Remote Automation Solutions Manual: Bristol Lower Power I/O Expansion Board Manuals & Guides

Product Information Package

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PIP-EXP I/O TF
February, 2008

ow Power I/O Expansion Board

Low Power I/O Expansion Board
Part No. 392927-XX-X

(For TeleFlow Plus, TeleRTU Plus, TeleRTU Module & TeleRecorder)

CI-3530-20B, CI-3530-25B, CI-3530-35B & CI-3530-55B

For the following Instruction Manuals:

Remote Automa tion Solution

www.EmersonProcess.com/Remote

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 Emerson Process
Management, Remote Automation Solutions division (RAS) for further information.

IMPORTANT! READ INSTRUCTIONS BEFORE STARTING!

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 information is required, the purchaser is advised to contact RAS.

RETURNED EQUIPMENT WARNING

When returning any equipment to RAS for repairs or evaluation, please note the following: The
party sending such materials is responsible to ensure that the materials returned to RAS 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 RAS and save RAS harmless from
any liability or damage which RAS 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 supplemental document
S14006 at the back of this manual for proper care and handling of ESD-sensitive components.

Remote Automation Solutions

A Division of Emerson Process Management
1100 Buckingham Street, Watertown, CT 06795
Telephone [phone]

WARRANTY

A. Remote Automation Solutions (RAS) warrants that goods described herein and manufactured by RAS are

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

B. RAS 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 RAS 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 RAS consent, (iii) not installed,
maintained and operated in strict compliance with instructions furnished by RAS 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 RAS unless endorsed
herein in writing. Further, there are no warranties which extend beyond the description of the face hereof.

F. No agent of RAS 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 RAS 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 the RAS Watertown office, unless the RAS Watertown office
designates a different location, transportation prepaid, within thirty (30) days of the sending of such
notification and which upon examination by RAS proves to be defective in material and workmanship. RAS
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 RAS, the Buyer can arrange to have a RAS
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 n ot chargeable.

B. Under no circumstances will RAS 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 Remote Automation Solutions (RAS) 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 RAS
Watertown 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 RAS Repair Dept. representative will

return the call (or other requested method) with a RA number.

B. E-MAIL
Accessing the form (GBU 13.01) via the RAS Web site (www.emersonprocess.c om/Bristol) and sending it

via E-Mail to [e-mail]

. A RAS Repair Dept. representative will return E-

Mail (or other requested method) with a RA number.

C. Mail
Mail the form (GBU 13.01) to

Remote Automation Solutions

A Division of Emerson Process Management
Repair Dept.
1100 Buckingham Street
Watertown, CT 06795

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

Calling the RAS Repair Department at [phone]. A RAS Repair Department representative will

record a RA number on the form and complete Part I, 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.

Remote Automation Solutions (RAS)

Repair Authorization Form (on-line completion)

(

Providing this information will permit Bristol, also doing business as Remote Automation Solutions (RAS) 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

• Return to Customer

Part I Please complete the following information for single unit or multiple unit returns
Address No. (office use only)

Bill to : Ship to:
Purchase Order: Contact Name:
Phone: Fax: E-Mail:

Please be aware of the Non warranty standard
charge:

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

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 the terms of warranty,, 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 RAS 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: Remote Automation Solutions, Repair Dept., 1100 Buckingham Street, Watertown, CT 06795
Phone: [phone] Fax: [phone]

Form GBU 13.01 Rev. D 12/04/07

Emerson Process Management

Training

GET THE MOST FROM YOUR EMERSON

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. Emerson offers a full
schedule of classes conducted by full-time, professional instructors. Classes are offered
throughout the year at various locations. By participating in our training, your personnel
can learn how to install, calibrate, configure, program and maintain your Emerson products
and realize the full potential of your system.

For information or to enroll in any class, go to http://www.EmersonProcess.com/Remote
click on “Training” or contact our training department in Watertown at [phone].

and

PIP-EXPI/OTF

LOW POWER I/O EXPANSION BOARD

PT. Number 392927-XX-X

Product Information Package

TABLE OF CONTENTS

SECTION TITLE PAGE #

Section 1 - INTRODUCTION

1.1 GENERAL INTRODUCTION .......................................................................................... 1

1.1.1 Configuration Hardware ................................................................................................... 2

Section 2 - INSTALLATION & SERVICE

2.1 REMOVAL/REPLACEMENT & INSTALLATION OF THE LPI/OEB .......................... 5

2.1.1 Removal/Replacement of the Low Power I/O Expansion Board ..................................... 5

2.1.2 Installation of the Low Power I/O Expansion Board....................................................... 7

2.2 I/O CONFIGURATION & WIRING ................................................................................. 9

2.2.1 LPI/OEB Discrete Input Wiring (TB4)............................................................................. 9

2.2.2 LPI/OEB Discrete Output Wiring (TB4) .......................................................................... 9

2.2.3 LPI/OEB Analog Input Wiring (TB2) ............................................................................. 10

2.2.4 LPI/OEB Analog Output Wiring (TB3) .......................................................................... 12

2.2.5 LPI/OEB High Speed Counter Wiring (TB3) ................................................................. 13

2.3 RS-232/RS-485 COMMUNICATIONS ........................................................................... 13

Section 3 - TROUBLESHOOTING

3.1 FIELD WIRING SIGNAL CHECKS .............................................................................. 15

Section 4 - SPECIFICATIONS

4.1 INPUT/OUTPUT SPECIFICATIONS ............................................................................ 16

4.1.1 Discrete Inputs ................................................................................................................ 16

4.1.2 Discrete Outputs.............................................................................................................. 16

4.1.3 Analog Inputs................................................................................................................... 16

4.1.4 Analog Outputs................................................................................................................ 17

4.1.5 Communication Port........................................................................................................ 18

4.1.6 High Speed Counter ........................................................................................................ 18

4.2 ENVIRONMENTAL SPECIFICATIONS....................................................................... 18

Supplements

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

PIP-EXPI/OTF Page 0-1 Table Of Contents

Section 1

INTRODUCTION

1.1 GENERAL INTRODUCTION

The Low Power I/O Expansion Board (LPI/OEB) measures approximately 4” by 7.25” and
mounts piggy-back on either the TeleFlow or TeleRTU CPU Board. Removable card-edge
connectors are provided to accommodate field wiring. A 1.25” by 1.2” cutout area is in­corporated into the board’s design to accommodate mounting of the Multivariable Trans­ducer’s Wet End Connector and Balance Board onto the TeleFlow CPU Board. The
LPI/OEB operates in conjunction with Revision 3 and higher TeleFlow CPU Boards and
with TeleRTU CPU Boards. Three versions of the LPI/OEB are available; fully populated
version P/N 392927-01-2 (see Figure 1), depopulated version that supports DI/DO and the
Comm. Port P/N 392927-02-0 and a depopulated version that supports DI/DO only P/N
392927-03-9.

Figure 1 - Low Power I/O Expansion Board

PIP-EXPI/OTF Page 1 Low Power I/O Expansion Board

The Low Power I/O Expansion Board provides the following additional I/O capabilities to
the TeleFlow Plus EGMCs, TeleRTU Plus and TeleRTU Module RTUs and TeleRecorders:

• 8 Discrete I/O

All eight DI/O function in both input and output capacities. Field terminals for each
DI/O are I/O and GND. Each Discrete Input will accept signals from 0 to 16 VDC. The
Discrete Outputs utilize open drain FETs with a maximum working voltage of 16 VDC
and a minimum load of 100 mA. DI/Os are not isolated.

• 4 Analog Inputs (available on 392927-01-2 only)

Two single-ended Analog Inputs are available for 4 to 20 mA or 1 to 5 VDC signal

operation (Jumper Configurable) and two additional single-ended Analog Inputs are
available for 1 to 5 VDC signal operation only. The two 4-20 mA Inputs will support
externally powered transmitters; however, internally powered 4-20 mA transmitters
will require an external power supply. All four channels support low power voltage
output transmitters such as Rosemount and Honeywell. Resolution is 12 bits (1.42
mV) and combined error (including linearity, hysteresis and temperature effects) is ≤
±0.2%. Each Analog Input channel includes field wiring terminals for signal,
transmitter power (+9.5V), and ground. Note: Analog Inputs are designated AI5

through AI8; AI1 through AI4 are assigned to the TeleRTU CPU.

• 1 Analog Output (available on 392927-01-2 only)

The Analog Output can be configured for 4 to 20 mA or 1 to 5 VDC operation (Jumper

Configurable). Resolution is 12 bits and combined error including linearity, hysteresis
and temperature effects is ≤ ±0.2% after calibration.

• 1 High Speed Counter Input (available on 392927-01-2 only)

The High Speed Counter input will accept pulses (with an input range from 0 to 16

VDC and up to 10KHz) from CMOS or TTL sources, including transistors, FETs,
mechanical relays, or other signaling devices.

• 1 RS-232 or RS-485 Asynchronous Serial Communications Port (not on 392927-03-9)

Note: Only supported by units with TeleFlow/ACCOL Firmware

The Asynchronous Serial Communications Port can be jumper configured for either

RS-232 or RS-485 operation at programmable speeds of up to 19.2 Kbps.

1.1.1 Configuration Hardware

Fully populated Low Power I/O Expansion Boards contain 8 potentiometers, 15 Jumper
Blocks and 5 removable card-edge (Terminal Blocks) connectors. Tabulated information
about Terminal Block, Jumper and Potentiometer assignments are contained in Tables 1, 2
and 3 respectively.

Table 1 - Low Power I/O Exp. Board Terminal Block Assignments

TB # PIN # MNEMONIC DESCRIPTION

TB1 1 +VEXT +21V EXTERNAL
TB1 2 -VEXT -21V EXTERNAL
TB2 1 EXC5 EXCITATION 5
TB2 2 AIN5 ANALOG IN 5
TB2 3 GND GROUND
TB2 4 EXC6 EXCITATION 6
TB2 5 AIN6 ANALOG IN 6
TB2 6 GND GROUND
TB2 7 AIN7 ANALOG IN 7
TB2 8 AIN8 ANLOG IN 8

Low Power I/O Expansion Board Page 2 PIP-EXPI/OTF