STAHL 9494 Series is1+ Bus Rail User Manual

: June 3, 2024
: STAHL

STAHL 9494 Series is1+ Bus Rail

STAHL 9494 Series is1+ Bus Rail-fig1

General information

Manufacturer

R. STAHL Schaltgeräte GmbH
Phone: +49 7942 943-0
Am Bahnhof 30
Fax: +49 7942 943-4333
74638 Waldenburg Germany Internet: r-stahl.com
E-mail: info@stahl.de

About these operating instructions

Read and observe these operating instructions, especially the safety notes, carefully before use.
Observe all other applicable documents (see also section 1.3).
Keep the operating instructions throughout the service life of the device.
Make the operating instructions accessible to operating and maintenance personnel at all times.
Pass the operating instructions on to each subsequent owner or user of the device.

Further documents
BusRail 9494 data sheet

Conformity with standards and regulations

See certificates and EC Declaration of Conformity: www.stahl-ex.com.
The device has IECEx approval. See IECEx homepage: http://iecex.iec.ch/
Further national certificates can be downloaded via the following link: https://r-stahl.com/en/global/support/downloads/

Safety

The device has been manufactured according to the state of the art of technology while observing recognised safety-related rules.
When using the device, it is nevertheless possible for hazards to occur to life and limb of the user or third parties or for the device, environment or material assets to be compromised.
Use the device only
- If it is not damaged
- For its intended use, in a safe manner, keeping in mind potential hazards and in accordance with these operating instructions.

Personnel qualification
Qualified specialist personnel are required to perform the activities described in these operating instructions. This primarily applies to work in the following areas:

Product selection, project engineering and modification
Mounting/dismounting the device
Installation
Commissioning
Maintenance, repair, cleaning
Specialists who perform these tasks must have a level of knowledge that meets applicable national standards and regulations:
IEC/EN 60079-14 (Electrical installations design, selection and erection)
IEC/EN 60079-17 (Inspection and maintenance of electrical installations)
IEC/EN 60079-19 (Equipment repair, overhaul and reclamation)

Intended use
The BusRail is inserted into a 35 mm DIN rail and provides an internal, electrical, intrinsically safe connection between the CPU & power modules and the I/O modules. The BusRail has a passive design. It consists of internal data bus, PowerBus and the address lines for the I/O modules. The internal data bus has a redundant design. Special design features ensure high availability of the PowerBus.

Safety information

The BusRail can be installed in hazardous areas of Zone 1/Division 1 and Zone 2/Division 2. The application area of the IS1 system that is actually permitted depends on the modules installed.
During use in Zone 1 or Zone 2, the BusRail must be installed in an enclosure that corresponds to a recognized type of protection in accordance with IEC/EN 60079-0 and a degree of protection for the enclosure of at least IP 54 in accordance with EN 60529.
During use in Zone 21 or Zone 22, the dust explosion protection is provided by an enclosure that corresponds to a recognized type of protection in accordance with IEC/EN 60079-0 and a degree of protection for the enclosure of at least IP 6X in accordance with EN 60529. This enclosure contains the BusRail.
Only the separately certified system modules of the remote IS1 / IS1+ I/O system are connected to the BusRail.
Modules with intrinsically safe and non-intrinsically safe field circuits may be operated simultaneously on one BusRail. In this case, a distance of 50 mm must be maintained between the terminals with intrinsically safe and those with nonintrinsically safe field circuits. (e.g. partition 220101 or empty space).
At the beginning or end of every BusRail segment, a BusRail termination must be assembled in order to secure the BusRail against loosening and to protect the pins of the extendable BusRail against soiling and unintended contact.
The DIN rail of each BusRail segment must be connected with equipotential bonding! The earth clamps of the BusRail must be clamped onto the DIN mounting rail so that they are secure.
In Zone 1 an Ex e terminal must also be used!
For assembly, only DIN rails similar to IEC 60715:2017, Type NS35/15 (35 x 15 x 1.5) are permitted. To ensure the BusRail is inserted correctly in the DIN rail, only screws with a maximum screw head height of 4 mm can be used for the DIN rail assembly.
During operation, all modules must be assembled vertically or horizontally. Assembly positions in which the rail is “lying” or “hanging upside down” are not permitted for any modules!(see Chap Operating Position)

Transport and storage

During transport and storage, the device can be subjected to mechanical and thermal loads and damaged. This kind of damage can, for example, render the device’s explosion protection partially or fully ineffective. This may result in explosions causing serious or even fatal injury to persons in the vicinity.

Only transport the device in special transport packaging that reliably protects the devices from external influences. Observe the ambient conditions when selecting the transport packaging (see data sheet).
Do not place any load on the device.
Check the packaging and the device for damage. Report any damage to R. STAHL immediately. Do not commission a damaged device.
Store the device in its original packaging in a dry place (with no condensation), and make sure that it is stable and protected against the effects of vibrations and knocks.
Do not damage the device and other system components during assembly.

Project engineering

The permitted mounting direction of the BusRail is based on the installed modules.
The distance between the BusRail and enclosure walls or other equipment depends on the installed modules.
The maximum number of modules for one BusRail segment:
- In Zone 1: 10 modules (2 x CPM 9440/22, 8 x IOM)
- In Zone 1/2: 18 modules (1 x Socket 9496/3*, 16 x IOM)
The number of I/O modules that can be used can be limited by the protocol.
The BusRail can be expanded to the maximum length at a later stage. To expand it, the last BusRail part of the segment should be capable of being expanded (Type 9494/S1-M4).
The maximum length of the BusRail with connection cable is 3 m!

Mounting and installation

Mount the device carefully and only in accordance with the safety notes (see “Safety” section).
Read through the following installation conditions and assembly instructions carefully and follow them precisely.

Operating position

STAHL 9494 Series is1+ Bus Rail-fig2

BusRail assembly on a rail

STAHL 9494 Series is1+ Bus Rail-fig3

Assemble the DIN rail (1).
Place the termination “BusRail Begin” (3) onto the DIN rail (1) and fasten it with a mounting screw (2).
Insert the BusRail part (4) into the DIN rail and push it until it reaches the termination “BusRail Begin” (3).
Clamp the ground clamps (5) onto the DIN rail.
If necessary, insert a further BusRail part (6) into the DIN rail and carefully push it to the BusRail part assembled previously until the ear of the plug connector latches in place.
Clamp the ground clamps (5) onto the DIN rail.
If necessary, assemble further BusRail parts until the planned length of the BusRail is achieved.
Place the termination “BusRail End” (7) on the DIN rail (1), push it to the last BusRail part and fasten it with a mounting screw (8).

Assembly of the BusRail on two rails

STAHL 9494 Series is1+ Bus Rail-fig4

Assemble the DIN-rails (1, 11).
Place the termination “BusRail Begin” (3) onto the DIN rail (1) and fasten it with a mounting screw (2).
Insert the BusRail part (4) into the DIN rail (1) and push it until it reaches the termination “BusRail Begin” (3).
Clamp the ground clamps (5) onto the DIN rail.
If necessary, insert a further BusRail part (6) into the DIN rail and carefully push it to the BusRail part (4) assembled previously until the ear of the plug connector latches in place.
Clamp the ground clamps (5) onto the DIN rail.
If necessary, assemble further BusRail parts so that the planned length of the first BusRail segment is achieved.
Place the termination of the connection cable (7) on the DIN rail (1), carefully push it to the last BusRail part (6) and fasten it with a mounting screw (8).
Place the second termination of connection cable (14) on the DIN rail (11), and fasten it with a mounting screw (13).
Insert the BusRail part (15) into the DIN rail (11) and push it carefully to the termination of the connection cable.
Clamp the ground clamps (5) onto the DIN rail.
If necessary, insert a further BusRail part (16) into the DIN rail (11) and carefully push it to the BusRail part (15) assembled previously until the ear of the plug connector latches in place.
Place the termination “BusRail End” (17) on the DIN rail (11), push it to the last BusRail part and fasten it with a mounting screw (18).

Commissioning

Prior to commissioning, check the following:

External damage
Correct, secure fit of the BusRail

Maintenance, overhaul, repair

Observe the relevant national regulations in the country of use.

Maintenance
Check the following points in addition to the national regulations:

Whether the device enclosure and/or protective enclosure has cracks or other visible signs of damage
Whether the permissible ambient temperatures are observed
Whether the parts are securely fastened.

Maintenance
The BusRail does not require regular maintenance.

Repair
Perform repairs to the device only using original spare parts and after consulting with R. STAHL.

Returning the device

Only return or package the devices after consulting R. STAHL!
- Contact the responsible representative at R. STAHL in these matters.
- R. STAHL’s customer service is available to handle returns if repair or service is required.
- Only return or package the devices after contacting and consulting R. STAHL!
Contact customer service personally.
or
Go to the www.r-stahl.com website.
Select “RMA form” under “Support”.
Fill out the form. Wait for confirmation. R. STAHL’s customer service will contact you. You will receive an RMA slip after speaking with customer service.
Send the device along with the RMA slip in the packaging to
R. STAHL Schaltgeräte GmbH (refer to Section 1.1 for the address).

Cleaning

Check the device for damage before and after cleaning it.
Take damaged devices out of operation immediately.
To avoid electrostatic charging, the devices located in hazardous areas may only be cleaned using a damp cloth.
When cleaning with a damp cloth, use water or mild, nonabrasive, non-scratching cleaning agents.
Do not use corrosive cleaning agents or solvents.

Disposal

Observe national, local and statutory regulations regarding disposal.
Separate materials when sending them for recycling.
Ensure environmentally friendly disposal of all components according to the statutory regulations.

Accessories and spare parts

Malfunction or damage to the device due to the use of non-original components.
Non-compliance can result in material damage.

Use only original accessories and spare parts from R. STAHL Schaltgeräte GmbH (see data sheet).

Technical data

Explosion protection:
- ATEX: PTB 17 ATEX 2003 X II 2 G
- IECEx: IECEx PTB 17.0013X Ex ia IIC T4 Gb
- UK: CML 21UKEX2875X II 2 G
Ambient conditions
- Ambient temperature:
- -40 °C to +75 °C
- -40 °C to +65 °C (Only for BusRail extension 9494/L1-V* 301953 and 301954)
- Storage temperature -40 °C to +80 °C
- Max. relative humidity 95% (without condensation)
- Max. operating height < 2000 m

EU Declaration of Conformity

STAHL 9494 Series is1+ Bus Rail-fig5 STAHL 9494
Series is1+ Bus Rail-fig6

The Type 9494 BusRail is a passively constructed bus rail mounted into standard 35 mm DIN rail. It consists of an internal data bus, Power bus and the address lines for the interconnection of the IS1 CPU &
Power supply to I/O Modules.
It is approved for installation in a Class I, Division 1, Group A-D or Class I, Zone 1, Group IIC/IIB and also in Class I, Division 2, Group AD or Class I, Zone 2, Group IIC/IIB hazardous location according to NEC Article 504/505 or Canadian Electrical Code, CSA C22.

Notes:

For Installation in Division 1 or Zone 1 see Certification drawing for IS1 resp. IS1+ Remote I/O System No. 9400 6 031 003 1 as part of the documentation of the CPU & Power Modules.
For Installation in Division 2 or Zone 2 see Certification drawing for IS1 resp. IS1+ Remote I/O System No. 9400 6 031 004 1 or 9400 6 031 006 1 as part of the documentation of the CPU & Power Modules.