12P2524E

FRSI DeltaV TM I.S.
I/O Code of Practice for Installation 12P2524

Austin, TX, USA REV E
and Maintenance in Zone 2 Hazardous Areas Page 1 of 21
Created By: PAL Date: 26 Feb 2001
Checked By: MJH Date: 14 Mar 2001
Approved By: PAL Date: 14 Mar 2001
Revised By RPT Date: 08 Jul 2010
2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

FRSI DeltaV TM I.S. I/O Code of Practice for Installation 12P2524
CONTENTS 02/01
1 Introduction............................................................................................... 3
1.1 Document Contents .....................................................................................4
1.2 Relevant Standards and Codes of Practice.....................................................4
1.3 Hazardous areas Areas and Their Consideration ............................................4
1.4 Terminology ................................................................................................5
2 The ATEX Directive..................................................................................... 7
2.1 Equipment Categories ..................................................................................7
2.2 Apparatus Standards....................................................................................8
2.3 Summary of Requirements for Category 3 Apparatus in Zone 2 ......................9
3 DeltaV I/O Mounting Options ................................................................. 10
3.1 DeltaV I/O card types ................................................................................ 10
4 Enclosures and Junction boxes ................................................................ 12
4.1 General Requirements................................................................................ 12
4.2 Unused openings ...................................................................................... 13
4.3 Cable Entry Devices (glands) ...................................................................... 13
5 Cables and wiring..................................................................................... 14
5.1 General ..................................................................................................... 14
5.2 Avoidance of Damage ................................................................................ 14
5.3 Internal Cabinet Wiring .............................................................................. 14
5.4 Passage and Collection of Flammables ........................................................ 14
6 Grounding and Bonding of Zone 2 Systems ............................................ 15
6.1 General Precautions ................................................................................... 15
6.2 IS DeltaV Field Wiring ................................................................................ 15
6.3 Power Supplies .......................................................................................... 15
6.4 Field Enclosures......................................................................................... 16
7 Labeling ................................................................................................... 17
7.1 General ..................................................................................................... 17
8 Maintenance of DeltaV IS I/O Cards in Zone 2........................................ 18
8.1 Permissible live-working in Zone 2 .............................................................. 18
8.2 Prohibited live-working in Zone 2................................................................ 18
9 Appendix A ............................................................................................... 20
9.1 IS I/O components for installation in Zone 2 ............................................... 20
9.2 DeltaV IS I/O card safety parameters ......................................................... 21

1 Introduction
This document is intended as a guide for the selection, installation, and maintenance of the
intrinsically safe I/O cards that form part of a DeltaV control system and applies to
equipment that has been designed to:
mount in a Zone 21 hazardous area
connect to intrinsically safe apparatus located in a Zone 1 or a Zone 0 hazardous area
It should be read in combination with the Zone 2 requirements of each I/O card, as
documented in the appropriate ATEX Category 3 Certificate.
Note that the requirements for intrinsically safe circuits are outside the scope of this
Code of Practice. EC-Type examination certificates have been issued by an ATEX
Notified Body (Baseefa) which approves the products as Associated Apparatus
with field connections in Zone 0 or Zone 1. A system certificate has also been
issued by Baseefa which, in combination with installation drawings approved by
them, defines the requirements for Zone 0 and Zone 1 field wiring. It is essential
that all requirements of these documents and of the CENELEC intrinsically safe
system installation standard EN 60079-25 are met for Zone 0 and Zone 1 field
wiring.
There are two ATEX directives, one that applies to equipment manufacturers
(DeltaV) and another for its end users (DeltaV customers). Directive 94/9/EC
(ATEX 100a), sometimes called the "Manufacturers' Directive" is intended to
facilitate the free movement of goods throughout the EU by harmonizing the
technical and legal standards to which equipment for use in potentially explosive
atmospheres is manufactured.
The other directive, Directive 99/92/EC or ATEX 137, is also known as the
Workplace or User Directive. ATEX 137 details the minimum workplace
requirements for improving the health and safety protection of workers potentially
at risk from explosive atmospheres. EU customers and installations that employ
persons working in a potentially explosive atmosphere are subject to ATEX 137
Directive. This is an end-user issue and not covered in this document.
Both directives went into effect on 1 July 2003. This document covers only ATEX
Directive 94/9/EC (ATEX 100a) as it applies to DeltaV IS products.
Directive 94/9/EC of the European Parliament and the Council, dated March 23, 1994,
otherwise known as the ATEX 100a directive was created to cover the design of all
apparatus to be used in explosive atmospheres. It specifies essential safety requirements
with which apparatus must comply. Among its details it declares that apparatus can be
certified by its own manufacturer, for use within certain categories of explosive
atmospheres, without the need for intervention by external certification agencies, such as
BASEEFA, CENELEC, Factory Mutual, and so on.
DeltaV IS I/O cards and associated system components for use in Zone 2 are manufacturer-
certified by GE Intelligent Platforms as Category 3 apparatus under the ATEX directive and
this makes them suitable for use in Zone 2 hazardous areas.
In addition to providing guidelines for selecting, installing, and maintaining DeltaV IS I/O
cards, this document is intended to help the reader to understand the ATEX directive as it
relates to the DeltaV IS I/O equipment, and to become more familiar with the terminology
associated with the ATEX directive.
1
See section 1.3.3 for a definition of this terminology.

1.1 Document Contents

This document contains three sections. "The ATEX Directive" provides an introduction to the
principles of the ATEX 100a directive and its terminology; "DeltaV I/O Mounting Options"
provides a general background to DeltaV IS I/O equipment; and "Enclosures and Junction
Boxes" provides specific instructions for maintaining DeltaV IS I/O equipment in a Zone 2
hazardous area.
Chapters 5, 6 and 7 describe specific requirements for cables, grounding, labelling and
junction boxes in Zone 2. Chapter 8 provides guidelines for maintenance activities. Chapter
9 gives details of certification parameters appropriate to Zone 2.
1.2 Relevant Standards and Codes of Practice

This Code of Practice and the Apparatus Standard used for certification of the DeltaV IS I/O
equipment have been drawn from a combination of existing standards. Where a
requirement is drawn directly from another standard, the source of that requirement is
acknowledged.
1.3 Hazardous Areas and Their Consideration

The precautions taken to prevent electrical apparatus from causing explosions depend upon
the severity of the flammable atmosphere. Such hazardous areas have been classified
according to the :
Nature of the hazard for example, flammable vapor /dust/ fibers (Gas Group)
Ease of its ignition by an electrical spark (Apparatus Group)
Ease of its ignition by a hot surface (Temperature Classification)
Probability of the hazard occurring and its duration (Area Classification)
1.3.1 Gas and Apparatus Groups

Within countries that use the IEC standards (including Europe), underground mining hazards
(predominantly methane or "firedamp") are classified as Group I and flammable gases and
vapours occurring in surface industries are classified as Group II.
Group II has subdivisions, IIA, IIB and IIC, that relate to the ease of ignition by an electrical
spark where IIC is the most easily ignited group and the IEC system coincides with the
CENELEC certification standards.
Representative test gas EUROPE Ease of spark

(IEC and CENELEC) ignition
Acetylene Group IIC Most easily ignited
Hydrogen Group IIC
Ethylene Group IIB
Propane Group IIA
Methane (firedamp) Group I Least easily ignited
Metal dust
Carbon dust Not classified
Flour, starch, grain
Fibers and flyings
Table 1 Gas & Dust Classification

1.3.2 Temperature Classification

A flammable atmosphere can be ignited if it comes into contact with a hot surface a
situation that could occur within a piece of electrical apparatus. Temperature Classification
provides a system for recognizing maximum surface temperatures within electrical
apparatus. Equipment designers can use this classification to ensure that surfaces are kept
below the ignition temperature of the surrounding atmosphere.
Electrical apparatus intended for use in flammable atmospheres is awarded a Temperature
Classification (T Class) according to the maximum surface temperature it could reach in use.
Refer to Table 2 for the temperature classifications. The T Class for DeltaV IS I/O equipment
has been assessed at a maximum, ambient temperature of 60C.
Maximum surface T Class

temperature C
450 T1
300 T2
200 T3
135 T4
100 T5
85 T6
Table 2 Temperature Classification
1.3.3 Area Classification

Hazardous areas are classified into zones depending upon how frequently the explosive gas
atmosphere occurs and for how long it lasts. The classification is :
Zone O: An area in which an explosive gas atmosphere is present continuously
or for long periods of time.
Zone 1: An area in which an explosive gas atmosphere is likely to occur in
normal operation.
Zone 2: An area in which an explosive gas atmosphere is not likely to occur in
normal operation and, if it does occur, will exist for a short time period
only.
1.4 Terminology
In addition to the above classification terminology, there are a few other terms, dealing with
electrical apparatus, that occur frequently in this document.
1.4.1 Energy-Limited Circuit
An energy-limited circuit is one in which any arc, spark, or thermal effect produced during
normal operation is prevented by energy limitation from igniting the surrounding flammable
atmosphere.
1.4.2 Non-Sparking Circuit
A non-sparking circuit is one in which any arc, spark, or thermal effect capable of igniting
the surrounding flammable atmosphere is prevented from occurring by mechanical design.
Non-sparking circuits are typically not energy-limited and can contain energy levels capable
of igniting the flammable atmosphere if interrupted without further means of protection.
1.4.3 Normal Operation
Apparatus is said to be in normal operation when it conforms electrically and mechanically
with its manufacturer's published specification and performs without any fault.
Note: Opening, shorting, and grounding of the field wiring is considered to be part of normal
operation for energy-limited circuits but not for non-sparking circuits.

1.4.4 Ex Certification Codes

The prefix Ex (or EEx2) is often used in certification codes. This is internationally
recognized and means Explosion protected. A range of protection techniques is available
and the reader will encounter codes such as Ex d, Ex e, Ex ia, and so on. These codes
refer to different protection methods, some of which are mentioned later in this document.
1.4.5 Intrinsically Safe Circuits
The field circuits of DeltaV IS I/O cards are intrinsically safe, and therefore may be
connected to appropriate equipment in Zone 0 and Zone 1 areas. The requirements for
intrinsically safe circuits, for example
compatibility of voltage, current, power, capacitance and inductance parameters
segregation from other circuits
are not covered in this document. Please refer to the introduction to this document for other
sources of information
2
The prefix Ex is typically related to IEC certification while the EEx prefix relates to the CENELEC
standard. In this document, the certification code Ex is predominantly used but EEx could be
interchanged with Ex in almost all circumstances.

2 The ATEX Directive

The ATEX directive concerns equipment and protective systems intended for use in
potentially explosive atmospheres". , The directive has been optional since March 1, 1996
but it is mandatory after July 1, 2003. After July 1, 2003, equipment and protective systems
that do not comply with the directive will not be permitted on the market or in service within
the European Community.3
Traditionally, and in line with most of the relevant standards when used in, or in association
with, hazardous areas, the DeltaV IS I/O is referred to as apparatus. The ATEX directive
uses the word equipment instead of apparatus but for the purpose of this document, the
two terms are synonymous and, unless quoting from the directive, the term apparatus is
used. The combination of this apparatus with other equipment, together with the method of
installation, is covered by this document.
2.1 Equipment Categories

The ATEX directive introduces the concept of categories of equipment that are based on
the:
acceptable risk of ignition
probability of gas being present
Table 3 summarizes the requirements for electrical apparatus.
Category Zone of Use No of Faults Certification Quality Control

Requirement
1 0 2 Notified Body Production Assurance
2 1 1 Notified Body Product Assurance
3 2 0 Self Certification Internal Control
Table 3 Certification requirements of ATEX directive for electrical apparatus
These categories have been compared with conventional methods of protection and it is
generally accepted that Ex d, Ex e, Ex n gives a level of protection equivalent to category 2.
Intrinsically safe apparatus, which achieves category ia, is generally considered to be
equivalent to category 1 apparatus; and category ib is equivalent to category 2 apparatus.
Category 3 equipment is not capable of causing ignition in normal operation; however, live
maintenance, without a gas clearance certificate, is included in the definition of normal
operation and so the combination of apparatus design and installation practice must ensure
that ignition is not possible during live maintenance.
2.1.1 Self Certification
Category 3 equipment is intended for Zone 2 installation. As there is a lower risk of the
presence of a flammable atmosphere in Zone 2, there is no requirement for third party
assessment of this equipment and self certification by the manufacturer is permitted. Self
certification is controlled through the use of a technical file and forms the basis of the
assessment. In the particular case of the DeltaV IS I/O cards, all technical files are based
on the requirements of all the relevant CENELEC, IEC and North American standards which
are considered applicable to the situation. (These standards are described more fully in
section Clause 2.2.) A certificate is available for each apparatus and it contains references to
its technical file and the relevant standards.
However, because the DeltaV IS equipment has field connections which may be connected
to wiring in Zone 0 or Zone 1, it is Associated Intrinsically Safe Apparatus and so is ATEX

Category 1 equipment. It is therefore manufactured under a Quality Assurance Notification

(QAN) from an ATEX Notified Body, and is subject to surveillance by that Notified Body.
2.2 Apparatus Standards

The standards that have been used to evaluate the equipment for use in Zone 2 are:
EN 60079-0: "Explosive atmospheres - Part 0: Equipment - General Requirements"
EN 60079-11: "Explosive atmospheres - Part 11: Equipment protection by intrinsic safety i"
EN 60079-15: "Electrical apparatus for explosive gas atmospheres Part 15: Construction,
test and marking of type of protection n electrical apparatus"
FMRC Approval Standard Class Number 3611: "Electrical Equipment for Use in Class I
Division 2, Class II Division 2 and Class III Division 1 and 2 Hazardous Locations."
EN 61010-1: "Safety requirements for electrical equipment for measurement control and
laboratory use. Part 1: General Requirements"
Note: The scope of standard EN 61010-1: specifically excludes apparatus "used in

hazardous atmospheres". Similarly, products for use in potentially explosive atmospheres
are explicitly excluded from the scope of the Low Voltage Directive 2006/95/EC (LVD), and
EN 61010-1 is one of the standards harmonised to the LVD. However clause 1.2.7 of Annex
II of the ATEX directive requires that equipment must "avoid physical injury or other harm
which might be caused by direct or indirect contact" and this standard is used to ensure that
an acceptable level of safety against the majority of hazards is achieved. The ATEX
directive also permits the standards published in the Official Journal of the European
Commission with reference to the Low Voltage Directive to be used to fulfil 1.2.7 of Annex
II. The object of standard EN 61010-1 is as follows and clearly indicates its relevance:
"Object:
The purpose of the requirements of this Part 1 is to ensure that the design and methods of
construction used provide adequate protection for the OPERATOR and the surrounding area
against:
- electric shock or burn (see clause 6);
- mechanical hazards (see clauses 7 and 8);
- excessive temperature (see clauses 9 and 10);
- spread of fire from the equipment (see clause 9),
- effects of radiation, including lasers sources, sonic and ultrasonic pressure (see clause
12):
- liberated gases, explosion and implosion (see clause 13)".
2.2.1 Code of Practice

The documents used as source material for this Code of Practice, in addition to those listed
above, are:
EN 60079-14 "Explosive Atmospheres - Part 14 Electrical installations design,
selection and erection"
EN 60079-17 "Explosive Atmospheres - Part 17 Electrical installations Inspection
and Maintenance"
EN 60079-19 "Explosive Atmospheres - Part 19. Equipment repair, overhaul and
reclamation"

2.3 Summary of Requirements for Category 3 Apparatus in Zone 2

2.3.1 Safety in Normal Operation
The ATEX directive states that the equipment must be designed and constructed to
prevent foreseeable ignition sources which can occur during normal operation, and surface
temperatures must not exceed the stated maximum surface temperatures under intended
operating conditions.
2.3.2 Construction Requirements
Use construction methods that draw on existing standards for Division 2 and Zone 2 and
demonstrate compliance with the above.
2.3.3 Safety Factors
In order that arcs or sparks that can occur in normal operation are not capable of igniting,
U.S. requirements call for levels of voltage or current present to have a 1.1 Factor of Safety.
The CENELEC type "n" standard (EN 60079-15) only requires a unity Factor of Safety, but
because the products are also approved to US requirements the more stringent 1.1 Factor of
Safety has been used. This does not apply to the intrinsically safe analysis, which has been
independently assessed by FM for US requirements and Baseefa for ATEX Category 1 and 2
requirements.

3 DeltaV I/O Mounting Options

This section identifies the types of I/O cards that are used within a DeltaV control system
and discusses how they are mounted and connected to ancillary equipment.
3.1 DeltaV I/O card types

Two types of DeltaV I/O cards are available: general purpose and Intrinsically Safe (IS).
Figure 1 shows a typical DeltaV node with the boundary between the General Purpose and
IS sections.
Zone 2 hazardous area

Installation in Zone 2 covered Installation in Zone 2 covered by
by Fisher-Rosemount GE Intelligent Systems Platforms
third-party certification Manufacturer Certification
LocalBus
Power/Controller Isolator IS System
8-wide I/O Interface 8-wide I/O Interface
Carrier Carrier Power Supply
Carrier (general Carrier (Intrinsically
purpose field wiring) Safe field wiring)
General purpose Intrinsically Safe

field circuits field circuits in
Zone 0 or Zone 1
Note: Zone 2 installation of IS types only is covered by this document.

Figure 1 Typical DeltaV node including General Purpose and IS I/O cards
I/O card type Equipment mounting Field wiring origin

location
General Zone 2 or safe area Safe area, Zone 1 or
purpose Zone 2, depending on
field device certification
Intrinsically Zone 2 or safe area Zone 1 or Zone 0 when
Safe (IS) connected to certified IS
field devices with
compatible safety
parameters.
Table 4 I/O card types

3.1.1 General Purpose I/O Cards

This type of card is for general-purpose applications as well as for mounting in Zone 2
hazardous areas. Certification of the general purpose cards for installation in Zone 2 is not
included under the GE Intelligent Platforms manufacturer-certification. General purpose
cards are certified by a third party on behalf of Fisher-Rosemount and evidence of their
certification and instructions for installation in Zone 2 must be sought elsewhere. Refer to
the DeltaVTM Scalable Process System Zone2 Installation Instructions for certification and
Zone 2 installation instructions.
General purpose cards can accept field wiring from a safe area or, where the field
instrument is appropriately certified, from a Zone 1 or Zone 2 hazardous area. For example,
general purpose cards can connect to a certified Ex d (flameproof) field instrument in Zone
1.
3.1.2 Intrinsically Safe I/O Cards
Intrinsically Safe I/O cards are for applications that require IS field wiring. They can be
mounted in a safe area or a Zone 2 hazardous area, and, by providing IS protection for the
field wiring, can also accept field wiring that originates in a Zone 1 or Zone 0 hazardous
area provided the safety parameters are compatible. The I/O cards used in this application
are also provided with additional isolation. They can be used within the same node as the
general purpose card, as long as the specially constructed LocalBus isolator is used between
them. The location of card and field wiring are shown in Figure 2.
Refer to Appendix A for a list of the IS I/O cards and ancillary components that are suitable
for installation in Zone 2. Fisher-Rosemount holds the certificates for these items.
Refer to Section 8 - Maintenance for the maintenance procedures appropriate to these cards
.
Figure 2 - Zone 2 mounting with intrinsically safe field wiring
3.1.2.1 Field wiring for DeltaV IS I/O cards
The field wiring for IS I/O cards is certified as intrinsically safe and can originate in a Zone 1
or Zone 0 hazardous area. The field circuits are certified by BASEEFA to CENELEC
standards, and are not covered under the scope of the Category 3 manufacturer-certification
for Zone 2. The national and international standards appropriate to the country of
installation, for example EN 60079-25 Electrical apparatus for explosive gas atmospheres
Part 25 Intrinsically safe systems. in CENELEC member countries, governs the installation
and maintenance of the IS field wiring.
IS I/O cards draw their power from an isolated 12V (LocalBus) system. The LocalBus
connection between an I/O card and the card carrier is always energy-limited.

4 Enclosures and Junction boxes
4.1 General Requirements

The fundamental requirement of an enclosure or junction box is to maintain the integrity of
the enclosed components. For terminal junction boxes, the degree of protection offered by
the enclosure must be sufficient to prevent the terminals from being contaminated or
corroded so as to reduce their effectiveness. Enclosures containing electronic assemblies
must offer protection from the environment such as mechanical stresses, dust, and water
ingress and must ensure that the proper functioning is not jeopardised.
4.1.1 Enclosures in Zone 2

Any enclosure in a hazardous area must also ensure that the certification of enclosed
components is not jeopardised by mechanical damage. The minimum ingress protection
requirement, except for very clean, well-controlled conditions, is normally IP54 (dust
protected - splashed water). For more adverse environments, such as offshore platforms,
the higher requirement IP65 (dust tight - water jets) is frequently specified. An adequate
impact rating (for example 7 Nm) is also necessary.
Certified Type N or Ex n enclosures, that meet the minimum requirements stated above, are
available for installation in Zone 2. An alternative solution is to use an approved increased
safety (Ex e) enclosure of the appropriate IP rating. Such an enclosure only maintains its Ex
e status if it is used with the terminals and marking specified in the certificate and therefore
in this type of application it should be designated Category 3 to signify that it is suitable for
use in Zone 2. There is a wide choice of Type N, Ex n, and Ex e enclosures that include
plastic, stainless steel, and protected metal boxes. The type used depends upon the
environment and the end-users preference.
4.1.2 Terminals
Where junction boxes are used in the field for termination of Zone 2 wiring, it is not
necessary to use separate boxes for energy-limited and non-sparking circuits; however, it is
necessary to identify junction boxes. Use labels such as the ones shown in Figure 3.
Figure 3 Junction box warning labels

Similarly, the choice of a suitable terminal is easily (and economically) settled by using an Ex
e component certified terminal which removes concern over creepage and clearance
distances and security of connection. This type of terminal also achieves an IP 20 level of
protection that is adequate to prevent inadvertent contact with live circuits when the
enclosure is open. There is no electrical safety reason for segregating energy-limited and
non-sparking circuits but they must be clearly distinguished from one another because of
the essential difference in maintenance procedures. Ideally, terminals associated with the
two different techniques should be mounted on separate rails within the junction box or
spaced out along a rail. When space is at a premium use a separator between the two
types of terminals. Terminals should be provided so that unused cores of a multicore are
safely terminated and can be used at a later date. Unused cores should be identified as
energy-limited.
Unless specifically permitted by the documentation do not connect two conductors into one
terminal unless they are secured with a single compression type ferrule.
Note that the requirements of IS wiring are not covered in this document.
4.1.3 Junction Box Maintenance

Clearly marked and easily identifiable terminals and wiring is a fundamental requirement for
effective maintenance.
Junction boxes are convenient points for carrying out maintenance checks. You can work
on energy-limited circuits individually without isolating the circuits but you must isolate live
non-sparking circuits before disconnecting them. Labeling each circuit is critical for safe
maintenance procedures because it is not always practical to isolate all the non-sparking
circuits within a junction box. Before disconnecting any non-sparking circuits, measure the
potential on the terminal with a suitable test meter to confirm that it is not receiving power.
Use a certified intrinsically safe test meter such as the Bartec EXAVO 66 to perform the
measurement. This instrument, when used on the voltage range, has a sufficiently high
input impedance not to create an incendive spark.
4.2 Unused openings

Close unused openings for cable or conduit entries in enclosures with blanking elements that
are suitable for the relevant type of protection (for example, use certified Ex e blanking
plugs in an Ex e enclosure in Zone 2).
4.3 Cable Entry Devices (glands)

Select cable entry devices or glands that:
adequately maintain the ingress protection level of the enclosure
are compatible with the cable being used.
To maintain the protection that is provided by the enclosure it might be necessary to use
cable entry devices (glands) that have a seal around the entering cable. A seal, such as a
washer or sealant compound, might also be required between the gland and the enclosure.
The correct choice of gland and accessories ensures the continuity of the electrical path of
the armour when armoured cable is used as part of the bonding and electrical protection
system. If you are using thread sealant, be sure it does not affect the current carrying
capacity of the joint and be especially careful when using plastic enclosures.

5 Cables and wiring
Note: The requirements stated in this section are derived from EN 60079-14, Clause 9.
5.1 General
Clause 9 (of EN 60079-14) specifies the requirements of cable systems. Please refer to this
and other clauses of this standard for more detailed information.
Other information regarding the design, installation and maintenance of Intrinsically Safe
systems is given in EN 60079-25 Electrical apparatus for explosive gas atmospheres Part
25 Intrinsically safe systems.
5.2 Avoidance of Damage

Whenever possible, install cable systems and accessories in positions that prevent them
from exposure to mechanical damage, corrosion, chemical influences (for example solvents)
and the effects of heat. Where exposure to one or more of these hazards is unavoidable,
take protective measures or use appropriate cables. For example, to minimize the risk of
mechanical damage, use armoured, screened, seamless aluminium sheathed, mineral
insulated metal sheathed or semi-rigid sheathed cables.
If cable systems are subject to vibration, use cables that are designed to withstand
vibration without damage.
Note: Take precautions to prevent damage to the sheathing or insulation materials of PVC
cables that are to be installed at temperatures below -5C.
5.3 Internal Cabinet Wiring

Ensure that wiring inside a cabinet or enclosure in Zone 2 is mechanically robust to prevent
sparking of conductors. It is recommended that you use cable ties or trunking to prevent
cables from shaking loose, especially if they are subject to vibration. PVC-covered stranded
copper wire is adequate for many applications, but consider other insulation materials for
high ambient temperatures. The requirements for Intrinsically Safe field wiring are outside
the scope of this Code of Practice. Please refer to EN 60079-25. Additional mechanical
protection of internal wiring is not necessary if the enclosure itself provides adequate
protection against the environment. The conductor cross-sectional area of cables should be
rated for the normal operating current, but grounding cables must be able to carry the
prospective current under predicted fault conditions.
5.4 Passage and Collection of Flammables

When trunking, ducts, pipes or trenches are used to accommodate cables, take precautions
to prevent flammable gases, vapours or liquids from passing through them from one area to
another and to prevent the collection of flammable gases, vapors or liquids in trenches. Seal
trunks, ducts, or pipes and vent or sand fill trenches.
If necessary, seal conduits, and in special cases, cables (for example where there is a
pressure differential), to prevent the passage of liquids or gases.
ISA standard ISA-S12.10:1991 suggests that a pressure differential in excess of 1.5 kPa (6
inches of water) would require a cable to be sealed.

6 Grounding and Bonding of Zone 2 Systems
6.1 General Precautions

The precautions described below are intended to minimize the risk of unspecified voltages
and currents invading circuits in Zone 2. Such invasions can occur in a plant's structures
because of the large distances involved and the abundance of metal work and can cause
malfunctions or create potentially hazardous situations due to spark ignition or hot surfaces.
In general, a Zone 2 circuit should be either fully-floating or bonded (at one point only) to
the reference potential associated with the hazardous area. The level of isolation required
(except at the one point) must be designed to withstand a 500 V insulation test. If this
requirement is not met, the circuit is considered to be grounded at that point.
In exceptional circumstances, for example, when checking the presence of a bonding
conductor it might be necessary to ground a circuit at more than one point. When this is
permitted, include an analysis in the Descriptive System Document to indicate that
potential differences have been taken into account.
A system is considered to be grounded at one point if the points of connection are not more
than 10 meters apart and the voltage that can be induced between them, by foreseeable
fault currents, is less than 1 V.
The following are not considered connections to ground:

A high resistance connection to ground (typically 0.2 M to 1 M) for the dissipation of
electrostatic charge
A screen decoupled to earth through a small capacitor (typically 1nF) to reduce the
effects of high frequency interference
6.2 IS DeltaV Field Wiring

The field wiring of DeltaV IS I/O cards is intrinsically safe. Certified IS field instruments are
required to withstand a 500V insulation test between the frame (if appropriate) and their
field wiring terminals. Normally, the IS wiring is not grounded if it is installed according to
the appropriate codes of practice. However, the field circuits of DeltaV IS I/O cards are
galvanically isolated from the LocalBus to permit a single connection to ground in the field
per I/O card. Separate grounding of the field circuits of more than one IS I/O card is also
permissible. Multiple connections to ground of more than one I/O channel within an I/O card
can result in malfunction, due to common channels within the card. Refer to EN 60097-25
for more details.
6.3 Power Supplies

6.3.1 Ground Return Conductor
When the DeltaV system and/or its associated power supplies require a return-fault current
path to operate its electrical protection, use a discrete conductor that does not rely on the
bonding path provided by the plant structure. For example, where power is derived from a
440 V, 3-phase, neutral ground system, use a separate conductor to provide the fault
current return path.
Many supplies are grounded or bonded at the source. Sometimes this is done directly as
with the 440 V 3-phase supply where the neutral is grounded and other times indirectly, as
with an isolated 110 V supply with ground leakage protection. Be sure that you know how
supplies are grounded before installation and design the installation accordingly.
Using the structure as a current carrying path during normal operation is not allowed.

6.4 Field Enclosures
When a metal field enclosure is used, ensure that the enclosure can be bonded to the plant
structure. When a plastic enclosure is used, ensure the continuity of any fault return paths
such as the armour of armoured cable. Ensure that exposed metal parts are bonded to the
structure and that screened field instrument cables are connected to the enclosure bonding
system.

7 Labeling
7.1 General
Label all systems in a strategic position, for example, label the DeltaV cabinet on the final
installation. At a minimum, the labelling should enable you to easily trace the relevant
descriptive system document. One acceptable technique is to use a clear instrument loop
number to identify the loop documentation which lists the descriptive system document.
All apparatus within the system should be readily identifiable. In the case of simple
apparatus a traceable plant identification label is acceptable.

8 Maintenance of DeltaV IS I/O Cards in Zone 2

DeltaV IS I/O cards are designed to be hot-swappable in Zone 2 hazardous areas. However,
it is important that you observe permit to work procedures and consider the impact on the
process of any interference with the DeltaV node. The power supplies which provide 12V
power for the IS I/O cards can only be removed when not under power. Refer to section
8.2 below, and the appropriate ATEX Certificate for full details.
8.1 Permissible live-working in Zone 2

The following maintenance activities are permitted in Zone 2 hazardous areas:
8.1.1 Hot-Swappable I/O cards
The electrical interconnection between DeltaV IS I/O cards and the LocalBus is energy-
limited. This means that IS I/O cards can be plugged onto, and removed from, carriers in
Zone 2 while the system power is applied and without gas clearance. It is not necessary to
switch off the system power to the entire DeltaV node in order to add or replace an IS I/O
card.
8.1.2 Intrinsically Safe Field Circuits
You can work on the DeltaV IS I/O cards' intrinsically safe field wiring while the cards are
under power as long as you adhere to established IS practice. For example, you can open,
short, or ground individual field circuits while under power.
8.2 Prohibited live-working in Zone 2

The following maintenance activities must not be undertaken in Zone 2 while the system is
under power, except under gas clearance conditions:
8.2.1 Power supply modules
The following power supply connections are non-sparking circuits, which must not be
interrupted while under power.
Local supply input (18 to 36VDC) to I/O card power supply (Fisher Rosemount model:
IS System Power Supply). Do not remove the input connector at the rear of the I/O
card power supply without removing power the local power supply input. If an
isolating switch is used within the Zone 2 hazardous area, it must be appropriately
certified.
Important: Do not disconnect the incoming feed by removing the free half of the two-part
connector at the rear of the power supply module in the hazardous area while the input
power is on.
Interconnection between the I/O card power supply (Fisher Rosemount model: IS
System Power Supply) and its carrier. Do not remove the power supply from the carrier
while its input is under power. If you must remove a power supply (for example if it
has failed in a redundant application), first power down the local supply input as
described above. Do not restore the supply input until after the power supply has
been replaced on its carrier.
(Redundant power supply applications are those in which two or more power supply
modules are installed in an n+1 arrangement. Removal of one supply is permitted
while the others are under power, provided the incoming feed to the supply to be
removed is first isolated.)
8.2.2 Faulty Power Supply Modules

Where a power supply module has a known or suspected fault, do not attempt to put it into
service.

8.2.3 Other Non-Sparking Connections

The interconnection between IS I/O carriers at their DIN41612 LocalBus connectors is non-
sparking and must not be broken in Zone 2 while under power. This means that you must
not separate card carriers from each other without first removing all power from the IS sub-
system. This also applies to carrier extenders and extension cables.

9 Appendix A
9.1 IS I/O components for installation in Zone 2

The following DeltaV IS I/O components have been assessed for use in Zone 2:
Component type Description Hazardous area approval

I/O cards Component I/O Field wiring Certificate
marking number
2/1 cards IS AI, 4-20 mA with HART EEx nL IIC T4 Intrinsically safe GEF08ATEX01-8201
IS AO, 4-20 mA with HART EEx nL IIC T4 Intrinsically safe GEF08ATEX01-8202
IS AO, 4-20 mA, KJ3102X1-BB2 EEx nL IIC T4 Intrinsically safe GEF08ATEX01-8204
IS DO EEx nL IIC T4 Intrinsically safe GEF08ATEX01-8215
IS DI EEx nL IIC T4 Intrinsically safe GEF08ATEX01-8220
Carriers, IS card carrier, 8 card See below N/A See below
carrier IS carrier extender, right-hand See below N/A See below
extenders IS carrier extender, left-hand See below N/A See below
and extender Carrier extender cables See below N/A See below
cables IS Carrier, LocalBus isolator See below N/A See below
IS Carrier, IS module power supply See below N/A See below
Field IS standard See below Intrinsically safe See below
terminals IS loop disconnect See below Intrinsically safe See below
IS 16-channel See below Intrinsically safe See below
Power supply IS System Power supply Ex nA IIC T4 N/A GEF08ATEX01-8920X
LocalBus LocalBus Isolator Ex nL IIC T4 N/A GEF08ATEX01-8922X
Isolator
ATEX documentation for ancillary components used with the IS DeltaV System:
The I/O cards, power supplies and LocalBus Isolator used in the IS DeltaV system, intended
for mounting in Zone 2, are manufacturer-certified by GE Intelligent Platforms as Category 3
equipment in accordance with the ATEX directive. Ancillary components used to
interconnect these pieces of apparatus have not been separately certified since they have
no autonomous function. These components include card carriers, carrier extenders,
extender cables, and field terminals, as listed in the table above. Such interconnections are
not covered in the 94/9/EC directive since they are not capable of causing an explosion
through their own potential sources of ignition. This requirement is stated in Article 1
clause 3(a) of the directive. A similar argument supports the use of "simple apparatus" in
intrinsically safe systems and permits the use of uncertified cables in power systems. Hence
the use of non-certified auxiliaries in Zone 2 is not without precedent.
However such apparatus must comply with all relevant parts of the appropriate CENELEC
Standard EN60079-15 for Category 3 apparatus. The relevant parts are primarily creepage
and clearance distances, the construction of terminals and the current carrying capacity of
tracks.
All the products listed in the above table are also Associated IS apparatus, which is not
suitable for mounting in Zone 0 or Zone 1, but with field connections suitable for connection
to suitable equipment which is mounted in Zone 0 or Zone 1. The products have been
approved for this purpose by EC-Type Examination certificates which have been issued by
an ATEX Notified Body, namely Baseefa.

9.2 DeltaV IS I/O card safety parameters

Description Field wiring safety description (per channel)[Note 2]
Uo Io Po Lo[Note 3] Co[Note 3]
IS AI, 4-20 mA with HART 28 V 93 mA 0.65 W <4.3 mH <0.083 F
IS AO, 4-20 mA with HART 24.6 V 93 mA 0.57 W <4.3 mH <0.116 F
IS AO, 4-20 mA, KJ3102X1-BB1 23.3 V 88 mA 0.65 W <4.80 mH <0.136 F
IS AO, 4-20 mA, KJ3102X1-BB2[Note 1] 24.6 V 93 mA 0.57 W <4.3 mH <0.116 F
IS DI 10.5 V 14 mA 0.04 W <175 mH <2.41 F
IS DO 25 V 110 mA 0.69 W <3.08 mH < 0.11 F
Note 1 The AO Card KJ3102X1-BB1 has been superseded by AO Card KJ3102X1-BB2

Note 2 The field wiring safety descriptions are for ATEX Category 1 or 2, as assessed by the ATEX
Notified Body Baseefa. They may differ from those assessed for US applications by FM.
Note 3 The maximum inductances and capacitances are quoted for gases in Group IIC. If the application
is for gases in Groups IIA or IIB, the maximum inductances and capacitances will be greater. Refer to the
ATEX Notified Body (Baseefa) EC-Type examination certificates for details.

12P2524E

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FRSI DeltaV TM I.S.

I/O Code of Practice for Installation 12P2524

Created By: PAL Date: 26 Feb 2001

Checked By: MJH Date: 14 Mar 2001

Approved By: PAL Date: 14 Mar 2001

Revised By RPT Date: 08 Jul 2010

2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

1.1 Document Contents

1.2 Relevant Standards and Codes of Practice

1.3 Hazardous Areas and Their Consideration

1.3.1 Gas and Apparatus Groups

Representative test gas EUROPE Ease of spark

Table 1 Gas & Dust Classification

2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

1.3.2 Temperature Classification

Maximum surface T Class

Table 2 Temperature Classification

1.3.3 Area Classification

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1.4.4 Ex Certification Codes

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2 The ATEX Directive

2.1 Equipment Categories

Table 3 summarizes the requirements for electrical apparatus.

Category Zone of Use No of Faults Certification Quality Control

1 0 2 Notified Body Production Assurance

2 1 1 Notified Body Product Assurance

3 2 0 Self Certification Internal Control

Table 3 Certification requirements of ATEX directive for electrical apparatus

2001-2010 Fisher-Rosemount Systems, Inc., All Rights Reserved.

Category 1 equipment. It is therefore manufactured under a Quality Assurance Notification

2.2 Apparatus Standards

Note: The scope of standard EN 61010-1: specifically excludes apparatus "used in

2.2.1 Code of Practice

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2.3 Summary of Requirements for Category 3 Apparatus in Zone 2

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3 DeltaV I/O Mounting Options

3.1 DeltaV I/O card types

Zone 2 hazardous area

General purpose Intrinsically Safe

Note: Zone 2 installation of IS types only is covered by this document.

I/O card type Equipment mounting Field wiring origin

Table 4 I/O card types

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3.1.1 General Purpose I/O Cards

Figure 2 - Zone 2 mounting with intrinsically safe field wiring

3.1.2.1 Field wiring for DeltaV IS I/O cards

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4 Enclosures and Junction boxes

4.1 General Requirements

4.1.1 Enclosures in Zone 2

Figure 3 Junction box warning labels

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4.1.3 Junction Box Maintenance

4.2 Unused openings

4.3 Cable Entry Devices (glands)

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5 Cables and wiring

5.2 Avoidance of Damage

5.3 Internal Cabinet Wiring

5.4 Passage and Collection of Flammables