Remote Automation Solutions FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide Manuals & Guides

FB1200 Flow Computer 6-Channel I/O Expansion Board Field Replacement Guide

FB1200 Flow Computer
6-Channel I/O Expansion Board
Field Replacement Guide

D301819X012

November 2020

For Part Numbers (Kits):

 400215010-KIT

Remote Automation Solutions

FB1200 Flow Computer 6-Channel I/O Expansion Board Field Replacement Guide

D301819X012
November 2020

Device Safety Considerations

 Reading these Instructions

Before operating the device, read these instructions carefully and understand their safety implications. In some situations,
improperly using this device may result in damage or injury. Keep this manual in a convenient location for future reference.
Note that these instructions may not cover all details or variations in equipment or cover every possible situation regarding
installation, operation, or maintenance. Should problems arise that are not covered sufficiently in the text, immediately
contact Customer Support for further information.

 Protecting Operating Processes

A failure of this device – for whatever reason -- may leave an operating process without appropriate protection and could result
in possible damage to property or injury to persons. To protect against this, you should 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.). Contact Remote Automation Solutions for additional information.

 Returning Equipment

If you need to return any equipment to Remote Automation Solutions, it is your responsibility to ensure that the equipment
has been cleaned to safe levels, as defined and/or determined by applicable federal, state and/or local law regulations or
codes. You also agree to indemnify Remote Automation Solutions and hold Remote Automation Solutions harmless from any
liability or damage which Remote Automation Solutions may incur or suffer due to your failure to ensure device cleanliness.

 Grounding Equipment

Ground metal enclosures and exposed metal parts of electrical instruments in accordance with OSHA rules and regulations as
specified in 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). You must also ground mechanical or pneumatic instruments that include
electrically operated devices such as lights, switches, relays, alarms, or chart drives.
Important: Complying with the codes and regulations of authorities having jurisdiction is essential to ensuring personnel
safety. The guidelines and recommendations in this manual are intended to meet or exceed applicable codes and regulations.
If differences occur between this manual and the codes and regulations of authorities having jurisdiction, those codes and
regulations must take precedence.

 Protecting from Electrostatic Discharge (ESD)

This device contains sensitive electronic components which be damaged by exposure to an ESD voltage. Depending on the
magnitude and duration of the ESD, it can result in erratic operation or complete failure of the equipment. Ensure that you
correctly care for and handle ESD-sensitive components.

System Training

A well-trained workforce is critical to the success of your operation. Knowing how to correctly install, configure, program,
calibrate, and trouble-shoot your Emerson equipment provides your engineers and technicians with the skills and confidence
to optimize your investment. Remote Automation Solutions offers a variety of ways for your personnel to acquire essential
system expertise. Our full-time professional instructors can conduct classroom training at several of our corporate offices, at
your site, or even at your regional Emerson office. You can also receive the same quality training via our live, interactive
Emerson Virtual Classroom and save on travel costs. For our complete schedule and further information, contact the Remote
Automation Solutions Training Department at 800-338-8158 or email us at [e-mail].

Ethernet Connectivity

This automation device is intended to be used in an Ethernet network which does not have public access. The inclusion of this
device in a publicly accessible Ethernet-based network is

not recommended.

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

Item

Field Replacement Kit
Part Number

WARNING

WARNING

D301819X012

November 2020

Replacing the 6-Channel Expansion I/O Board

You can replace the optional 6-channel expansion I/O board provided you replace it with the exact
same part.

Restriction

Hazardous area approvals require that any part replaced in the field be the exact same part (“like­for-like”). Upgrading or substituting different parts violates hazardous area certification.

Refer to the table below for the correct field replacement part number.

Board Type UL Field Replacement Kit

Part Number

6-Channel Expansion I/O Board 400215010-KIT

Ambient Temperature Range

May be used up to a maximum ambient temperature of 80°C and a minimum ambient
temperature of –40°C; refer to the data plate attached to the device for ambient
temperature.

Required Tools



#1 Phillips-head screwdriver



#2 Phillips-head screwdriver



3/32-inch flat head screwdriver (for 3.81 mm pitch terminal block connections and
disconnecting the internal connector to the sensor)



Hexagonal torque wrenches with 3mm, #1, and #2 Phillips-head bits. Ranges must include 1
to 2 in-lbs (0.1 to 0.2 N-m), 4 to 6 in-lbs (0.5 to 0.7 N-m), and 10 to 12 in-lbs (1.1 to 1.4 N-m).

Electrical Ratings



Input Voltage: 5.7-30Vdc, 10 Watts Max



I/O Ratings (FB1200 Flow Computer):

o

4 Digital Outputs: 0.5A, 24Vdc

o

2 Analog Outputs: 4-20 mA

EXPLOSION HAZARD – Substitution of any components may impair suitability for Class I, Division
1 or Class I, Division 2.

EXPLOSION HAZARD - Do not disconnect equipment unless power has been removed or the area

is known to be non-hazardous.

1

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

DANGER

1

Screw

2

Retaining Clamp

3

Washer

D301819X012
November 2020

DANGER

EXPLOSION HAZARD: Ensure the area in which you perform this operation is non-hazardous.
Performing this operation in a hazardous area could result in an explosion.

EXPLOSION HAZARD: Never remove end cap(s) in a hazardous location. Removing cover(s) in a
hazardous location could result in an explosion.

Removing/Replacing the 6-Channel Expansion I/O Board

UL Listed 6-Channel I/O Expansion Board Field Installed Accessory Kit for Use in Class I, Division 1,
Groups C, and D; and Class I, Division 2, Groups A, B, C, and D, Part No. 400215010-KIT for use with
UL Listed Model Series FB1200.

1. Remove the retaining clamps on the end caps (if present) using a 3 mm hexagonal wrench.

Components of Retaining Clamp Assembly

2

2. Grasp the end cap.

Front End Cap Rear End Cap

3. Unscrew the end cap by turning it counter-clockwise until it comes off. Set the end cap aside
in a safe location.

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012

November 2020

Note

If you need more leverage, place a long screwdriver or other appropriate tool across the two
notches in the end cap to act as a pry bar.

Front End Cap (unscrewed) Rear End Cap (removed)

4. Unplug terminal block TB1 to disconnect main power. TB1 has eight connectors See the
graphic below for detail:

TB1 (Eight connectors)

3

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012
November 2020

5. With a #2 Phillips-head screwdriver, loosen the two captive fastening screws in the recessed
areas of the battery pack enclosure.

Note

Not all units include an internal battery but the battery enclosure is always present.

Captive Screws

6. With a #1 Phillips-head screwdriver, loosen the two bottom captive fastening screws on the
HMI module. Leave the two top screws on the HMI module connected to the battery pack
enclosure.

Captive Screws (loosened)

7. Grasp the HMI module and gently pull it and the battery pack enclosure out of the housing.

4

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012

November 2020

HMI Module (removed)

8. If the battery pack holds an internal battery, disconnect it.

Internal Battery (disconnected)

9. Set the battery pack enclosure and HMI module assembly aside.

5

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012
November 2020

10. With a #2 Phillips-head screwdriver, loosen the two captive fastening screws in the plastic

bezel that hold the CPU module in place.

Bezel Fastening Screws

11. Grasp the plastic bezel and gently pull the CPU module out of the housing.

CPU Module (removed)

12. Use a 3/32-inch flathead screwdriver to separate the internal wire connector plug from the
plug on the bottom of the CPU module.

6

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012

November 2020

Internal Wire Connector Plug on CPU Module

13. Use a #1 Phillips-head screwdriver to remove the four screws that attach the I/O expansion
board to the CPU module and separate the board from the CPU module. Set the old 6­channel expansion I/O board aside and now use those four screws to attach the
(replacement) 6-channel expansion I/O board to your CPU module. Torque screws to 1 to 2
in-lbs (0.1 to 0.2 N-m).

Correct IO Expansion Board Screw Locations

new

7

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012
November 2020

14. Snap the internal wire connector plug (from Step 12) onto the mating plug on the bottom of

the CPU module and gently slide the CPU module with the new 6-channel expansion I/O
board into the housing, being careful not to pinch wires. Press firmly into place.

15. Tighten the two captive fastening screws that hold the CPU module in the housing with a

torque value of 4 to 6 in-lbs (0.5 to 0.7 N-m).

16. Slide the HMI module/battery pack enclosure assembly (from Step 7) back into the housing.

With a torque value of 4 to 6 in-lbs (0.5 to 0.7 N-m), tighten the captive fastening screws on
the top of the battery pack enclosure and then tighten the bottom screws on the HMI
module.

17. Reconnect battery power (if present). (See the connector shown in Step 8).

18. Restore main power at connector TB1.

19. Carefully align the end cap threads with the threads of the enclosure and replace the end

caps. Screw each end cap clockwise (eight full turns) until it is tightly sealed to the enclosure.
Endcaps must have at least 8 full threads engaged upon reassembly.

Note

If you need more leverage place a long screwdriver or other appropriate tool across the two
notches in the end cap to act as a pry bar.

20. If applicable, tighten the retaining clamp onto the end cap using a 3mm hexagonal wrench.

When tightening, torque to 10 to 12 in-lbs (1.1 to 1.4 N-m).

8

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

D301819X012

November 2020

9

FB1200 Flow Computer 6-Channel Expansion I/O Board Field Replacement Guide

For customer service and technical support,

Global Headquarters,
North America, and Latin America:

end-user.

Europe:

Middle East/Africa:

Asia-Pacific:

T [phone]| F [phone]

D301819X012
November 2020

visit www.Emerson.com/SupportNet

Emerson Automation Solutions
Remote Automation Solutions
6005 Rogerdale Road
Houston, TX 77072 U.S.A.
T [phone] | F [phone]

www.Emerson.com/RemoteAutomation

Emerson Automation Solutions
Remote Automation Solutions
Unit 1, Waterfront Business Park
Dudley Road, Brierley Hill
Dudley DY5 1LX UK
T [phone] | F [phone]

Emerson Automation Solutions
Remote Automation Solutions
Emerson FZE
P.O. Box 17033
Jebel Ali Free Zone – South 2
Dubai U.A.E.
T [phone] | F [phone]

Emerson Automation Solutions
Remote Automation Solutions
1 Pandan Crescent
Singapore 128461

© 2018-2020 Remote Automation Solutions, a business unit of Emerson Automation
Solutions. All rights reserved.

This publication is for informational purposes only. While every effort has been made to ensure
accuracy, this publication shall not be read to include any warranty or guarantee, express or
implied, including as regards the products or services described or their use or applicability.
Remote Automation Solutions (RAS) reserves the right to modify or improve the designs or
specifications of its products at any time without notice. All sales are governed by RAS terms
and conditions which are available upon request. RAS accepts no responsibility for proper
selection, use or maintenance of any product, which remains solely with the purchaser and/or

Remote Automation Solutions