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1、Instruction Manual INM4840 MTL4840 HART maintenance system ii CONTENTS PAGE 2007 MTL Instruments Group plc. All rights reserved. INM4840-5 Nov 2007ii 1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 DESCRI
2、PTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.1 General purpose or IS? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3、 . . . 1 2.2 Generic or custom? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2.3 Large or small scale application? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4、. . . . . . . . . . . . . . . . . . . . . . . . . 3 2.4 Connection methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
5、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.1 Precautions - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.2 Precautions - BPHM64 . . . . . . . . . . . . . . . . . . . . .
6、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.1 System overview . . . . . . . . . . . . . . .
7、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.2 BPHM64 HART backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.3 HCU16
8、HART connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 4.4 HCU16AO HART connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9、. . . . . . . . . . 8 4.5 MTL customised backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.6 HMU HART Backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4.7 BPMH and BPSH Backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.8 Backplane mounting . . . . . . . . . . . . . . . . . . . . . . . . . .
11、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 4.9 Backplanes identification and tagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.10 Backplane earth rails . . . . . . .
12、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 4.11 Backplanes connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
13、3 4.12 Cabling recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 5 MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14、. . . . . . . 16 5.1 MTL4841 and 4842 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.2 Isolator modules (if used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15、 . . . . . . . . . . . . . . . . . . . . . . . . . 16 5.3 Modules setting and configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6 FAULT FINDING AND ROUTINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . .
16、 . . . . . . . . . . . . . . . . . 17 6.1 Maintenance precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.2 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 6.3 Routine maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7 SOFTWARE CONNECTIVITY . . . . . . . . . .
18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.2 Communication modes . . . . .
19、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 7.3 Software setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、 . . . . 18 APPENDIX A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 MTL4000 Series, HART enabled backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、. . . . . . . . . . . 19 HART connection and maintenance units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Contents Page Symbols This publication includes Warnings, Cautions and Information issues where appropriate
22、to point out safety-related or other important information. The corresponding symbols should be interpreted as follows: WARNING: these indicate where there is a danger of personal injury or death. CAUTION: these indicate the presence of a hazard which could result in equipment or property damage. IN
23、FORMATION (NOTE): these alert the reader to pertinent facts and conditions. Although Caution hazards are associated with equipment or property damage, it should be understood that use of damaged equipment could, under certain operational conditions, result in degraded process performance and even pe
24、rsonal injury or death. The user is urged therefore, to comply fully with all Caution notices. 1INM4840-5 Nov 20071 1. INTRODUCTION This instruction manual describes the procedures for installing, connecting, checking and maintaining the MTL4840 HART maintenance system, which is a simple interface b
25、etween smart devices in the field and HART instrument management software running on a PC. The following sections are outlined here. Section 2 describes the system and the solutions available Section 3 covers some safety aspects. Section 4 deals with installing the backplanes Section 5 describes ins
26、talling and configuring the modules Section 6 provides information on fault finding, and maintenance Section 7 introduces software for the MTL4840 System. See the MTL web site (www.mtl-) for the full specifications of the MTL4840 system components and accessories, and of the MTL4000 Series isolators
27、. 2 DESCRIPTION The MTL4840 HART Maintenance System enables a user to calibrate, configure and maintain an entire network of smart field devices from a single workstation. The key elements that make this possible are the MTL4841 communications module and the MTL4842 HART interface module. These two
28、modules provide the multiplexing for the individual field devices, making each one addressable and identifiable. The other important element is the terminal circuit board that simplifies the interconnection of all these devices to the MTL484x modules. A range of terminal boards and backplanes has be
29、en designed to suit the more standard applications but custom versions can also be designed to suit individual OEMs and their applications. The MTL4841and MTL4842 use the compact plug-in style of the MTL4000 Series of intrinsically safe isolating interface units. This provides a quick and easy insta
30、llation method onto the backplanes. The system is organised in multiples of 16 (sixteen). The MTL4842 HART interface module can handle up to sixteen field devices. The MTL4841 communications module is the next “layer“, which can manage up to sixteen of the MTL4842 modules, making a possible total of
31、 256 HART devices per MTL4841 module. The MTL4841 modules are then connected via an RS485/RS232 converter to the host PC. Depending upon the management software running on the PC, up to 31 of the MTL4841 modules could be connected to it, making a potential device count of 7,936! See Figure 2.1 for a
32、 diagram of this structure. In addition to this standard configuration, the MTL4840 system will support the multi-drop connection of HART devices. With up to fifteen HART devices on a single loop, it is possible to expand the capacity of each backplane (and consequently the system). For intrinsicall
33、y safe applications, consideration must be given to the safety parameters for each loop. For further information, please refer to MTL or your local representative. 2.1 General purpose or IS? The MTL HART Management System can be used to control and maintain field devices that are located in a safe a
34、rea or a hazardous areas. For safe areas, HART Connection Units (HCUs - and their related HMUs - see Section 2.3.1) provide the necessary terminals to connect up to 16 field devices, with organised links to the MTL4842 interface module. Hazardous-area field devices can be handled through backplane-m
35、ounted, IS isolating interfaces (BPxH). Having the isolators mounted on a backplane dramatically reduces the amount of hand wiring required and therefore reduces the number of potential wiring errors. The hazardous-area wiring terminates on the isolating modules, not the backplane, consequently the
36、backplanes do not need IS certification. 2.2 Generic or custom? A range of generic connection units is available for both input and output field-device wiring. These are not designed for any particular DCS type and may be used universally. The alternative is to choose a connection unit or backplane
37、that integrates with the type of DCS being used on the plant. The key advantage of this method is the use of a DCSs specific connector type, which simplifies the wiring of the connection units into the system. INM4840-5 Nov 2007 MTL4840 HART maintenance system Figure 1.1 - BPHM64 HART backplane 2INM
38、4840-5 Nov 20072 HART transmitters and valve 116 To up to 31 MTL4841 communications modules MTL4841 communications modules 2311 Each MTL4841 handles up to 16 MTL4842 HART interface modules* 12316 HART HART Each MTL4842 handles up to 16 HART transmitters or valve positioners MTL4842 HART interface mo
39、dules 4/20mA + HART signals Workstation PC running instrument management software Up to 7936 * HART devices RS232/485 convertor 1 2 I PMTL4046P MTL4041 B 16 I5 I P Process control system eg DCS, PLC 3 116116 116116 HART HART 116 HART signals HART signals Terminal Terminal HART signals HART signals R
40、S232 RS485 Notes: The diagram shows a mix of IS and general purpose applications (Refer to your local code of practice for rules governing the segregation of IS and non-IS loops) * The number of HART devices that can be supported may be dependent on the instrument management software selected. HART
41、is a registered trademark of the HART Communication Foundation Safe area Hazardous area Figure 2.1 - System Overview ( typical installation) 3INM4840-5 Nov 20073 Various solutions are available to suit individual DCS types and a listing of the currently available connection units and backplanes is g
42、iven in Appendix A. 2.3 Large or small scale application? The MTL HART maintenance solution is capable of addressing several thousand field devices, but most real world applications are significantly smaller than this. MTL has also devised a simple, integrated solution (HMUxx) that is proving popula
43、r for smaller installations of up to 32 devices. 2.3.1 Up to 32 field loops The HMU range of connection units (see Section 4.6) is designed for applications where a smaller footprint is required and there is only a small number of HART signals to be connected. The type of HART signal defines the typ
44、e of HMU that will be used: HMU16 Provides connections for up to 16 AI signals HMU32 Provides connections for up to 32 AI signals HMU16AO Provides connections for up to 16 AO signals HMU32AO Provides connections for up to 32 AO signals Each HMU accommodates one MTL4841 communications module and one,
45、 or two - as appropriate, MTL4842 multiplexer modules, each of which can handle 16 signals. This method can be expanded to accommodate more signals but, depending on the amount of expansion required, it would probably be better to use the method described next for more than 32 loops. 2.3.2 More than
46、 32 field loops For larger installations, the system should probably be based on the BPHM64 HART interface - see Section 4.2. This unit will accommodate one MTL4841 communications module and up to four MTL4842 multiplexer modules to accommodate a total of 64 signals. However, the MTL4841 can manage
47、a total of 16 MTL4842 modules, i.e. 256 signals, so three more BPHM64 carriers can be linked to the first, each fitted with four MTL4842 modules. Further expansion is possible by repeating this structure up to 30 times. The overall method is illustrated in Figure 2.1. See Section 5.3.1 for configura
48、tion details. 2.4 Connection methods There are three basic methods of interfacing to the HART signals: a) via a connection unit b) via an I/O module backplane c) via a HART + I/O module backplane A connection unit - see Figure 2.2 - has one set of screw terminals for the field devices and another se
49、t of screw terminals for connection to the main system. The HART signals, for routing to the maintenance system, are derived from those passing through the connection unit. The connection unit method is used for field devices in non-hazardous areas. The second method of getting the HART signals for the maintenance system is to pick them off the backplane (Figure 2.3) used to accommodate intrinsic safety isolators, e.g. MTL4000 Series units. The backplane can be customised to provide a host/system connector that best suits the users choice of DCS or PLC. In t