IEC 61918:2013

IEC 61918 ®
Edition 3.0 2013-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Industrial communication networks –
Installation of communication networks in industrial premises

Réseaux de communication industriels –
Installation de réseaux de communication dans des locaux industriels

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IEC 61918 ®
Edition 3.0 2013-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
colour
inside
Industrial communication networks –

Installation of communication networks in industrial premises

Réseaux de communication industriels –

Installation de réseaux de communication dans des locaux industriels

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
CODE PRIX XH
ICS 25.040.40; 33.020; 35.240.50 ISBN 978-2-8322-1054-3

– 2 – 61918 © IEC:2013
CONTENTS
FOREWORD . 10

INTRODUCTION . 12

1 Scope . 15

2 Normative references . 15

3 Terms, definitions, and abbreviated terms . 18

3.1 Terms and definitions . 18

3.2 Abbreviated terms . 28

3.3 Conventions for installation profiles . 30
4 Installation planning . 30
4.1 General . 30
4.1.1 Objective . 30
4.1.2 Cabling in industrial premises . 30
4.1.3 The planning process . 33
4.1.4 Specific requirements for CPs . 34
4.1.5 Specific requirements for generic cabling in accordance with
ISO/IEC 24702 . 34
4.2 Planning requirements . 34
4.2.1 Safety . 34
4.2.2 Security . 34
4.2.3 Environmental considerations and EMC . 35
4.2.4 Specific requirements for generic cabling in accordance with
ISO/IEC 24702 . 36
4.3 Network capabilities . 36
4.3.1 Network topology . 36
4.3.2 Network characteristics . 38
4.4 Selection and use of cabling components . 42
4.4.1 Cable selection . 42
4.4.2 Connecting hardware selection . 46
4.4.3 Connections within a channel/permanent link . 48
4.4.4 Terminators . 54
4.4.5 Device location and connection . 55
4.4.6 Coding and labelling . 55
4.4.7 Earthing and bonding of equipment and devices and shielded cabling . 55

4.4.8 Storage and transportation of cables . 65
4.4.9 Routing of cables . 65
4.4.10 Separation of circuits . 67
4.4.11 Mechanical protection of cabling components . 68
4.4.12 Installation in special areas . 69
4.5 Cabling planning documentation . 69
4.5.1 Common description . 69
4.5.2 Cabling planning documentation for CPs . 69
4.5.3 Network certification documentation . 70
4.5.4 Cabling planning documentation for generic cabling in accordance
with ISO/IEC 24702 . 70
4.6 Verification of cabling planning specification . 70
5 Installation implementation . 70
5.1 General requirements . 70

61918 © IEC:2013 – 3 –
5.1.1 Common description . 70

5.1.2 Installation of CPs . 70

5.1.3 Installation of generic cabling in industrial premises . 70

5.2 Cable installation . 70

5.2.1 General requirements for all cabling types . 70

5.2.2 Installation and routing . 77

5.2.3 Specific requirements for CPs . 78

5.2.4 Specific requirements for wireless installation . 78

5.2.5 Specific requirements for generic cabling in accordance with

ISO/IEC 24702 . 78

5.3 Connector installation . 78
5.3.1 Common description . 78
5.3.2 Shielded connectors . 79
5.3.3 Unshielded connectors . 79
5.3.4 Specific requirements for CPs . 79
5.3.5 Specific requirements for wireless installation . 79
5.3.6 Specific requirements for generic cabling in accordance with
ISO/IEC 24702 . 79
5.4 Terminator installation . 79
5.4.1 Common description . 79
5.4.2 Specific requirements for CPs . 80
5.5 Device installation . 80
5.5.1 Common description . 80
5.5.2 Specific requirements for CPs . 80
5.6 Coding and labelling . 80
5.6.1 Common description . 80
5.6.2 Specific requirements for CPs . 80
5.7 Earthing and bonding of equipment and devices and shield cabling . 80
5.7.1 Common description . 80
5.7.2 Bonding and earthing of enclosures and pathways . 81
5.7.3 Earthing methods . 82
5.7.4 Shield earthing methods . 84
5.7.5 Specific requirements for CPs . 86
5.7.6 Specific requirements for generic cabling in accordance with
ISO/IEC 24702 . 86
5.8 As-implemented cabling documentation . 86

6 Installation verification and installation acceptance test . 87
6.1 General . 87
6.2 Installation verification . 87
6.2.1 General . 87
6.2.2 Verification according to cabling planning documentation . 88
6.2.3 Verification of earthing and bonding . 89
6.2.4 Verification of shield earthing . 90
6.2.5 Verification of cabling system . 90
6.2.6 Cable selection verification . 90
6.2.7 Connector verification . 91
6.2.8 Connection verification . 91
6.2.9 Terminators verification . 92
6.2.10 Coding and labelling verification . 93

– 4 – 61918 © IEC:2013
6.2.11 Verification report . 93

6.3 Installation acceptance test . 93

6.3.1 General . 93

6.3.2 Acceptance test of Ethernet-based cabling . 95

6.3.3 Acceptance test of non-Ethernet-based cabling . 97

6.3.4 Specific requirements for wireless installation . 98

6.3.5 Acceptance test report . 98

7 Installation administration . 98

7.1 General . 98

7.2 Fields covered by the administration . 99
7.3 Basic principles for the administration system . 99
7.4 Working procedures . 99
7.5 Device location labelling . 100
7.6 Component cabling labelling . 100
7.7 Documentation . 101
7.8 Specific requirements for administration . 101
8 Installation maintenance and installation troubleshooting . 101
8.1 General . 101
8.2 Maintenance . 102
8.2.1 Scheduled maintenance . 102
8.2.2 Condition-based maintenance . 104
8.2.3 Corrective maintenance . 104
8.3 Troubleshooting . 104
8.3.1 General description . 104
8.3.2 Evaluation of the problem . 105
8.3.3 Typical problems . 105
8.3.4 Troubleshooting procedure . 108
8.3.5 Simplified troubleshooting procedure . 109
8.4 Specific requirements for maintenance and troubleshooting . 110
Annex A (informative) Overview of generic cabling for industrial premises . 111
Annex B (informative) MICE description methodology . 112
B.1 General . 112
B.2 Overview of MICE . 112
B.3 Examples of use of the MICE concept . 113

B.3.1 Common description . 113
B.3.2 Examples of mitigation . 114
B.4 Determining E classification . 115
B.5 The MICE table . 118
Annex C (informative) Network topologies. 120
C.1 Common description . 120
C.2 Total cable demand . 120
C.3 Maximum cable segment length . 120
C.4 Maximum network length . 120
C.5 Fault tolerance . 120
C.5.1 General . 120
C.5.2 Use of redundancy . 120
C.5.3 Failure analysis for networks with redundancy . 121

61918 © IEC:2013 – 5 –
C.6 Network access for diagnosis convenience . 121

C.7 Maintainability and on-line additions . 121

Annex D (informative) Connector tables . 122

Annex E (informative) Power networks with respect to electromagnetic interference –

TN-C and TN-S approaches . 135

Annex F (informative) Conductor sizes in electrical cables . 137

Annex G (informative) Installed cabling verification checklists . 139

G.1 General . 139

G.2 Copper cabling verification checklist . 139

G.3 Optical fibre cabling verification checklist . 143
Annex H (normative) Cord sets . 144
H.1 General . 144
H.2 Constructing cord sets . 144
H.2.1 Straight through cord sets with M12-4 D-coding connectors . 144
H.2.2 Crossover cord sets with M12-4 D-coding connectors . 145
H.2.3 Straight through cord sets with 8-way modular connectors . 145
H.2.4 Crossover cord sets with 8-way modular connectors . 146
H.2.5 Straight conversion from one connector family to another . 147
H.2.6 Crossover conversion from one connector family to another . 147
Annex I (informative) Guidance for terminating cable ends . 149
I.1 General . 149
I.2 Guidance for terminating shielded twisted pair cable ends for 8-way modular plugs . 149
I.3 Guidance for terminating unshielded twisted pair cable ends for 8-way modular
plugs . 152
I.4 Guidance for M12-4 D-coding connector installation . 153
I.5 Guidance for terminating optical fibre cable ends . 155
Annex J (informative) Recommendations for bulkhead connection performance and
channel performance with more than 4 connections in the channel . 156
J.1 General . 156
J.2 Recommendations . 156
Annex K (informative) Fieldbus data transfer testing . 157
K.1 Background . 157
K.2 Allowable error rates for control systems . 157
K.2.1 Bit errors . 157
K.2.2 Burst errors . 157
K.3 Testing channel performance . 158
K.4 Testing cable parameters . 158
K.4.1 General . 158
K.4.2 Generic cable testing. 158
K.4.3 Fieldbus cable testing. 159
K.5 Testing fieldbus data rate performance . 159
K.5.1 General . 159
K.5.2 Fieldbus test . 159
K.5.3 Planning for fieldbus data rate testing . 159
K.5.4 Fieldbus data rate test reporting template . 160
K.5.5 Values for acceptable fieldbus performance . 160

– 6 – 61918 © IEC:2013
Annex L (informative) Communication network installation work responsibility . 161

L.1 General . 161

L.2 Installation work responsibility . 161

L.3 Installation work responsibility table . 161

Annex M (informative) Trade names of communication profiles . 162

Annex N (informative) Validation measurements . 165

N.1 General . 165

N.2 DCR measurements . 165

N.2.1 Purpose of test . 165
N.2.2 Assumptions . 165
N.2.3 Measurements . 165
N.2.4 Calculations . 167
N.2.5 Measurement results . 167
Annex O (informative) End-to-end link . 171
O.1 General . 171
O.2 End-to-end link . 171
O.3 Deliverables . 172
O.4 End-to-end link test schedules and methods . 172
O.4.1 End-to-end link test method 1 . 172
O.4.2 End-to-end link test method 2 . 173
Bibliography . 174

Figure 1 – Industrial network installation life cycle . 13
Figure 2 – Standards relationships . 14
Figure 3 – Structure of generic cabling connected to an automation island . 31
Figure 4 – Automation island cabling attached to elements of generic cabling. 31
Figure 5 – Automation islands . 32
Figure 6 – Automation island network external connections . 32
Figure 7 – How to meet environmental conditions . 36
Figure 8 – How enhancement, isolation and separation work together . 36
Figure 9 – Basic physical topologies for passive networks . 37
Figure 10 – Basic physical topologies for active networks . 37

Figure 11 – Example of combination of basic topologies . 38
Figure 12 – Basic reference implementation model . 49
Figure 13 – Enhanced reference implementation model . 51
Figure 14 – Selection of the earthing and bonding systems . 58
Figure 15 – Wiring for bonding and earthing in an equipotential configuration . 60
Figure 16 – Wiring of the earths in a star earthing configuration . 61
Figure 17 – Schematic diagram of a field device with direct earthing . 62
Figure 18 – Schematic diagram of a field device with parallel RC circuit earthing . 63
Figure 19 – Insert edge protector . 72
Figure 20 – Use an uncoiling device and avoid forming loop . 73
Figure 21 – Avoid torsion . 73
Figure 22 – Maintain minimum bending radius . 74

61918 © IEC:2013 – 7 –
Figure 23 – Do not pull by the individual wires . 74

Figure 24 – Use cable clamps with a large (wide) surface . 74

Figure 25 – Cable gland with bending protection . 75

Figure 26 – Spiral tube . 75

Figure 27 – Separate cable pathways . 78

Figure 28 – Use of flexible bonding straps at movable metallic pathways . 81

Figure 29 – Surface preparation for earthing and bonding electromechanical

connections . 82

Figure 30 – Example of isolated bus bar . 83

Figure 31 – Example of isolator for mounting DIN rails . 84
Figure 32 – Parallel RC shield earthing . 84
Figure 33 – Direct shield earthing . 85
Figure 34 – Examples for shielding application . 85
Figure 35 – Voltage offset mitigation . 86
Figure 36 – First example of derivatives of shield earthing . 86
Figure 37 – Second example of derivatives of shield earthing . 86
Figure 38 – Installation verification process . 88
Figure 39 – Test of earthing connections . 89
Figure 40 – Pin and pair grouping assignments for two eight position IEC 60603-7
subparts and four position IEC 60603 series to IEC 61076-2-101 connectors . 92
Figure 41 – Two pair 8-way modular connector . 92
Figure 42 – Transposed pairs, split pairs and reversed pair . 92
Figure 43 – Validation process . 94
Figure 44 – Schematic representation of the channel . 95
Figure 45 – Schematic representation of the permanent link . 95
Figure 46 – Communication network maintenance . 103
Figure 47 – Troubleshooting procedure . 108
Figure 48 – Fault detection without special tools . 109
Figure B.1 – MICE classifications . 112
Figure B.2 – Example MICE classifications within a facility . 113
Figure B.3 – Enhancement, isolation and separation . 113
Figure B.4 – Example 1 of mitigation. 114
Figure B.5 – Example 2 of mitigation. 115
Figure B.6 – Frequency range of electromagnetic disturbance from common industrial
devices . 115
Figure B.7 – Example of a general guidance for separation versus EFT value . 117
Figure E.1 – Four-wire power network (TN-C) . 135
Figure E.2 – Five wire power network (TN-S) . 136
Figure H.1 – Straight through cord sets with M12-4 D-coding connectors . 144
Figure H.2 – Straight through cord sets with 8-way modular connectors, 8 poles . 145
Figure H.3 – Straight through cord sets with 8-way modular connectors, 4 poles . 146
Figure I.1 – Stripping the cable jacket . 149
Figure I.2 – Example of wire preparation for type A cables . 150
Figure I.3 – 8-way modular plug . 150

– 8 – 61918 © IEC:2013
Figure I.4 – Inserting the cable into the connector body . 151

Figure I.5 – Crimping the connector . 151

Figure I.6 – Example of a cable preparation for type A wiring . 152

Figure I.7 – Connector components . 153

Figure I.8 – Cable preparation . 153

Figure I.9 – Connector wire gland, nut and shell on the cable . 153

Figure I.10 – Conductors preparation . 153

Figure I.11 – Jacket removal . 154

Figure I.12 – Shield preparation . 154
Figure I.13 – Conductors preparation . 154
Figure I.14 – Installing conductors in connector . 154
Figure I.15 – Assembling the body of the connector . 155
Figure I.16 – Final assembling . 155
Figure N.1 – Loop resistance measurement wire to wire . 166
Figure N.2 – Loop resistance measurement wire 1 to shield . 166
Figure N.3 – Loop resistance measurement wire 2 to shield . 166
Figure N.4 – Resistance measurement for detecting wire shorts . 166
Figure N.5 – Resistance measurement between wire 1 and wire 2 . 167
Figure N.6 – Validation of the cable DCR . 168
Figure N.7 – Conclusions for cable open or shorts . 169
Figure N.8 – Determination of proper cable terminator value . 170
Figure O.1 – Channel according to ISO/IEC 11801 . 171
Figure O.2 – End-to-end link . 172

Table 1 – Basic network characteristics for balanced cabling not based on Ethernet . 39
Table 2 – Network characteristics for balanced cabling based on Ethernet . 40
Table 3 – Network characteristics for optical fibre cabling . 41
Table 4 – Information relevant to copper cable: fixed cables . 43
Table 5 – Information relevant to copper cable: cords . 44
Table 6 – Information relevant to optical fibre cables . 45
Table 7 – Connectors for balanced cabling CPs based on Ethernet . 47

Table 8 – Connectors for copper cabling CPs not based on Ethernet . 47
Table 9 – Optical fibre connecting hardware . 47
Table 10 – Relationship between FOC and fibre types (CP x/y) . 48
Table 11 – Basic reference implementation formulas . 50
Table 12 – Enhanced reference implementation formulas . 51
Table 13 – Correction factor Z for operating temperature above 20 °C . 52
Table 14 – Equalisation and earthing conductor sizing and length . 57
Table 15 – Bonding straps cross-section . 59
Table 16 – Bonding plates surface protection. 59
Table 17 – Cable circuit types and minimum distances . 68
Table 18 – Parameters for balanced cables . 71
Table 19 – Parameters for silica optical fibre cables . 71

61918 © IEC:2013 – 9 –
Table 20 – Parameters for POF optical fibre cables . 71

Table 21 – Parameters for hard clad silica optical fibre cables . 72

Table 22 – Typical problems in a network with balanced cabling . 106

Table 23 – Typical problems in a network with optical fibre cabling . 107

Table B.1 – Example 1 of targeted MICE area . 114

Table B.2 – Example 2 of targeted MICE area . 114

Table B.3 – Relationship between electromagnetic disturbance-generating devices and

“E” classification . 116

Table B.4 – Coupling mechanism for some interfering devices . 117

Table B.5 – MICE definition . 118
Table D.1 – Conventions for colour code used in the connector table . 122
Table D.2 – Pair numbers and colour scheme . 123
Table D.3 – 8-way modular connector .
...