Remote Automation Solutions Bristol Expansion RS-485 and/or AO Board Manuals & Guides

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abcock

EXPANSION RS-485 and/or

ANALOG OUTPUT BOARD

Series No. 392971-XX-X

(For Models 3530-XXX)

For The Following BBI Instruction Manuals:

CI-3530-10B, CI-3530-15B, CI-3530-20B, CI-3530-25B,

CI-3530-35B, CI-3530-40B & CI-3530-50B

Bri

Product Information Package PIP-EXP485/AO - January 2003

l B

NOTICE

Copyright Notice

The information in this document is subject to change without notice. Every effort has been
made to supply complete and accurate information. However, Bristol Babcock assumes no
responsibility for any errors that may appear in this document.

Request for Additional Instructions

Additional copies of instruction manuals may be ordered from the address below per
attention of the Sales Order Processing Department. List the instruction book numbers or
give complete model number, serial or software version number. Furnish a return address
that includes the name of the person who will receive the material. Billing for extra copies
will be according to current pricing schedules.

TM

TeleFlow
righted products mentioned in this document are for information only, and belong to their
respective companies, or trademark holders.

and TeleRTUTM are trademarks of Bristol Babcock. Other trademarks or copy-

Copyright (c) 2003 Bristol Babcock, 1100 Buckingham St., Watertown, CT 06795. No part of
this manual may be reproduced in any form without the express written permission of
Bristol Babcock.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

Be sure that these instructions are carefully read and understood before any
operation is attempted. Improper use of this device in some applications may result
in damage or injury. The user is urged to keep this book filed in a convenient location
for future reference.

These instructions may not cover all details or variations in equipment or cover
every possible situation to be met in connection with installation, operation or main­tenance. Should problems arise that are not covered sufficiently in the text, the
purchaser is advised to contact Bristol Babcock for further information.

EQUIPMENT APPLICATION WARNING

The customer should note that a failure of this instrument or system, for
whatever reason, may leave an operating process without protection. Depending
upon the application, this could result in possible damage to property or injury to
persons. It is suggested that the purchaser review the need for additional backup
equipment or provide alternate means of protection such as alarm devices, output
limiting, fail-safe valves, relief valves, emergency shutoffs, emergency switches, etc.
If additional in-formation is required, the purchaser is advised to contact Bristol
Babcock.

RETURNED EQUIPMENT WARNING

When returning any equipment to Bristol Babcock for repairs or evaluation,
please note the following: The party sending such materials is responsible to ensure
that the materials returned to Bristol Babcock are clean to safe levels, as such levels
are defined and/or determined by applicable federal, state and/or local law
regulations or codes. Such party agrees to indemnify Bristol Babcock and save Bristol
Babcock harmless from any liability or damage, which Bristol Babcock may incur or
suffer due to such party's failure to so act.

ELECTRICAL GROUNDING

Metal enclosures and exposed metal parts of electrical instruments must be
grounded in accordance with OSHA rules and regulations pertaining to "Design
Safety Standards for Electrical Systems," 29 CFR, Part 1910, Subpart S, dated: April
16, 1981 (OSHA rulings are in agreement with the National Electrical Code).

The grounding requirement is also applicable to mechanical or pneumatic
instruments that include electrically-operated devices such as lights, switches, relays,
alarms, or chart drives.

EQUIPMENT DAMAGE FROM ELECTROSTATIC DISCHARGE VOLTAGE

This product contains sensitive electronic components that can be damaged by
exposure to an electrostatic discharge (ESD) voltage. Depending on the magnitude
and duration of the ESD, this can result in erratic operation or complete failure of the
equipment. Read BBI document S14006 for proper care and handling of ESD­sensitive components.

Bristol Babcock 1100 Buckingham Street, Watertown, CT 06795

Telephone [phone]

WARRANTY

A. Bristol warrants that goods described herein and manufactured by Bristol are free

from defects in material and workmanship for one year from the date of shipment
unless otherwise agreed to by Bristol in writing.

B. Bristol warrants that goods repaired by it pursuant to the warranty are free from

defects in material and workmanship for a period to the end of the original warranty
or ninety (90) days from the date of delivery of repaired goods, whichever is longer.

C. Warranties on goods sold by, but not manufactured by Bristol are expressly limited

to the terms of the warranties given by the manufacturer of such goods.

D. All warranties are terminated in the event that the goods or systems or any part

thereof are (i) misused, abused or otherwise damaged, (ii) repaired, altered or
modified without Bristol's consent, (iii) not installed, maintained and operated in
strict compliance with instructions furnished by Bristol, or (iv) worn, injured or
damaged from abnormal or abusive use in service time.

E. THESE WARRANTIES ARE EXPRESSLY IN LIEU OF ALL OTHER

WARRANTIES EXPRESS OR IMPLIED (INCLUDING WITHOUT LIMITATION
WARRANTIES AS TO MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE), AND NO WARRANTIES, EXPRESS OR IMPLIED, NOR ANY
REPRESENTATIONS, PROMISES, OR STATEMENTS HAVE BEEN MADE BY
BRISTOL UNLESS ENDORSED HEREIN IN WRITING. FURTHER, THERE ARE
NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION OF THE
FACE HEREOF.

F. No agent of Bristol is authorized to assume any liability for it or to make any written

or oral warranties beyond those set forth herein.

REMEDIES

A. Buyer's sole remedy for breach of any warranty is limited exclusively to repair or

replacement without cost to Buyer of any goods or parts found by Seller to be
defective if Buyer notifies Bristol in writing of the alleged defect within ten (10) days
of discovery of the alleged defect and within the warranty period stated above, and if
the Buyer returns such goods to Bristol's Watertown office, unless Bristol's Water­town office designates a different location, transportation prepaid, within thirty (30)
days of the sending of such notification and which upon examination by Bristol
proves to be defective in material and workmanship. Bristol is not responsible for
any costs of removal, dismantling or reinstallation of allegedly defective or defective
goods. If a Buyer does not wish to ship the product back to Bristol, the Buyer can
arrange to have a Bristol service person come to the site. The Service person's
transportation time and expenses will be for the account of the Buyer. However,
labor for warranty work during normal working hours is not chargeable.

B. Under no circumstances will Bristol be liable for incidental or consequential damages

resulting from breach of any agreement relating to items included in this quotation
from use of the information herein or from the purchase or use by Buyer, its
employees or other parties of goods sold under said agreement.

How to return material for Repair or Exchange

Before a product can be returned to Bristol Babcock for repair, upgrade, exchange, or to
verify proper operation, form (GBU 13.01) must be completed in order to obtain a RA
(Return Authorization) number and thus ensure an optimal lead time. Completing the form
is very important since the information permits the Bristol Babcock Repair Dept.to ef­fectively and efficiently process the repair order.

You can easily obtain a RA number by:

A. FAX

Completing the form (GBU 13.01) and faxing it to [phone]. A BBI Repair
Dept. representative will return call (or other requested method) with a RA number.

B. E-MAIL

Accessing the form (GBU 13.01) via the Bristol Babcock Web site
(www.bristolbabcock.com) and sending it via E-Mail to [e-mail].
A BBI Repair Dept. representative will return E-Mail (or other requested method)
with a RA number.

C. Mail

Mail the form (GBU 13.01) to

Bristol Babcock Inc.

Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

A BBI Repair Dept. representative will return call (or other requested method) with
a RA number.

D. Phone

Calling the BBI Repair Department at [phone]. A BBI Repair Department
representative will record a RA number on the form and complete Part I, then send
the form to the Customer via fax (or other requested method) for Customer
completion of Parts II & III.

A copy of the completed Repair Authorization Form with issued RA number should be in­cluded with the product being returned. This will allow us to quickly track, repair, and
return your product to you.

Bristol Babcock Inc. Repair Authorization Form

(Providing this information will permit BBI to effectively and efficiently process your return. Completion is required to

receive optimal lead time. Lack of information may result in increased lead times.)

Date___________________ RA #___________________SH_ Line No.____________

Standard Repair Practice is as follows: Variations to this is

practice may be requested in the “Special Requests” section.

· Evaluate / Test / Verify Discrepancy

· Repair / Replace / etc. in accordance with this form

Please be aware of the Non warranty standard charge:

· There is a $100 minimum evaluation charge, which is
applied to the repair if applicable (Ö in “returned” B,C,
or D of part III below)

· Return to Customer

Part I Please complete the following information for single unit or multiple unit returns

Address No. (office use only) Address No. (office use only)

Bill to : Ship to:

Purchase Order: Contact Name:____________________________________

Phone: Fax: E-Mail:

Part II Please complete Parts II & III for each unit returned

Model No./Part No. Description

Range/Calibration S/N

Reason for return :

Failure Upgrade Verify Operation Other

1. Describe the conditions of the failure (Frequency/Intermittent, Physical Damage, Environmental Conditions,
Communication, CPU watchdog, etc.)

(Attach a separate sheet if necessary)

2. Comm. interface used:

Standalone RS-485 Ethernet Modem (PLM (2W or 4W) or SNW) Other:______________

3. What is the Firmware revision? _____________________ What is the Software &version?

Part III If checking “replaced” for any question below, check an alternate option if replacement is not available

A. If product is within the warranty time period but is excluded due

to BBI’s warranty clause, would you like the product:

repaired returned replaced scrapped?

B. If product were found to exceed the warranty period,

would you like the product:

C. If product is deemed not repairable would you like your product:

D. If BBI is unable to verify the discrepancy, would you like the product:

repaired returned replaced scrapped?

returned replaced scrapped?

returned replaced *see below?

* Continue investigating by contacting the customer to learn more about the problem experienced? The person to contact that

has the most knowledge of the problem is: _______________________________ phone

If we are unable to contact this person the backup person is: _________________________

phone

Special Requests:

Ship prepaid to: Bristol Babcock Inc., Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: [phone] Fax: [phone]

Form GBU 13.01 Rev. A

Bristol Babcock

Training

GET THE MOST FROM YOUR BRISTOL

BABCOCK INSTRUMENT OR SYSTEM

● Avoid Delays and problems in getting your system on-line

● Minimize installation, start-up and maintenance costs.

● Make the most effective use of our hardware and software.

● Know your system.

As you know, a well-trained staff is essential to your operation. Bristol Babcock offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at four locations: Houston, Birmingham, Orlando and our Watertown,
CT headquarters. By participating in our training, your personnel can learn how to install,
calibrate, configure, program and maintain any and all Bristol Babcock products and realize
the full potential of your system.

For information or to enroll in any class, contact our training department in Watertown at
[phone]. For Houston classes, you can also contact our Houston office, at (713) 685-

6200.

A Few Words About Bristol Babcock

For over 100 years, Bristol7 has been providing innovative solutions for the measurement
and control industry. Our product lines range from simple analog chart recorders, to
sophisticated digital remote process controllers and flow computers, all the way to turnkey
SCADA systems. Over the years, we have become a leading supplier to the electronic gas
measurement, water purification, and wastewater treatment industries.

On off-shore oil platforms, on natural gas pipelines, and maybe even at your local water
company, there are Bristol Babcock instruments, controllers, and systems running year-in
and year-out to provide accurate and timely data to our customers.

Getting Additional Information

In addition to the information contained in this manual, you may receive additional assis­tance in using this product from the following sources:

Contacting Bristol Babcock Directly

Bristol Babcock's world headquarters are located at 1100 Buckingham Street, Watertown,
Connecticut 06795, U.S.A.

Our main phone numbers are:

[phone]
[phone] (FAX)

Regular office hours are Monday through Friday, 8:00AM to 4:30PM Eastern Time,
excluding holidays and scheduled factory shutdowns. During other hours, callers may leave
messages using Bristol's voice mail system.

Telephone Support - Technical Questions

During regular business hours, Bristol Babcock's Application Support Group can provide
telephone support for your technical questions.

For technical questions about TeleFlowÔ products call [phone].

For technical questions about ControlWave call [phone] or [phone].

For technical questions regarding Bristol’s OpenEnterprise product, call [phone] or
e-mail: [e-mail]

For technical questions regarding ACCOL products, Open BSI Utilities, as well as
Bristol's Enterprise Server

For technical questions about Network 3000 hardware, call [phone].

You can e-mail the Application Support Group at: [e-mail]

7

/Enterprise Workstation7 products, call [phone].

The Application Support Group maintains an area on our web site for software updates and
technical information. Go to: www.bristolbabcock.com/services/techsupport/

For assistance in interfacing Bristol Babcock hardware to radios, contact Bristol Babcock’s

Communication Technology Group in Orlando, FL at [phone] or (407) 629-

9464.

Telephone Support - Non-Technical Questions, Product Orders, etc.

Questions of a non-technical nature (product orders, literature requests, price and delivery
information, etc.) should be directed to the nearest sales office (listed on the rear cover) or to
your Bristol-authorized sales representative. A list of

Please call the main Bristol Babcock number (860-945-2200) if you are unsure which office
covers your particular area.

Visit our Site on the World Wide Web

For general information about Bristol Babcock and its products, please visit our site on the
World Wide Web at: www.bristolbabcock.com

Training Courses

Bristol Babcock’s Training Department offers a wide variety of courses in Bristol hardware
and software at our Watertown, Connecticut headquarters, and at selected Bristol regional
offices, throughout the year. Contact our Training Department at [phone] for course
information, enrollment, pricing, and scheduling.

PIP-EXP485/AO

EXPANSION RS-485 COMMUNICATIONS

and/or ANALOG OUTPUT BOARD

PT. Number 392971-XX-X

Product Information Package

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 DESCRIPTION................................................................................................................... 1

1.1.1 Function .............................................................................................................................. 1

1.1.2 Features............................................................................................................................... 2

1.2 COMPONENT IDENTIFICATION................................................................................... 3

1.3 INSTALLATION COMPATIBILITY................................................................................ 3

1.3.1 Restrictions ......................................................................................................................... 3

Section 2 – INSTALLATION & SERVICE

2.1 EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION ................................... 4

2.1.1 Installation/Removal of the EXP485/AO Board ................................................................ 4

2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B & -50B ...................................... 4

2.1.1.2 Installation/Removal for Models 3530-20B & -25B ........................................................ 11

2.1.1.3 Installation/Removal for Models 3530-35B ..................................................................... 13

2.2 RS-485 and AO WIRING................................................................................................. 14

Section 3 - SPECIFICATIONS

3.1 PERFORMANCE SPECIFICATIONS ............................................................................16

3.2 ENVIRONMENTAL SPECIFICATIONS ....................................................................... 16

3.3 ENTITY PARAMETERS (INTRINSICALLY SAFE EXPAO Bd.)............................... 17

SUPPLEMENTS

Special Instructions for Class I, Division 2 Hazardous Locations ..............................................Appendix A

Special Instructions for Class I, Division 1 Hazardous Locations ..............................................Appendix B

PIP-EXP485/AO Page 0-1 Table Of Contents

Section 1

INTRODUCTION

1.1 DESCRIPTION

1.1.1 Function

The Expansion RS-485 Comm. Port with Analog Output Board (EXP485/AO) provides a
single RS-485 communications port to ACCOL-based 3530-XXX models. In addition to
assignments of the resident (host) CPU’s “local” and “network” RS-232 ports, any model
3530-XXX unit equipped with a fully populated EXP485/AO Board can establish RS-485
asynchronous communications with other 3530-XXX devices and/or can interface to an
Analog Output circuit. The EXP485/AO Board plugs into the Expansion Connector of the
TeleFlow or TeleRTU CPU Board, is stood-off by three 15/32” long hex standoffs and is
secured via three screws or standoffs depending on the model. The CPU Board Expansion
Connector supplies power and 3530-XXX communication to the EXP485/AO Board.

EXP485/AO Boards measure 4.25” by 3.75” and utilizes a 9-position Industrial 3.5mm pitch
plugable connector to interface (RS-485) to a series of remote 3530-XXX devices and or a
single 1-5Vdc or 4-20mA AO device.

Programmable baud rates up to 19.2Kbps are supported by the EXP485/AO Board.
Interface signals are available at TB1 of the EXP485/AO. When the SLEEP+ & SLEEP­signals (supplied by the Master 3530-XXX) are Low and High respectively, the remote
3530-XXX CPU Boards will be awakened. If no activity is required, the EXP485/AO Board‘s
serial communications controller (SCC) chip and RS-485 drivers can be put to sleep (low
power mode) along with the host/parent 3530-XXX and the SLEEP+ and SLEEP- signals
will be set High and Low respectively.

Figure 1 - EXP485/AO Board (with RS-485 & Configurable AO)

PIP-EXP485/AO Page 1 EXP485/AO Option

Figure 2 - EXPAO Board (with 1-5Vdc AO and without RS-485)

1.1.2 Features

· Low Power

+5Vdc @ 20mA (Max) regulated power and 5.8Vdc to 16Vdc @ 50mA (Max)
unregulated power are supplied by the host/parent 3530-XXX via the 40-pin
Expansion Interface Connector P1.

· ESD & Transient Susceptibility

The RS-485 I/O circuitry has been designed to meet the requirements of IEC 801-2
for ESD withstand capability up to 10KV and the requirements of ANSI/IEEE
C37.90.1-1989 (formerly IEE 472) for surge withstand capability.

· EMI Compatibility

EXP485/AO Boards have been designed to coexist inside a shielded enclosure with
the TeleFlowä electronics. EMI radiation is insignificant and susceptibility is
comparable or superior to associated electronics.

· Mounting

The EXP485/AO Board measures 3.75” (9.525cm) in width x 4.25” (10.795cm) in
height and mounts piggy-back on a TeleFlow or TeleRTU CPU Board.

· RS-485 Comm. Port

EXP485/AO Boards provide an RS-485 communications port that is programmable
for asynchronous rates up to 19.2Kbps. 3530-XXX units equipped with the
EXP485/AO Board can communicate with a network of 3530-XXX units (equipped

EXP485/AO Option Page 2 PIP-EXP485/AO

with EXP485/AO Boards), even though a radio or modem may be installed on the
CPU Board’s network port.

1.2 COMPONENT IDENTIFICATION

EXP485/AO Boards do not contain LEDs or switches. Fully populated EXP485/AO Boards
(P/N 392971-01-0) are provided with seven (7) configuration jumpers (see Figures 1 & 11).
Depopulated EXPAO Boards (P/N 392971-02-0) are factory set for 1-5Vdc AO operation and
don’t have configuration jumpers (see Figure 2). Two connectors are provided; 40-pin con­nector P1 mates with the host 3530-XX-X (connector J4 - TeleFlow CPU or J18 - TeleRTU
CPU) and accommodates the TTL interface between the two entities, while 9-pin connector
TB1 mates with the RS-485 device that is being interfaced to the 3530-XXX and/or an
analog output device. Additionally, the 3.5mm pitch plugable connector TB1 is removable
from its mating EXP485/AO Board socket.

1.3 INSTALLATION COMPATIBILITY

An EXP485/AO Board can be installed into any of the following 3530-XXX models:

3530-10B - TeleFlow 3530-35B - TeleRTU Module
3530-15B - TeleRTU 3530-40B - TeleFlow ECR
3530-20B - TeleFlow Plus 3530-50B - TeleFlow Corrector
3530-25B - TeleRTU Plus

1.3.1 Restrictions

The 3530-XXX in question must be equipped with ACCOL application software. The
TeleFlow Plus (3530-20B), TeleRTU Plus (3530-25B) and the TeleRTU Module (3530-35B)
support installation of either a Low Power I/O Expansion Board (LPI/OEB), an
EXPCOM232 Board, or the EXP485/AO Board discussed herein, i.e., YOU CAN ONLY
INSTALL ONE (1) OF THESE ITEMS.

EXP485/AO Board (P/N 392971-01-0) is fully populated and supports RS-485 network
communications and interface to either a 1-5Vdc or a 4-20mA analog output device.

P/N 392971-02-0 is a depopulated version of the EXP485/AO Board and only supports
interface to a 1-5Vdc analog output device. Connector TB1 has two usable pins (08 = AO
and 09 = AOGND). This version is designed for use in a Class I, Division 2, Groups C and D
nonincendive environment or a Class I, Division 1, Groups C and D intrinsically safe en­vironment.

Intrinsically safe EXPAO Boards can be installed in 3530-XXX units with 6V Lead Acid or

7.2V Lithium battery systems.

PIP-EXP485/AO Page 3 EXP485/AO Option

Section 2

INSTALLATION & SERVICE

2.1 EXP485/AO REMOVAL/REPLACEMENT & INSTALLATION

2.1.1 Installation/Removal of the EXP485/AO Board

In addition to hardware normally contained within the 3530-XXX in question, units with an
installed EXP485/AO Option will contain the following major parts.

1. Expanded Comm. Port RS-485/AO Board (EXP485/AO)

2. Three (3) #4-40 x 15/32” Standoffs (Note: Models 3530-10B, -15B, -40B & -50B will

also contain Three (3) #4-40 x .188” Standoffs & Two (2) #4-40 x 1/8” SEM Screws)

3. Modified PC Shield Assembly (for models 3530-10B, -15B, -40B & -50B)

WARNING

Never attempt to service a TeleFlow, TeleFlow ECR, TeleRTU or
TeleFlow Corrector while it is powered and operating in a hazardous
environment. Either the area must be made safe or the unit must be
powered down, unwired, unmounted, and taken to a safe, non­hazardous area.

WARNING

Never attempt to install or remove any components (PCBs, Field
Wiring, Transducers, etc.) while the unit is powered and running.
Doing so can cause sudden electrical transients or imbalances that
are capable of causing damage to the module or component in
question, as well as other associated circuit boards. Always turn off
the external/internal power source, including any additional supply
sources used for externally-powered I/O circuits, before changing or
adding any components.

CAUTION

Place any related critical processes under manual or auxiliary
control prior to shutting down or performing any of the steps
discussed herein.

2.1.1.1 Installation/Removal for Models 3530-10B, -15B, -40B & -50B

To install the optional EXP485/AO Board into a model 3530-10B, -15B, -40B or -50B, follow
steps 1 through 14 below. To remove the optional EXP485/AO Board, see step 15. Note: The

Instrument Front Cover must be open.

1. To open the Instrument Front Cover, remove the lock if present and turn each of the
three captive screws a quarter (1/4) turn counterclockwise.

EXP485/AO Option Page 4 PIP-EXP485/AO

Note:
The CPU Board is not to be removed under any circum­stances unless the unit has been moved to an ESD safe
area (see ESDS Manual - S14006).

2. Remove the Power Plug(s), Solar Panel Power Plug, and the Auxiliary Power Plug as
required, from the CPU Board in question.

3. Remove the optional radio or modem if installed.
To remove an optional modem:
Disconnect the phone wires. Loosen the four (4) screws that secure the Modem/Radio
Mounting Plate (with modem) to the Battery Mounting Bracket. Slide the modem to
the left and remove it and then disconnect the D-Type connector from the modem.
To remove an optional radio:
Disconnect the Radio/TeleFlow Interface Cable from the bottom of the Radio. Unplug
the 2-wire power connector associated with the 2-wire Radio Power Interface Cable
from the bottom of the Radio. Loosen the four (4) screws that secure the Modem/Radio
Mounting Plate (with radio) to the Battery Mounting Bracket. Slide the radio to the
left and remove it.

4. Remove the Battery(s) (if present).
To remove the battery(s) from units without an optional modem or radio:
Hold the battery securely and remove the Left Battery Mounting Bracket (secured
with 2 screws. Loosen the screws which secure the Right Battery Mounting Bracket
(Carefully remove the battery (with wiring harness). Remove the Right Battery
Mounting Bracket.
To remove the battery(s) from units with an optional modem or radio:
Carefully remove the battery (with wiring harness). Note: You may have to loosen the

two left 1/4-20 x 3/8” screws that secure the left side of the Battery Mounting Bracket
and the Main Mounting Bracket to the rear of the unit. While holding the Main

Mounting Bracket, remove the four (4) 1/4-20 x 3/8” screws and lock washers that
secure the Battery Mounting Bracket and Main Mounting Bracket to the rear of the
unit. Remove the Battery Mounting Bracket and temporarily reinstall the four screws
to secure the Main Mounting Bracket to the 3530-10B, 15B, -45B or -50B.

5. Disconnect the Local Port, Network Port, RTD, and Field I/O wires from the CPU
Board connectors by unplugging their associated Terminal Plugs on the front edge of
the CPU.

6. Carefully remove the PC Shield which is secured to the Main Mounting Bracket by 2
(#4-40 x 1/4”) screws and to the CPU Board by 2 (#4-40 x 1/4”) screws.

7. Remove the screw (location ‘A’ in Figures 3 & 4) and the two (2) #4-40 x 5/8” Standoffs
(location ‘B’ in Figures 2 & 3) which secure the CPU Board to the Main Mounting
Bracket. Replace these items with the three new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

8. Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530­10B or -50B) or J18 (for 3530-15B). Push the EXP485/AO Board toward the CPU
Board until Connector P1 is fully seated.

PIP-EXP485/AO Page 5 EXP485/AO Option

Figure 3 - TeleFlow CPU Board – Installation Drawing #1

9. Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x .188”
Standoffs at locations ‘A’ and ‘B’ (see Figures 3 & 4).

10. Carefully install the Modified PC Shield, securing it to the Main Mounting Bracket (at
locations ‘C’) with two #4-40 x 1/4” screws and to the CPU Board (at location ‘B’) with
two (2) #4-40 x 1/8” SEM screws (see Figures 5, 6, 7 & 8).

11. Follow steps 2 through 6 in reverse order, replacing rather than removing the item in
question.

EXP485/AO Option Page 6 PIP-EXP485/AO

12. Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to
which it is to be interfaced (see Section 2.2).

13. Configure the new network port in the ACCOL Load resident in the host 3530-XXX
device.

Figure 4 - TeleRTU CPU Board – Installation Drawing #1

14. Close and secure the Instrument Front Cover.

15. To remove an optional EXP485/AO Board, follow steps 1 through 6 (unplug the RS-485
cable during step 5). Remove the PC Shield along with the three Standoffs that secure

PIP-EXP485/AO Page 7 EXP485/AO Option

the EXP485/AO Board to the CPU Board. Then unplug the EXP485/AO Board from
the CPU Board in question.

Figure 5 - TeleFlow CPU Board (with EXP485/AO Installed)

Installation Drawing #2

EXP485/AO Option Page 8 PIP-EXP485/AO

Figure 6 - TeleRTU CPU Board (with EXP485/AO Installed)

Installation Drawing #2

PIP-EXP485/AO Page 9 EXP485/AO Option

Figure 7 - 3530-10B, 3530-40B & 3530-50B (with EXP485/AO Installed)

Figure 8 - 3530-15B (with EXP485/AO Installed)

EXP485/AO Option Page 10 PIP-EXP485/AO

2.1.1.2 Installation/Removal for Models 3530-20B & -25B

To install the optional EXP485/AO Board into a model 3530-20B or 3530-25B, follow steps 1
through 11 below. To remove the optional EXP485/AO Board, perform steps 1 and 2 and
then follow steps 4 through 9 in reverse order, removing rather than installing the item in
question after the system has been shut down. Note: The Instrument Front Cover must be

open.

1. Open the Instrument Front Cover

2. Disconnect power by removing harness connector plug (P8 for TeleFlow - P2 for
TeleRTU) from the CPU Board edge connector (J8 for TeleFlow - J2 for TeleRTU).

Figure 9 - 3530-20B CPU (with EXP485/AO Installed)

PIP-EXP485/AO Page 11 EXP485/AO Option

3. Unplug the remaining removable Terminal Blocks (with wiring harnesses installed)
from the CPU Board’s front edge connectors.

4. Remove the two screws that secure the CPU Board’s Sliding Mounting Bracket to the
Fixed Bracket on the bottom of the Battery Bracket. Carefully slide the CPU Board
(and optional EXP485/AO Board) toward the front of the unit. Remove harness
connections from the Front Panel Switch (J12 on the TeleFlow CPU - J14 on TeleRTU
CPU), the Display Module (J2 on TeleFlow CPU - J16 on TeleRTU CPU), the Wakeup
Switch (J3 on TeleFlow CPU - J16 on TeleRTU CPU), and for TeleFlow CPU Boards
connector J1 (associated with the Multivariable Transducer).

Figure 10 - 3530-25B CPU (with EXP485/AO Installed)

5. Remove the three screws (of five) that secure the CPU Board to the Sliding Mounting
Bracket (locations ‘A’ & ‘B’ in Figures 3 & 4) and replace these items with the three
new #4-40 x 15/32” Standoffs.

EXP485/AO Option Page 12 PIP-EXP485/AO

Note:

This operation should only be performed in an ESD safe area.

6. Align the EXP485/AO Board Connector P1 with CPU Board Connector J4 (for 3530­20B) or J18 (for 3530-25B). Push the EXP485/AO Board toward the CPU Board until
Connector P1 is fully seated.

7. Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”
SEM screws as illustrated in Figures 9 & 10.

8. Route the RS-485 and AO cables through a ¾” conduit fitting (user installed) on the
bottom of the enclosure.

9. Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to
which it is to be interfaced (see Section 2.2).

10. Configure the new network port in the ACCOL Load resident in the host 3530-XXX
device.

11. Close and secure the Instrument Front Cover.

2.1.1.3 Installation/Removal for Models 3530-35B

To install the optional EXP485/AO Board into a model 3530-35B, follow steps 1 through 8
below. To remove the optional EXP485/AO Board, perform step 1 and then follow steps 5
through 7 in reverse order, removing rather than installing the item in question after the
system has been shut down.

1. Disconnect power by removing harness connector plug P2 from the CPU Board edge
connector J2.

2. Unplug the remaining removable Terminal Blocks (with wiring harnesses installed)
from the CPU Board’s front edge connectors.

3. Remove harness connections from the Front Panel Switch (J14), the Display Module
(J16) and the Wakeup Switch (J16).

4. Remove the three screws (of five) that secure the CPU Board to the RTU Mounting
Bracket (locations ‘A’ & ‘B’ in Figures 2 & 3) and replace these items with the three
new #4-40 x 15/32” Standoffs.

Note:

This operation should only be performed in an ESD safe area.

5. Align the EXP485/AO Board Connector P1 with CPU Board Connector J18. Push the
EXP485/AO Board toward the CPU Board until Connector P1 is fully seated.

6. Secure the EXP485/AO Board to the CPU Board by installing three (3) #4-40 x 1/4”
SEM screws as illustrated in Figure 11.

7. Connect wiring between the EXP485/AO Board and the remote 3530-XXX units to
which it is to be interfaced (see Section 2.2).

PIP-EXP485/AO Page 13 EXP485/AO Option

8. Configure the new network port in the ACCOL Load resident in the host 3530-XXX
device.

Figure 11 - 3530-35B (with EXP485/AO Installed)

2.2 RS-485 and AO WIRING

Figure 12 must be referenced to configure the RS-485 cable. It is recommended that a low
capacitance 24-gauge communications grade 2-twisted pair cable such as Belden 9842 be
used for RS-485 networking.

EXP485/AO Option Page 14 PIP-EXP485/AO

Figure 12 - EXP485/AO Wiring Diagrams

The device uses compression-type terminals that accommodate up to #14 AWG wire. A
connection is made by inserting the bared end (1/4 inch Max.) into the clamp beneath the
screw and then securing the screw. Insert the bared end fully to prevent short circuits.

Allow some slack in the wires when making terminal connections. The slack makes the
connections more manageable and minimizes mechanical strain on the printed circuit
boards and harnesses.

PIP-EXP485/AO Page 15 EXP485/AO Option

Section 3

SPECIFICATIONS

3.1 PERFORMANCE SPECIFICATIONS

Baud Rate (Max.): 19.2K Asynchronous

Power Requirements: +5Vdc @ 20mA Max. (Regulated)

+5.8Vdc to +16Vdc @ 50mA Max. (Unregulated)

Transient Protection: 5V Bi-directional Transient Absorption Zeners across all

RS-485 communication points
12V Bi-directional Transient Absorption Zeners across the
AO points (when configured for 1-5Vdc operation)
16V Bi-directional Transient Absorption Zeners across the
AO points (when configured for 4-20mA operation)

RS-485 Inputs/Outputs: TXD/RDX+ (TB1-3)

TXD/RXD- (TB1-4)
SLEEP+ (TB1-5)
SLEEP- (TB1-6)

Analog Output Pins: AO (TB1-8) - 1-5Vdc @ 5mA Max. ONLY on

392971-02-0
(TB1-8) - 1-5Vdc @ 5mA Max. or 4-20mA on
392971-01-0

AOGND (TB1-9) - Analog Output Ground/Return

Interface Connector: 9-Pin Industrial 3.5mm Pitch Plugable Connector

3.2 ENVIRONMENTAL SPECIFICATIONS

Operating Temperature: -40° to +60° (C) [-40° to 140° (F)]

Storage Temperature: -40° to +85° (C) [-40° to 185° (F)]

Humidity: 15% to 90% RH (Non-Condensing)

Vibration: 10 to 500 Hz at 1g on any axis per SAMA PMC-31-1

without damage or impairment.

RFI Susceptibility: Meets the requirement of IEC 1000-4-6 level 2 (3V/M)

from 150kHz to 80MHz.

EMI Compatibility: Designed to coexist inside a shielded enclosure with the

TeleFlow electronics. EMI radiation is insignificant and
Susceptibility is comparable or superior to associated
Electronics.

EXP485/AO Option Page 16 PIP-EXP485/AO

Surge Susceptibility: Designed to meet the requirements of ANSI/IEEE

C37.90.1-1989 (Formerly IEEE 472) for surge withstand
capability.

EMI Radiated: Designed to meet the requirements of IEC 1004-4-3 for

radiated emissions.

3.3 ENTITY PARAMETERS (INTRISICALLY SAFE EXPAO Bd.)

F1: .125A

R66: 200 Ohms ±5%, .5W

D20/D21: 6.2V ±5%

Voc: 6.51V

Vmax: 15V

Isc: 34.3mA

Imax: 150mA

Ca: 400µF

Ci: 0µF

La: 80mH

Li: 0mH

PIP-EXP485/AO Page 17 EXP485/AO Option

Expansion RS-485 and/or Analog Output Board

Special Instructions for Class I, Division 2 Hazardous Locations

1. The BBI Expansion RS-485 and/or Analog Output (EXP485/AO) Board is listed by
Underwriters Laboratories (UL) as nonincendive and is suitable for use in Class I,
Division 2, Groups C and D hazardous locations or non-hazardous locations only. Read
this document carefully before installing a nonincendive BBI Expansion RS-485 and/or
Analog Output Board. In the event of a conflict between the Expansion RS-485 and/or
Analog Output Board User Manual (PIP-EXP485/AO) and this document, always follow
the instructions in this document.

2. Wiring must be performed in accordance with Class I, Division 2 wiring methods as
defined in Article 501-4 (b) of the National Electrical Code, NFPA 70 for installations
within the United States, or as specified in Section 18-152 of the Canadian Electrical
Code for installation in Canada.

3. WARNING: EXPLOSION HAZARD - Substitution of components may impair

suitability for use in Class I, Division 2 environments.

4. WARNING: EXPLOSION HAZARD - When situated in a hazardous location,
turn off power before servicing/replacing the unit and before installing or
removing I/O wiring.

5. WARNING: EXPLOSION HAZARD - Do Not disconnect equipment unless the
power has been switched off or the area is known to be nonhazardous.

12/14/2001 Appendix A of PIP-EXP485/AO - EXP485/AO Board Page 1 of 1

Expansion RS-485 and/or Analog Output Board for 3530-XXX

Special Instructions for Class I, Division 1 Hazardous Locations

1. A version of the Expansion RS-485 and/or Analog Output (EXP485/AO) Board is
available that is listed by Underwriters Laboratories (UL) as intrinsically safe for use in
Class I, Division 1, Groups C and D hazardous locations. Read this document carefully
before installing an intrinsically safe Expansion RS-485 and/or Analog Output Board.
Refer to the Expansion RS-485 and/or Analog Output Board User’s Manual (PIP­EXP485/AO) for general information. In the event of a conflict between the Expansion
RS-485 and or Analog Output User’s Manual and this document, always follow the
instructions in this document.

2. Only the depopulated version of the Expansion RS-485 and/or Analog Output Board
(EXP485/AO) (P/N 392971-02-0) may be used in a Class I, Division 1 hazardous location.

3. TeleFlow models 3530-10B, 3530-40B and 3530-50B approved for use in Class I,
Division 1, Groups C and D hazardous locations and equipped with the EXP485/AO
Board option may reside in a Division 1, 2 or nonhazardous area. 3530-XXX units not
approved for use in a Class I, Division 1 environment may contain an EXP485/AO Board
but can only reside in a Class I, Division 2 or nonhazardous area.

CAUTION

When connecting the Expansion Analog Output Board to a
TeleFlow that is mounted in a Division 1 area, wire all circuits
using wiring methods specified in article 501-4(A) of the
National Electrical Code NFPA 70.

When installing an Expansion RS-485 and/or Analog Output
Board (EXP485/AO) into a TeleFlow that is mounted in a
Division 2 area, ensure that the area is nonhazardous before
connecting or disconnecting the nonhazardous interface.

4. Intrinsically safe TeleFlows equipped with an intrinsically safe EXPAO Board (P/N
392971-02-0) do not include any internal communications options.

01/11/02 Appendix B - Document PIP-EXP485/AO Page 1 of 1

READER RESPONSE FORM

Please help us make our documentation more useful to you! If you have a complaint, a
suggestion, or a correction regarding this manual, please tell us by mailing this page with your
comments. It's the only way we know we're doing our job by giving you correct, complete, and
useful documentation.

DOCUMENT NUMBER: PIP-EXP485/AO
TITLE: EXPANSION RS-485 and/or ANALOG OUTPUT BOARD (for Models 3530-XXX)

Product Information Package

ISSUE DATE: JAN., 2003
COMMENT/COMPLAINT:

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Mail this page to:
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U.S.A. Locations:

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[e-mail]

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Return to CI-3530-35B Table of Contents

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