no interference with the 4-20 mA signal. The relative simplicity of the HART protocol makes it easy for both end users and suppliers to gain experience and benefit from the enhanced two-way communication capability of smart field instruments using this technology. The digital signal is made up of two frequencies - 1,200 Hz and 2,200 Hz representing bits 1 and 0, respectively.

HIS (HART Interface Solutions) - A BETTER WAY

Traditional Connection with HART Field Devices The illustration in Figure 2 below shows the typical approach connecting with a HART field device using HHC (Hand Held Communicator). The HHC can be viewed as a simplified PAM component as it provides diagnostic information to a user, however its limited in usefulness for the following reasons; Only one instrument at a time can be accessed and communicated with. Valuable diagnostics and maintenance information cannot be shared easily and in real time with other users. New physical connection required for each field device to be interrogated. HIS Benefits Control System Independent Irrespective of the particular DCS, ESD or F&G system installed in a plant, HIS provides an independent means of connecting field devices to a PAM system. A Step to Fieldbus HIS is an ideal way for a user to receive many of the benefits available from digital Fieldbus communications without losing the training and expertise invested in the 4-20 mA infrastructure and without having to upgrade the DCS to Fieldbus. Pre-Packaged Solutions Elcon have made available solutions for the most common application scenarios including interfacing with field devices located in Hazardous explosive environments such as found in the Oil & Gas, Petrochemical, Pharmaceutical Industries, Glass and Food Industries. Control Integrity The design of each component that makes up HIS packages ensures that at no time will the use of HIS affect the integrity of the control system. Integral HART Filtering & Integral Impedance Boosting Some DCS or I/O cards do not have adequate minimum impedance (230 ), as specified by the HART standard to ensure reliable HART communications and/or can be adversely affected by the HART signal modulating the analog current. Elcon have developed a filter which is placed in series with that particular I/O channel. This filter allows the passing of low frequency 4-20 mA dc current, and can boost impedance to ensure reliable HART signals. As this is an issue only with a select number of DCS, ESD or F&G I/O modules Elcon ensure that adequate filtering circuit is packaged in solutions designed for specific systems. Cost Effective HIS solutions represent exceptional value. Installation costs are kept to a minimum due to the packaged approach taken ensuring that the right solution fits the application. In addition when costs are analyzed on a per instrument basis HIS represents a very small percentage of the price of that device.

Typical HART Connection Using HHC

Field Marshalling Cabinet
V1 V2 V3 B13 V4 V5 V6 V7 V8 V9 V10 B1 V11 V12 V13 V14 V15 V16 A1 A13

Fig. 2

DCS Cabinet

J1 J2 J3 J4

1 1 1 1

3 3 3 3

B13

A13

B1 A1

B13

A13

B1

A1

V17 V18 V19 V20 V21 V22 V23 V24 DS1 V25 V26 V27 X4 V28 V29 V30 V31 RSUP1 V32 RSUP2 DS2 B13 A13

I/O Card Racks

B1 A1

Field Mounted HART Transmitters & Valves

LDS2

+
LDS1

FTP (Field Termination Panels)

Legend: Color = 4-20 mA Signal Color = HART Signal

Hand Held Communicator

HIS Solutions To put it simply, HIS is the Enabling Hardware used for the implementation of a PAM (Plant Asset Management) system. It provides the physical layer connectivity between PAM software and the assets to be managed by that software, typically transmitters and valves, whilst still maintaining the control connectivity (4-20 mA) between field devices and Process Control Systems. As HART is an open standard, users wishing to set up a PAM system are no longer tied to the standard proprietary offering from their control system vendor. HIS allows you to tie together Asset Managements Software field devices and any DCS, PLC and F&G control system, even from different suppliers. HIS hardware solutions allow a PC running PAM software to be able to communicate with all HART field devices simultaneously 24 hours a day, 7 days a week. Elcon have developed a range of packaged hardware solutions that combine all the necessary hardware required to achieve this connection in a simple and cost effective manner.

HART INTERFACE SOLUTIONS

General Solutions
Integrated Control System Specific HIS Panels Replacement of proprietar y DCS, ESD or F&G termination panels. Best & lowest cost solution. Solutions for new or upgrade installations. Fully integrated, eliminates redundant hardware. Saves space and simplifies design. The most cost effective, elegant and integrated approach is shown in Fig. 3, where HIS Termination Panel is used as the field wiring termination assembly. This integrated concept reduces wiring and frees valuable control room space. The HIS panel incorporates the HART Multiplexer, contol system and filters (if required), to allow direct connection to the I/O cards using standard DCS vendor cable sets.
PWR ON FAULT HART TX

Fig. 3
Field Marshalling Cabinet DCS Cabinet

I/O Card Racks

MUX

2700
32 Channel Hart Multiplexer

Elcon HIS Panel AMS Workstation

RS-485 to RS-232 converter

External HIS Panel - Parallel Connection Using DCS, ESD or F&G termination panels and separate external HIS panels. Ideal for retrofitting existing installations. Maintains all existing hardware and field wiring. The illustration in Fig. 4 shows typical scenario of multiple field devices, connected to a DCS, ESD or F&G control System I/O card via the Field wiring Termination Panel with a parallel connection to a remote HIS Panel. As all field signals are available at this one location this is an ideal point to link over to HIS panel, by simply wiring across the field marshalling terminals, or by using special 1 In 2 Out terminals. HART filtering can be supplied with this solution.
V1 V2 V3 B13 V4 V5 V6 V7 V8 V9 V10 B1 V11 V12 V13 V14 V15 V16 A1 A13

Fig. 4
I/O Card Racks

J1 J2 J3 J4

1 1 1 1

3 3 3 3

B13

A13

B1 A1

B13

A13

B1

A1

V17 V18 V19 V20 V21 V22 V23 V24 DS1 V25 V26 V27 X4 V28 V29 V30 V31 RSUP1 V32 RSUP2 DS2 B13 A13

B1 A1

+
LDS2

+
LDS1

FTP (Field Termination Panels)

Field Mounted HART Transmitters & Valves

AMS Workstation

PWR ON

SHD

SHD

FAULT HART TX

MUX

RS-485

2700
32 Channel Hart Multiplexer

A B

RS-485 to RS-232 converter Elcon HIS Panel

External HIS Panel - Series Connection Using DCS, ESD or F&G termination panels and separate external HIS panel, but breaking into the loop for a cleaner Series wiring solution. Can replace marshalling terminals. Cleaner installation.

Fig. 5

V1 V2

1
V3 B13 V4 A13

1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 10 11
PWR ON

V5 V6 V7 V8 V9 V10 B1 V11 V12 V13 V14 V15 V16 A1

I/O Card Racks

J1 J2 J3 J4

1 1 1 1

3 3 3 3

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 31 31 32

B13

A13

FAULT HART TX

12 13 14 15 16 17

B1 A1

MUX

2700
32 Channel Hart Multiplexer

B13

A13

18 19 20 21 22 23 24 25 26 27 28 29 31 31 32

B1

A1

V17 V18 V19 V20 V21 V22 V23 V24 DS1 V25 V26 V27 X4 V28 V29 V30 V31 RSUP1 V32 RSUP2 DS2 B13 A13

As seen in Fig. 5, the existing wiring from field devices to the Field wiring Termination Panel (FTP) is removed and wired through the HIS panel. Using this approach, the 4-20 mA signal connects to the control system via a traditional hardware configuration, while allowing a point of connection for the HART Multiplexer. HART filtering is not supported with this solution.

B1 A1

+
LDS2

+
LDS1

Elcon HIS Panel Field Mounted HART Transmitters & Valves

FTP (Field Termination Panels) AMS Workstation

Legend: Color = 4-20 mA Signal = HART Signal Color

RS-485 to RS-232 converter

ARCHITECTURE
Intrinsic Safety and Remote I/O
Integrated Intrinsic Safety, FTP and HIS Fully integrated Intrinsic Safety and HIS Mux panels. Solutions available to replace DCS Field Terminations Panels. Connects your analog 4-20 mA control signals direct to your DCS I/O cards. Solutions for new or upgrade installations. Simple to implement. Saves space and simplifies design. You can apply our HiD2000 hazardous area interface solution, whereby the termination containing Intrinsic Safety interface modules, also incorporates the HART multiplexer, and direct connection facilities to DCS, ESD or F&G systems using the standard vendor I/O cables, as shown in Fig. 6. HiD2000 I.S. isolator modules pass the HART signal to the integral HART MUX, so all the HART signals can be sent to a PC running AMS software.
Field DCS Cabinet

Fig. 6

Elcon Custom HIS FTP (Field Termination Panel) with HiD2000 Intrinsic Safety
Model 2116/HAT FR-AI-HART-01-R

BUS FAULT

IN OUT MODEL

CH 2

2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000 2000

FAULT

I/O Card Racks

PWR ON

CH 1

BUS FAULT

IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL

CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1

FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT

PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON

Field Mounted HART Transmitters & Valves

32 Channel Hart Multiplexer

BUS FAULT

IN OUT MODEL

CH 2

RS-485 to RS-232 converter

2000 2000
2700
MUX

FAULT

PWR ON

CH 1

BUS FAULT

IN OUT MODEL

CH 2 CH 1
FAULT HART TX

FAULT

PWR ON
PWR ON

AMS Workstation

Remote I/O with or without Intrinsic Safety Fully integrated Intrinsic Safety, I/O and HIS Mux panels. Replaces DCS I/O cards. Can mount in Hazardous Areas (Zone 2). PC programmable for I/O selection. Mix and match I/O modules to suit your application needs. HiD3000 remote I/O as seen in Fig. 7, provides you with the ultimate integration. Using the Fieldbus output direct from the gateway modules eliminates the need for purchasing expensive control system I/O cards. All HiD3000 modules are approved for accepting any hazardous area signal or even mounting in a hazardous area (zone 2) installation. The panel features an extra position for the HART Mux, so all the HART signals can be sent to a PC running AMS software.
Field Field/Control Room Mounting DCS Cabinet

Fig. 7

Elcon Fieldbus I/O HIS using HiD3000 to replace FTP (Field Termination Panel) and DCS I/O
232 TX FAULT ON CONF LINE ERROR ERROR

PBDP1 PBDP1
2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 2 Channel Analog Input/Output 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input 4 Channel Digital Input

INT

Fieldbus Communication Card

BUS

PWR ON

DEX 232 TX

EXT

FAULT

ON CONF LINE ERROR ERROR

INT

BUS

PWR ON

DEX IN OUT MODEL

EXT CH 2

BUS FAULT

3010 3010 3010 3010 3010 3010 3010 3010 3824 3824 3824 3824 3824 3824 3824 3824
CH 4 CH 4 CH 4 CH 4 CH 4 CH 4 CH 4 CH 4 CH 3 CH 3 CH 3 CH 3 CH 3 CH 3 CH 3 CH 3

FAULT

PWR ON

CH 1

BUS FAULT

IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL IN OUT MODEL CH 2 CH 2 CH 2 CH 2 CH 2 CH 2 CH 2 CH 2

CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 CH 2 CH 1 FAULT STATUS FAULT STATUS FAULT STATUS FAULT STATUS FAULT STATUS FAULT STATUS FAULT STATUS FAULT STATUS

FAULT FAULT FAULT FAULT FAULT FAULT FAULT CH 1 CH 1 CH 1 CH 1 CH 1 CH 1 CH 1 CH 1

PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT PWR ON BUS FAULT

Field Mounted HART Transmitters & Valves

PWR ON

Hand Held Communicator (on HART test jacks)

FAULT HART TX

32 Channel Hart Multiplexer

2700

MUX

PWR ON

AMS Workstation

Legend: Color = 4-20 mA Signal = HART Signal Color Color = Fieldbus Signal

RS-485 to RS-232 converter

HIS SOLUTIONS

Integrated Control System Specific HIS Panels

Replacement of Proprietary DCS, ESD or F&G Termination Panels. Solutions for new or upgrade installations. Simple to implement. Most integrated solution and eliminates redundant DCS/PLC hardware. Saves space and simplifies design. Lowest cost solution. Solutions where a HIS panel replaces the standard Field Termination Panel normally supplied by the DCS System vendor. As seen in Fig. 8 below, Elcon HIS panels combine all the standard features included in the proprietary panels along with a position for the HART Multiplexer and adds HART filters (if required). This is by far the most cost effective and elegant HIS solution. Example of existing Panels: - ABB. - Elsag Bailey. - Foxboro. - Honeywell. - Siemens Moore Products. - Triconex. - YISS Yokogawa Safety System.

Foxboro

Honeywell

Integrated Control System Specific HIS Panels

Field DCS Cabinet

Fig. 8

I/O Card Racks

Field Mounted HART Transmitters & Valves

10
AMS Workstation

Yokogawa

Legend: Color = 4-20 mA Signal Color = HART Signal

RS-485 to RS-232 converter

GENERAL APPLICATION

External HIS Panels

Used in conjunction with proprietary DCS termination Panels Ideal solution for retrofit installations. Simple to implement. Small footprint to add HART. Retains all existing DCS, ESD or F&G hardware. The Illustrations below highlight the two most popular methods of accessing HART signals externally to the DCS FTP using the popular HPSM/32/MM-01 "MiniMux" Panel. General purpose panels such as these are purely passive devices that in no way affect the integrity of the 4-20mA control signal. Connection to marshalling terminals (See Fig. 9). Using either the existing terminals (with wiring in parallel) or for neater wiring "1 in 2 Out" terminals. Specific signal pairs containing HART signals can be connected over to the HPSM/32/MM-01 via screw terminals. Series connection (See Fig. 10). The HPSM/32/MM-01 panel, is wired between the field Signals and DCS FTP. This particular solution is also ideal for connecting to PLC I/O cards, as it provides a convenient field wiring termination point.
HPSM/32/MM-01

HPSM/32/MM-01 MiniMux (Single Mux) panel with field and control system terminal connections. Suitable for series connection and patching to marshalling terminals. HPSM/32/TB-02/HF16 (or 32) Single Mux panel with either 16 or 32 HART filters and terminals for field and control system connection. Suitable for pass through or patching to marshalling terminals. HPMM/2108/64-HART-D Two position Mux panel with four Sub D connectors. Suitable for patching to marshalling terminals.

External HIS Panel - Parallel Connection

Field Marshalling Cabinet DCS Cabinet

Fig. 9

External HIS Panel - Series Connection

Field DCS Cabinet

Fig. 10

I/O Card Racks Elcon HIS Panel Field Mounted HART Transmitters & Valves

I/O Card Racks

Field Mounted HART Transmitters & Valves

FTA (Field Termination Assembly)

11
AMS Workstation AMS Workstation

Legend: Color = 4-20 mA Signal = HART Signal Color

Elcon HIS Panel

RS-485 to RS-232 converter

RS-485 to RS-232 converter

HIS SOLUTIONS - INTRINSIC SAFETY

Integral and Remote MUX Panels

Elcon HiD2000 Termination Panels with Intrinsic Safety Isolators. Fully integrate Intrinsic Safety and HART Mux panels. Replaces DCS, ESD or F&G field termination panels. Solutions for new or upgrade installations Simple to implement Saves space and simplifies design. HiD2000 is an ideal solution for applications where field devices with HART are located in a hazardous area and therefore need to pass through I.S. Isolators. This solution uses Elcon HiD2000 plug-in I.S. Isolator family with either integral HART multiplexer position or HART connectors to patch over to a separate MultiMux HART panel. Two options are available. 1. If -HART appears in the HiD2000 termination board model number, then a position is available to plug on a Mux 2700 directly on the I.S. termination board (see Fig. 11). 2. If -H appears in the HiD2000 termination board model number, then this I.S. termination board feature HART connectors which can be patched over to an external HART panel like the MultiMux Model No. HPMM/64/CONA-01 (see Fig. 12). Note both models are available with either a standard Sub D connector (Elcon standard boards) or with DCS/PLC connectors to plug directly to DCS, ESD or F&G system I/O cards using their standard system cabling.
HiD2000 with integrated MUX 2700

Intrinsic Safety with Integrated HIS & FTP

Field DCS Cabinet

Fig. 11

Intrinsic Safety with Remote HIS Panel

Field DCS Cabinet

Fig. 12

Elcon Custom HIS FTP (Field Termination Panel) with HiD2000 Intrinsic Safety

Elcon Custom HIS FTP (Field Termination Panel) with HiD2000 Intrinsic Safety I/O Card Racks

I/O Card Racks

12

Field Mounted HART Transmitters & Valves

RS-485 to RS-232 converter

Field Mounted HART Transmitters & Valves

Patch Cable

Remote MultiMUX HART Panel AMS Workstation

Legend: Color = 4-20 mA Signal = HART Signal Color

RS-485 to RS-232 converter AMS Workstation

HIS SOLUTIONS - INTRINSIC SAFETY AND REMOTE I/O

Remote Fieldbus I/O Mux Panels

HiD3000 Fieldbus Remote I/O with integral Mux 2700. Remote I/O for Safe and Hazardous Area's. Can accept signals from Zone 0,1 and 2. Zone 2 mounting. Redundant Fieldbus gateway modules. Fully integrate Intrinsic Safety and HART Mux panels. Replaces DCS/PLC I/O cards. Simple to implement. Saves space and simplifies design. HiD3000 Remote I/O system can accept signals from a safe or hazardous area and converts these to industr y standard Fieldbuses output like Profibus, Modbus RTU using either a single or dual (redundancy) Gateway Modules. A position on the termination board is included to mount the Mux2700. Intrinsic Safety 3116/HAT-2G/SABUS-R-HART (16 module position panel). 3108/HAT-2G/SABUS-R-HART (8 module position panel). Both feature integral HART MUX 2700 position. Supplied with blue terminals for connecting hazardous area field devices. Output is an industry standard Fieldbus (e.g. Profibus, Modbus RTU) which is wired direct to the contral system Fieldbus communication card, which eliminates control system FTP and I/O cards. General Application 3116/FCT-2G/SABUS-R-HART (16 module position panel). 3108/FCT-2G/SABUS-R-HART (8 module position panel). Both feature integral HART MUX 2700 position. Supplied with grey terminals for connecting field devices. Output is an industry standard Fieldbus (e.g. Profibus, Modbus RTU) which is wired direct to the contral system Fieldbus communication card, which eliminates control system FTP and I/O cards.
HiD3000 with integrated MUX 2700

Intrinsic Safety and Remote I/O System

Field Field/Control Room Mounting

Fig. 13
DCS Cabinet

Elcon Fieldbus I/O with HART. HiD3000 replaces FTP (Field Termination Panel) and DCS I/O

Fieldbus I/O Card

Hand Held Communicator (on HART test jacks)

Field Mounted HART Transmitters & Valves

13
RS-485 to RS-232 converter

Legend: = 4-20 mA Signal Color Color = HART Signal Color = Fieldbus Signal

AMS Workstation

MUX 2700 HART MULTIPLEXER

32 channel input. RS485 serial data connection. Communicate with HART Transmitters and HART I/P Valve positioners. No complicated master/slave configuration. Low power consumption, compact solution.

Application
The Mux2700 HART Multiplexer provides 32 signal channels for connection to smart transmitters or control devices supporting digital communication according to the HART standard. Alternatively up to 16 HART only (i.e. no 4-20mA signal) devices can be connected to each channel in multidrop configuration. Full three-port isolation is included and each input channel has dualcapacitor isolation for freedom of loop connection. It acts as a gateway between a workstation - typically a PC with suitable PAM software - and the field instrumentation. Each Mux2700 is networked simply by connecting the high-speed RS485 output in multi-drop configuration. The Mux2700 interrogates each field device, under the supervision of the workstation, retrieving information for storage in its internal database, which can then be accessed at ease. Specifications DC Supply Current consumption: Power dissipation: 28 mA at 24 V, typical, RS485 quiescent. 0.7 W at 24 V.

Selector Switches SW1-SW5: SW6-SW7: SW8: LED Indicators Power ON: HART transmission: Fault:

Unit slave address. Baud rate. Test mode. green. yellow. red.

Signal channels Number of channels: 32. Dc isolation: dual capacitor each channel. Common mode voltage: up to 30 V. Differential mode clamping: 5.2 V (for transient or ac signals). Common mode clamping: 10 V (for transient or ac signals). Receive signal range: 0.12 Vpp < signal < 1.5 Vpp. Receive impedance: > 5000 ohms. Carrier detect level: signal > 0.12 Vpp, CD asserted. signal < 0.08 Vpp, CD not asserted. Transmit amplitude: 200 load - 0.43 Vpp < signal < 0.49 Vpp. 500 load - 1.1 Vpp < signal < 1.2 Vpp. Device type: secondary device. Impedance level: High impedance device. Data link type: HART Primary or Secondary Master. Field multi-drop support: option available upon request. Note: the Mux 2700 generally complies with the HART FSK Physical Layer Specification Rev. 8.0 available from the HART Communication Foundation. HART is a registered trademark of the HART Communication Foundation. Galvanic Isolation Specifications 24 V supply/Field channels: 1400 Vac, rms. 24 V supply /RS-485 serial port: 1400 Vac, rms. RS-485 serial port/Field channels: 500 Vac, rms.

Fig. 14

Mux Connections
WE VE G
PR OTO CO

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

FIEL

DC O

OT

MM

UN

ICA TIO

NS

FAULT HART TX

32 Channel Hart Multiplexer

PWR ON

2700

MUX

ABI LIT Y

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

FAULT HART TX

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

Multi-drop RS-485 network (up to 31 units)

14

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

32 Channel Hart Multiplexer

PWR ON

2700

MUX

Serial Port Line type: Line speed: Line topology: Unit address:

FAULT HART TX

RS-485, differential pair plus ground. 9600 or 19200 Baud, switch selectable. multi-point, master-slave connection. 1 to 31, switch selectable.

1 2

S3

4 5 6

7 8 9 10 S 11 12 13 14 S 15161718 S 19202122 S 23242526 S 27282930 S 3132

32 Channel Hart Multiplexer

PC Host Maintenance Workstation

PWR ON

2700

MUX

RS-485 to RS-232 converter

DESIGN FEATURES

High Specification Front end Design Two Decoupling Capacitors are provided, one for ecch signal connection. Both + Ve (positive) & - Ve (negative) signal wires are therefore decoupled from DC signal. Only the high frequency digital HART protocol signal passes through to the internal Multiplexer circuitry. Failure of any one capacitor from either a short circuit or open circuit means that availability of 4-20 mA control signal will not be affected. No DC loading of 4-20 mA Control Signal. No single point of failure. High Noise Immunity. The purpose of these capacitors is to block the DC signal component present on each 4-20 mA external loop, avoiding both a DC error induced on the loop and any undesirable ground-loop. The presence of a non-polarised capacitor in series with both the + and the terminal of each channel is very convenient for a variety of reasons, as summarised in the following: It is possible to sense the HART signal at different DC voltage levels on each channel, as often required when the same MUX interfaces both Transmitters and I/P devices or in other mixed configurations. It is not mandatory, to connect the + MUX terminal to the + side of the 4-20 mA current loop (in fact, the MUX input terminals are basically not polarised). As better explained on page 16, the MUX can tolerate one or more short-failed input capacitors while still working properly, the probability of loop interference is also very low for a wide range of internal MUX faults. The MUX input isolation was designed to allow the highest flexibility in connecting the channels to sense the HART signal. The max 30 Vdc input voltage (specified between all terminals, both belonging to the same channel or not) makes it possible to connect any MUX terminal to whatever voltage level can be derived from a 24 Vdc supply, +20% tolerance included.

Self Contained Architecture

Each Multiplexer module is a stand alone device containing all necessary hardware to communicate with up to 32 HART protocol enabled Field Devices and a host PC via RS485 (see Fig. 14). Fast Polling. One module design. RS485 direct from module. No communications bottleneck. Ideal for valve diagnostics.
Wide Software Compatibility

Fully compatible with F-R AMS (Ver 5.0 is also an OPC server), ValveLink, and Cornerstone. Additional compatability extends to HART OPC server software available from HCF (HART Communication Foundation). Allowing users to write dedicated applications for their specific needs. Fully tested, by all key PAM vendors. Reliable support & upgrade path through strong F-R Partnership.
Three-port Isolation

The three-port isolation structure of the MUX2700 is depicted in Fig. 16 below. As you can see, both the 24 V supply input and the RS-485 serial interface are isolated from the HART section, that is to say, from the HART signals on the field devices. This is full galvanic isolation, implemented either by transformer or by optocoupler.

Fig. 15

Mux Block Diagram

Fig. 16

Mux Three Port Isolation

Ch. 1 RS485 I/F Ch. 2 Mux. & HART

RS485 Data Bus

RS-485 INTERFACE POWER SUPPLY UNIT OPTO MUX ISOLATOR A CPU

HART MODEM
0.68 F

A A31 B A30 A32 C32 B32 C1

2.2 F

24 V
~
A1
+
F

CH 1 CH 2

2.2 F 0.68 F

15

A3
DC Supply Bus

Ch. 32

B1

SCREEN
A4, A5, A6

I/O I n t e r f a c e, I n t r i n s i c S a f e t y a n d

ELCON INSTRUMENTS
Solutions

OPC SERVER SOFTWARE

What is OPC?
The OPC Specification is a non-proprietary technical specification that defines a set of standard interfaces based upon Microsofts OLE/COM technology. The application of the OPC standard interface makes possible interoperability between automation/control applications, field systems/devices and business/office applications. Traditionally, each software or application developer was required to write a custom interface, or driver, to exchange data with hardware field devices. OPC eliminates this requirement by defining a common, high performance interface that permits this work to be done once, and then easily reused by any standard or custom software application. This means that a software application designer can concentrate on the core objective, as all the housekeeping functions are provided by OPC.

Ethernet Connectivity Once HART data is passed to an OPC Server it can then be made available via an enterprises LAN or Wan network using Ethernet. Information can also be made accessed via the Internet or a companys extranet infrastructure. This for example means that a instrument expert located at the factory in the USA can look at diagnostics information on a particular instrument in his customers plant located on the other side of Fig. 18 OPC Server / the world. Powerful Custom Applications Perhaps the most powerful feature is the potential for a user or sysPV; PV Units OPC Client tem integrator to quickly be able to design a cusPC Network tom application to perSubscribe: form a specific function. PV; PV Units For example field commissioning tools can be designed as a client application that allow mulHART Host tiple field devices from a specific area in a plant to be locked at certain values, all at the same time, so as to test out a DCS or ESD system's correct operation. Such applications can save time and money especially at commissioning and start up phases of a new project. A similar task using conventional methods would involve significantly more time and money. Elcon can advise on designing a custom application to meet your specific needs. What is Available from the HART Device Using OPC HART Host? Each HART device has a wealth of information that can be classified as Device Common and Device Specific. Most control systems can only access one piece of this information, usually the primary variable via 4-20 mA. OPC allows the full potential of a HART devices functionality to be realized especially the new bred of multivariable instruments, independently of the control system. Listed below is a sampling of what information is available any HART field Device to an OPC server;

HART Host

OPC & HIS

In a HART environment this means that the field dynamic device data once only available within the HART host applications local envionment (if the host application is also an OPC server) can now be made available to any OPC compliant application.

What is an OPC Server?

OPC Server is a software application that resides on a PC. It provides the connectivity between the HIS serial network and any client OPC application. Using an OPC Server connected to an Elcon HIS package HART information Fig. 17 HART Server can now be distributed to any OPC OPC Server HART - Pass-Trough compliant client softSCADA Device Setup ware located anyTrending Valve Diagnostics where across an enMIS/MRP Instrument Management terprise's network inSPC/SQC Web Server Field Device Manufacturing frastructure. OPC server softOPC Server ware is included as an optional module HART within the FisherHOST I/O Systems Modem Rosemount's Asset Management Solutions (AMS) V. 5.0 Multiplexers software or available from the HART Communications Foundation as a standalone application package. HART OPC Server enables 1. SCADA / HMI software connectivity. 2. Ethernet Connectivity. 3. Custom Applications.
1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 10 11 9 10 11
FAULT HART TX

16

SCADA / HMI software connectivity The primary benefit of using an OPC Server such as AMS with Elcon HIS products, is the ability to share device information from HART instruments with other software applications. Most popular SCADA or MMI/HMI software are now OPC compliant and therefore are able to communicate with the HART OPC Server and individually talk with any HART field device on the plant for reporting, trending, graphing etc.

12 13 14 15 16 17

12 13 14 15 16 17

18 19 20 21 22 23 24 25 26 27 28 29 31 31 32

18 19 20 21 22 23 24 25 26 27 28 29 31 31 32

Typical HART data items available via OPC

Digital Proces Data Primary Variable (PV); PV Units Secondary Variable (SV); SV Units Tertiary Variable (TV); TV Units Quaternary Variable (QV); QV Units PV Damping Time PV Upper Sensor Limit PV Lower Sensor Limit PV Minimum Span 4-20 mA Data Loop Current (mA) Percent Range Upper Range Value (Span) Lower Range Value (Zero) Device Information Manufacturer Code Device Code Tag Descriptor Message Device Status Device Malfunction More Status Available Configuration Changed PV Out of Limits Non-PV Out of Limits Loop Current Fixed Loop Current Saturated

32 Channel Hart Multiplexer

2700

MUX

PWR ON

Note: Contact instruments device vendors for specific details.

MUX 2700 HART MULTIPLEXER

Mux Connections

Fig. 19

Normal Operation Each

Under normal operation, the 4-20 mA control signal is protected by the in line capacitors which ensure that no DC loading is placed on the loop. Both the 4-20 mA and HART communication signal is operational.

CH 1
RS485 I/F

CH 2

Mux. & HART

ELCON INSTRUMENTS

Short Circuit Failure of One Decoupling Cap

Short Circuit failure of one capacitor does not effect the loop operation and the HART signal is fully operational.

CH 1
RS485 I/F

CH 2

Mux. & HART

CH 32

+
F

ELCON INSTRUMENTS

Open Circuit Failure of One Decoupling Cap

Open Circuit failure of one capacitor does not effect the loop operation and the HART signal is fully operational.

CH 1
RS485 I/F

CH 2
CH 1 CH 2 CH 3 Power Supply

Mux. & HART

CH 32

+
F

ELCON INSTRUMENTS

24 Vdc
0V

Typical DCS Termination Assembly Panel

CH 32

+
F

17

To DCS I/O Card

ACCESSORIES

Power Supplies
Model No.: PS1550 & PS2500 Each HIS package requires a nominal 24Vdc supply to power the Mux2700. However if a integrated Control System specific HIS solution is required, then this will also need to supply power to the field device, placing a heavy burden on the power supply employed. Therefore Elcon have available various high integrity power supply solutions, offering modular redundancy and high availability.
PS1550

For further details consult our PS-Range brochure or website www.elconinstruments.com.

PS2500

Adapters
Model No.: MUX ADAPT 27/17

PCB adapter to use the new Model MUX2700 on older style MUX1700 termination boards.
MUX ADAPT 27/17

Model No.: 1700 HHT & 2700 HHT

PCB Adapter used for trouble shooting single HART loops. The 1700HHT & 2700HHT plugs onto the termination board in place of the MUX and provides access to all 32 HART signals via test jacks for HHC hook-up.

1700 HHT

RS485/232 Converter
Model No.: Westermo MA-44

PC's do not normally include a RS485 port, therefore it is recommended to use an external module to convert the RS485 signal from each of the MUX2700 modules to RS232. For this function Elcon recommends the Westermo MA-44.

18

Up to 31 MUX2700s can be connected on a maximum of 1200 m of cable to each PC Serial Port. For additional information refer to the Westermo website www.westermo.se

MORE INFORMATION?

www

his.elconinstruments.com

[email protected]

19

ELCON REPRESENTATIVE & DISTRIBUTOR:

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e-mail: [email protected]

website: www.elconinstruments.com
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