Pepperl+Fuchs FB Remote I/O Hardware Manual
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Pepperl+Fuchs FB Remote I/O Hardware Manual

Pepperl+Fuchs FB Remote I/O Hardware Manual

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PROCESS AUTOMATION
MANUAL
FB Remote I/O
Hardware

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Summary of Contents for Pepperl+Fuchs FB Remote I/O

  • Page 1 PROCESS AUTOMATION MANUAL FB Remote I/O Hardware...
  • Page 2 FB Remote I/O With regard to the supply of products, the current issue of the following document is ap- plicable: The General Terms of Delivery for Products and Services of the Electrical Indus- try, published by the Central Association of the Electrical Industry (Zentralverband Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the...

  • Page 3: Table Of Contents

    Content of this Document ..............5 Target Group, Personnel..............5 Symbols Used ..................6 Product Specifications............... 7 Prerequisites for Operating the FB Remote I/O Unit ......7 Introduction ..................7 System Components ................8 Field Units (Surrounding Enclosures) ..........9 Backplanes ..................
  • Page 4 FB Remote I/O Coding ....................48 Line Fault Detection ................49 Cold Junctions in Thermocouples............49 3.10 Line Resistance in Resistance Thermometers ........50 3.11 Strain Gage Measurement..............51 3.12 Status Monitoring of the Output Shutdown ........52 3.13 Redundancy in PROFIBUS Communication ........52 3.13.1 Basic Principles................52 3.13.2 Media Redundancy ................

  • Page 5: Introduction

    FB Remote I/O Introduction Introduction Content of this Document This document contains information required to use the finished device or system in the relevant phases of the product life cycle. This may include information on the following: Product identification Delivery, transport, and storage...

  • Page 6: Symbols Used

    FB Remote I/O Introduction Symbols Used This document contains symbols for the identification of warning messages and of informative messages. Warning Messages You will find warning messages, whenever dangers may arise from your actions. It is mandatory that you observe these warning messages for your personal safety and in order to avoid property damage.

  • Page 7: Product Specifications

    Prerequisites for Operating the FB Remote I/O Unit Note! Requirements for equipment protection level Gb Components of the FB remote I/O system may be installed and operated in Zone 1 only if they are installed in a surrounding enclosure that complies with equipment protection level Gb. Note!

  • Page 8: System Components

    FB Remote I/O Product Specifications System Components System Overview Figure 2.1 FB remote I/O system components Field Unit (Surrounding Enclosure) Power supply Bus termination module Com unit I/O module Backplane Cable gland for field lines Cable gland for power supply and bus cables...

  • Page 9: Field Units (Surrounding Enclosures)

    FB Remote I/O Product Specifications Field Units (Surrounding Enclosures) Field units serve to protect all electronic components against environmental influences and are an integral part of explosion protection. The enclosures are made of glass fiber reinforced polyester or stainless steel and are available in various versions. The surrounding enclosures contain backplanes for the connection of modules.
  • Page 10 FB9248-PG0-0-0-0-0-0 FB9248-PH0-0-0-0-0-0 FB9248-S70-0-0-0-0-0 FB9249-PG0-0-0-0-0-0 FB9249-PH0-0-0-0-0-0 FB9249-S80-0-0-0-0-0 We also offer custom solutions for our customers. Experienced project engineers from our Solution Engineering Center (SEC) will assist you with designing your ideal FB remote I/O. More information can be found at www.pepperl-fuchs.com.

  • Page 11: Backplanes

    FB Remote I/O Product Specifications Backplanes 2.5.1 Function The modules are plugged into the backplane, which in turn is installed in a plastic or stainless steel enclosure. The backplane supplies the modules with energy and provides internal wiring. Any I/O module can be inserted into any I/O slot, enabling a mixture of I/O functions in one field unit.

  • Page 12: Design And Dimensions

    FB Remote I/O Product Specifications 2.5.2 Design and Dimensions Universal backplane The following backplanes are operated as a base backplane and extension backplane. Connect the two backplanes using the backplane cordset. FB9262BP10220.1 Redundant configuration with slots for 2 com units, 2 bus termination modules, 2 power supplies Slots for max.
  • Page 13 FB Remote I/O Product Specifications FB9262BP20220.1 Redundant configuration with slots for 2 gateways/com units, 2 bus termination modules, 2 power supplies Slots for max. 20 narrow or 10 wide I/O modules For PROFIBUS DP, MODBUS RTU, MODBUS TCP, Ethernet 11 12 13 14 15 16 17 18 19 20 Figure 2.5...
  • Page 14 FB Remote I/O Product Specifications Base and extension backplane The following backplanes are available in non-redundant design. The base backplane can be expanded with the extension backplane. Connect both backplanes using the cordset. FB9262BP24110.1 Base backplane Non-redundant configuration with slots for 1 com unit, bus termination modules (see chapter 2.6) and 1 power supply...

  • Page 15: Backplane And Module Compatibility

    FB Remote I/O Product Specifications FB9262BP24200.1 Extension backplane Expansion unit for base backplane for 2 power supplies and termination modules (see chapter 2.6) Slots for max. 24 narrow or 12 wide I/O modules For PROFIBUS DP, MODBUS RTU, MODBUS TCP, Ethernet...

  • Page 16: I/O Modules, Com Units, Bus Termination Modules, Power Supplies

    Note! All new I/O modules (Ex q) are fully compatible with the existing FB remote I/O and are therefore ideally suited for a plant expansion. The backwards compatibility offers you the opportunity to combine old modules (Ex d) and new modules (Ex q) on one backplane.

  • Page 17: Function

    FB Remote I/O Product Specifications 2.6.2 Function I/O modules I/O modules are used to modify signals between field devices in explosion-hazardous areas and controllers or control systems in the safe area. The slots for the I/O modules on the backplane are equal, so you can use I/O modules with different functions next to each other.
  • Page 18 When pulling out an M12 connector in Zone 1, a spark may form that ignites an explosive mixture. Do not pull out M12 connectors in potentially explosive atmospheres. Use only original Pepperl+Fuchs cables. Warning! Property damage due to incorrect terminal assignment Incorrect terminal assignment and incorrectly positioned plug-in jumpers can cause damage to the Ex-q gateway.
  • Page 19 Power supplies The power supplies provide power to all components of the FB remote I/O. The slots for com units are mechanically coded on the backplane and marked accordingly.

  • Page 20: Design And Dimensions Of The Modules

    Design and Dimensions of the Modules The FB remote I/O system is designed in such a way that each I/O module can be connected to the I/O slot it requires on the backplane. The slots on the backplane are limited. Depending on the size, for example, a base backplane can accommodate max.

  • Page 21: Accessories

    FB Remote I/O Product Specifications Accessories 2.7.1 Field Wiring The following accessories are available for field wiring. Terminal blocks Terminal blocks are wired to the field devices, attached to the front sockets of the I/O modules, and tightened using the side screws. Terminal blocks can come in the form of screw terminals, front screw terminals, or spring terminals.
  • Page 22 FB Remote I/O Product Specifications Spring terminals 20.8 Figure 2.13 Spring terminal dimensions L = 33.3 mm for 6-pin terminals and 40.9 mm for 8-pin terminals 19.2 20.6 Figure 2.14 Spring terminal dimensions 8-pole terminal Note! The LB9130A spring terminal for the FB1209 I/O module is only inserted and not screwed in.
  • Page 23 FB Remote I/O Product Specifications Cold junctions Cold junctions have a prewired Pt100 thermocouple on terminal openings 1 and 2 for numerically correcting the thermoelectric voltage. Cold junctions are available exclusively in blue. Use blue cold junctions for intrinsically safe circuits.
  • Page 24 FB Remote I/O Product Specifications KF-CP Figure 2.18 KF-CP coding pins Watchdog plugs The watchdog plug is used with digital outputs with a feedback input (FB2201B - FB2213E). The watchdog plug sends the output signal from the I/O module back to its input channel, making it possible to check the function of the I/O module, as well as the communication between the process control system and the I/O module.
  • Page 25 FB Remote I/O Product Specifications Resistor network Most I/O modules have a line fault detection function that can recognize a lead breakage or a short circuit. If binary I/O modules are used, for example with a mechanical contact, an additional resistor network must be installed to ensure that the line fault detection function can work correctly.

  • Page 26: Cordsets

    FB Remote I/O Product Specifications 2.7.2 Cordsets Warning! Explosion hazard through use of incorrect cordset. The use of incorrect cables in a potentially explosive atmosphere can create sparks that can ignite the surrounding atmosphere. Com unit cordset If two com units are used in a redundant system, they must be connected using a cordset via the front socket to enable internal data exchange.

  • Page 27: Fb Removal Tool For Ex-D Modules

    FB Remote I/O Product Specifications 2.7.3 FB Removal Tool for Ex-d Modules The removal tool allows for quick installation and safe module exchange during operation. That way, the module can be replaced without a hot work permit via the two-stage removal process.

  • Page 28: Installation

    Operating the components of the FB remote I/O without a certified enclosure can cause sparks. This may ignite the surrounding potentially explosive atmosphere. Install and operate components of the FB remote I/O in zone 1 if they are installed in a certified enclosure that meets equipment protection level Gb.

  • Page 29: Backplanes

    FB Remote I/O Installation Backplanes Warning! Explosion hazard due to thermal ignition and violation of protection type. Make sure that the maximum ambient temperature for the components used is not exceeded. Details of ambient temperature can be found in the relevant datasheets. Note that the temperature rises with an increasing number of active modules in the field unit.

  • Page 30: Connections For Fb9262Bp

    FB Remote I/O Installation Connections for FB9262BP* The power supply and the bus cables are wired using the Ex e terminal strip (1), which is located on the left side of the backplane. In addition, the Ex-e terminal strip forms the connection between the base backplane and the extension backplane.
  • Page 31 FB Remote I/O Installation Danger! Explosion hazard due to the use of non-suitable devices Devices that do not meet the requirements for use in explosion-hazardous areas can cause explosive mixtures to ignite. Only use volt-free contacts approved for use in the respective environment. For installation in Zone 1, for example, use a volt-free contact designed with Ex e protection.

  • Page 32: Maximum Number Of I/O Modules

    The maximum number of I/O modules that can be installed, taking into account the temperature class, is determined by the permissible power dissipation in the surrounding enclosure. If, in addition to the FB remote I/O, other loads are installed, their power consumption may reduce the power available to the FB remote I/O.

  • Page 33: Inserting And Removing Modules

    FB Remote I/O Installation Inserting and Removing Modules The connector pins on the modules and the female connectors on the backplane form a flameproof enclosure when plugged together. Danger! Explosion hazard when connecting or disconnecting the field connections on the module.
  • Page 34 FB Remote I/O Installation Figure 3.4 Bent connector pins Figure 3.5 Damaged pins with nicks or scratches Fixed slots are reserved on the backplane for com units, bus termination modules, and power supplies. Com units are equipped with mechanical coding pins on the underside of the enclosure to prevent these modules from being accidentally plugged into the slot of an I/O module.
  • Page 35 FB Remote I/O Installation Inserting modules Note! If you use redundant gateways, establish a front connection between the primary com unit and the redundant com unit before you insert the redundant gateway into the backplane. This ensures that communication between the gateways begins immediately after the power supply is established.
  • Page 36 FB Remote I/O Installation Figure 3.7 Insert module, left column with Ex-d modules and right column with Ex-q modules The I/O module is now mounted to the backplane. Note! All modules with Ex-e front connections must be treated in a particular way. Refer to the...
  • Page 37 FB Remote I/O Installation Removing Ex-d modules Warning! Explosion hazard due to damaged modules Forcibly removing modules or using unsuitable tools can damage the module or the backplane, meaning that explosion protection can no longer be guaranteed. Only remove modules using the built-in removal device. The built-in removal device forces a two-stage removal process that contains any potential ignition spark within the pressure- resistant terminal area.
  • Page 38 FB Remote I/O Installation 4. Turn the FB removal tool over and place it on the left side of the module. Slide the FB removal tool towards the backplane until the second catch is released. Figure 3.10 FB removal tool releases the second rear catch 5.
  • Page 39 FB Remote I/O Installation Removing Ex-q modules Warning! Explosion hazard due to damaged modules Forcibly removing modules or using unsuitable tools can damage the module or the backplane, meaning that explosion protection can no longer be guaranteed. Only remove modules using the built-in removal device. The built-in removal device forces a two-stage removal process that contains any potential ignition spark within the pressure- resistant terminal area.
  • Page 40 FB Remote I/O Installation Figure 3.13 First rear catch The first rear catch is released and the module no longer has electrical contact with the backplane. 4. Release both removal levers. These automatically return to their original position. Figure 3.14 Integrated removal device 5.

  • Page 41: Field Wiring

    FB Remote I/O Installation Field Wiring I/O modules are wired differently depending on the type. Figure 3.16 Overview of I/O module connections Overview of connections Position Type Designation Description Ex d, Ex q Modules with Field connections can be made to the I/O...
  • Page 42 FB Remote I/O Installation Wires • Insulation stripping: 9 mm • Core cross-section (conductor): 0.5 mm ... 1.5 mm • External diameter (conductor + insulation): 2 mm ... 3 mm Stranded conductors • Insulation stripping: 9 mm • Core cross-section for wire end ferrules with plastic sleeve: 0.5 mm...

  • Page 43: I/O Modules With Front Socket

    FB Remote I/O Installation 3.6.1 I/O Modules with Front Socket Field connections can be made to the I/O modules using screw terminals, front screw terminals, or spring terminals. Use the terminal blocks and protective covers from the range of accessories. See chapter 2.7.1...
  • Page 44 FB Remote I/O Installation Installing field wiring for non-intrinsically safe circuits Danger! Explosion hazard when removing the protective caps If intrinsically safe and non-intrinsically safe circuits are present, removing the protective cap in a potentially explosive atmosphere can create sparks that can ignite the surrounding atmosphere.
  • Page 45 FB Remote I/O Installation 11.Place the adapted protective cover for Ex e modules onto the terminal and screw the protective cover into place using the side screws. Figure 3.19 Terminal with adapted protective cover for Ex e modules 12.Apply the warning marking “Warning - non-intrinsically safe circuits protected by internal cover with degree of protection IP30!”...

  • Page 46: I/O Modules With Cable Tail

    FB Remote I/O Installation 3.6.2 I/O Modules with Cable Tail I/O modules with a cable tail must be connected to separately approved terminals that comply with type of protection Ex-e. These terminals must be equipped with a cover with degree of protection IP30.
  • Page 47 FB Remote I/O Installation Color coding for single-width I/O modules Connection Color pink gray yellow green brown white Color coding for dual-width I/O modules Left connection Right connection Color blue pink gray yellow green brown white...

  • Page 48: Coding

    FB Remote I/O Installation Coding You can code the front sockets and the terminals of the I/O modules so that the terminals and the connected field devices can be assigned to exactly one front socket. Use coding pins KF-CP. Coding connections...

  • Page 49: Line Fault Detection

    FB Remote I/O Installation Line Fault Detection Most I/O modules have a line fault detection function that can recognize a lead breakage or a short circuit. If digital I/O modules are used, for example with a mechanical contact, an additional resistor circuit must be installed to ensure that the line fault detection function can work correctly.

  • Page 50: Line Resistance In Resistance Thermometers

    FB Remote I/O Installation 3.10 Line Resistance in Resistance Thermometers If you operate I/O modules FB5201* and FB5204* in a 2-wire configuration, the line resistance amounts to that of a resistor connected in series to the sensor and affects the measurement result.

  • Page 51: Strain Gage Measurement

    FB Remote I/O Installation 3.11 Strain Gage Measurement I/O modules FB4*01* and FB5202* can be interconnected for strain gage measurements. Use analog output FB4*01* to create a constant current, and the measuring input for temperature input FB5202* to process the millivolt signal for the resulting bridge voltage.

  • Page 52: Status Monitoring Of The Output Shutdown

    The I/O module FB1308 allows you to monitor the status of output shutdown. Configuring I/O modules for status monitoring Configure the I/O module as a passive voltage input. Disable the channel supply. See the manual "FB Remote I/O - Software". Danger! Explosion hazard due to incorrect connection Improper installation and configuration of the device can cause sparks and other hazards in potentially explosive atmospheres, which can ignite the surrounding atmosphere.

  • Page 53: Media Redundancy

    FB Remote I/O Installation 3.13.2 Media Redundancy Media redundancy is when the master communicates with a com unit via a voter and a redundant fieldbus cable. The com unit that communicates with the master is active and controls the I/O module on the backplane. The second com unit is passive and reads the data traffic on the backplane.

  • Page 54: Fieldbus Connection

    FB Remote I/O Installation 3.14 Fieldbus Connection 3.14.1 RS-485-Based Fieldbuses Danger! Explosion hazard due to improper installation Improperly installed fieldbuses can cause explosive mixtures to ignite. Observe the wiring specifications set out in IEC/EN 60079-14 for laying lines in an explosion- hazardous area.
  • Page 55 FB Remote I/O Installation In accordance with DIN EN 61158 and DIN EN 61784, the following principles apply: Linear bus structure without branches, consisting of a cable with terminators Length of the spur to the node < 0.3 m Total length of all spurs < 6 m Data transfer via shielded twisted pair cable Terminator 100 ...

  • Page 56: Ethernet-Based Fieldbuses

    FB Remote I/O Installation 3.14.2 Ethernet-based fieldbuses The gateway is connected to the Ethernet network using the two Ethernet interfaces on the front. Mechanically, this occurs through an M12 plug connection according to IEC 61076-2- 101:2012. Three basic connection scenarios are shown below: GW IOM <...
  • Page 57 Risk of injury due to improper device connection! Errors when connecting the device can result in danger to people and machines. Use only original type V1SD-F-*M-PUR-ABG* cables from Pepperl+Fuchs GmbH. Never fabricate the M12 plug for the gateway. Always use the original plug supplied with the cable.

  • Page 58: Cable Gland For Prefabricated Cables To Ethernet Gateways

    FB Remote I/O Installation 3.14.3 Cable gland for prefabricated cables to Ethernet gateways This section describes how to seal a cable gland at a switch cabinet for a prefabricated cable in a Zone 1 explosion-hazardous area. Product Data Torque lock nut Width across flats Opening Ø...
  • Page 59 FB Remote I/O Installation 6. Make sure you create a gap of 0.1 - 1 mm (A) between the two halves of the seal when you insert the cable between them. 7. Lubricate the inside and outside surfaces of the seal thoroughly but economically with a suitable lubricant.

  • Page 60: Potential Equalization And Shielding

    FB Remote I/O Installation 3.15 Potential Equalization and Shielding Note! The following subchapters cannot provide the reader with a complete picture of all requirements in terms of grounding, shielding, and lightning protection. More information on this topic can be found in the technical literature and the applicable standards.

  • Page 61: Wiring

    FB Remote I/O Installation 3.15.2 Wiring Danger! Explosion hazard due to improper installation Improperly installed wiring can cause explosive mixtures to ignite. Observe the wiring specifications set out in IEC/EN 60079-14 for laying lines in an explosion- hazardous area. Lay the signal lines such that they are separate from the power cables. Please note that AC voltages and current spikes can induce stray voltages in neighboring lines.

  • Page 62: System Expansion

    FB Remote I/O Installation 3.16 System Expansion Adding I/O modules By adding an I/O-module, input or output data will be transferred to a slot that was previously empty. To do this, the configuration of the com unit must be adapted. Changes to the configuration of the com unit usually result in the function being interrupted due to a fieldbus restart.

  • Page 63: Commissioning

    If the 1.1 V voltage is not present, there is either no terminator connected at the end, the cable is faulty, or there is no terminating voltage at the FB remote I/O unit. 4. Measure the current at the bus connector between A and B.

  • Page 64: Configuration Of An Rs-485-Based Bus System

    3. Measure the voltage between A and B on the bus connection of each FB remote I/O unit. A voltage of U = 1.1 V must be present between A and B on each FB remote I/O unit. 4. Activate the terminator on the bus connector for the master.

  • Page 65: Operation

    FB Remote I/O Operation Operation During operation, you can access up-to-date measured values and diagnostic information for the I/O modules via the com unit. For more information, refer to the software manual for the com unit used. In addition, you can read off basic information about supply and communication from the LEDs on the I/O modules and com units.

  • Page 66: Troubleshooting

    FB Remote I/O Troubleshooting Troubleshooting This chapter describes troubleshooting for RS-485-based bus systems. Danger! Risk of explosion When work is performed on the remote I/O unit in hazardous areas, there is a risk of explosion from spark formation. Before starting any work on the remote I/O unit, familiarize yourself with the instruction manuals for the components and their relevant certificates.
  • Page 67 FB Remote I/O Troubleshooting Error Remedy Bus-independent Check that the plug-in jumpers are set correctly. deactivation of the I/O modules is not possible Multiple I/O modules fail Check that the power supply is working properly. simultaneously Check that the base backplane and the extension backplane are wired correctly.
  • Page 68 FB Remote I/O Troubleshooting Error Remedy Measured values Check whether the measured value is being distorted by external influences. occasionally incorrect Check that the shielding is intact. I/O module reported to be Check that the correct I/O module is plugged in.
  • Page 69 PROCESS AUTOMATION – PROTECTING YOUR PROCESS Worldwide Headquarters Pepperl+Fuchs GmbH 68307 Mannheim · Germany Tel. +49 621 776-0 E-mail: info@de.pepperl-fuchs.com For the Pepperl+Fuchs representative closest to you check www.pepperl-fuchs.com/contact www.pepperl-fuchs.com Subject to modifications / DOCT-5976 Copyright PEPPERL+FUCHS • Printed in Germany 12/2018...

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