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BC-FIC-AIAO-01-1/-2

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Bulletin Rev : 2016_01

BC-FIC-AIAO-01 File (19 inches) for RS3™ FIC I/Os (AI/AO) migratio n toward a new system

Description :

The file BC-FIC-AIAO-01-1 or BC-FIC-AIAO-01-2 can replace, in the same location, the RS3 MPC Analog Card Cage and provides the connection utilities toward a new DCS or PLC. I/O configuration is made for each channel using suitable jumpers. The existing analog card cage was structured with 8 slots for I/O cards, each card with 2 or 3 channels :

• AI (2/4 wires) / AO card : o Channel 1 and 2 > AI o Channel 3 > AI or AO

• RTD (3 wires) or Thermocouple card (2 wires) : Channel 1 and Channel 2

• Pulse card :

o Channel 1 and 2 > PCI or PCO o Channel 3 > AO

The existing marshalling panels and their associated cables, are kept in place and listed as follow :

• European Analog Marshalling Panel : 10P5459-0001 (without fuse) - 10P5462-0001 (with fuses)

• Multistrategy Marshalling Panel : 1984-2415-0001

• Multistrategy Marshalling Panel : 1984-2412-000X

• Analog Marshalling Panel : 1984-2448-000X The field wiring is kept in place without any disconnection.

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BC-FIC-AIAO-01-1/-2

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Bulletin Rev : 2016_01 The connections with the new input or output cards are made using SUBD connectors as follow :

• Analog Input signals : o One SUBD37 pin male connector for 16 Analog inputs. o One SUBD25 pin male connector for 8 Analog inputs.

• Analog Output signals :

o One SUBD25 pin male connector for 8 Analog outputs.

• RTD Analog Input signals : o Two SUBD25 pin male connectors for 16 RTD Analog inputs (8 channels per connector).

• Pulse Count Input signals :

o Four SUBD9 pin male connectors for 16 PCI (4 channels per connector).

• Pulse Output signals : o One SUBD25 pin male connector for 16 PCO.

The power supply of the existing RS3 Analog Card Cage is kept in order to supply Pulse Inputs with free contacts.

Product options : Option -1 : BC-FIC-AIAO-01-1 : Without power supply for Pulse Count Inputs Option -2 : BC-FIC-AIAO-01-2 : With redundant power supply for Pulse Count Inputs

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Bulletin Rev : 2016_01

Technical specifications :

Dimensions : Power supply :

Wide: 482,6 mm (19 inches) Redundant Power Supply 18 – 36 Vdc (used only for PCI free contact)

Depth: 211.50 mm Consumption : 240mA@24,0Vdc

Height : 177.50mm (compatible with 4U) Redundant DC/DC converters (outputs 12Vdc) protected by 1A fuses

Weight : Each output of DC/DC converter is indicated by a green Led.

2,0Kg DC/DC converter integrity is monitored using a free voltage contact

Mounting : available on a screw terminal

In place of the existing RS3 legacy card cage

Temperature range : Configuration of input/output :

Operating: 0°C to 60°C Configuration of I/Os is done using jumpers located on the main PCB

Storage: -20°C to 70°C See view1 for configuration

Humidity :

Up to 90% (no condensation)

Connection to the DCS or to the PLC :

Analog Inputs : Channel specifications toward the DCS or PLC :

By two SUBD (37 and 25 pin) male connectors UNC 4-40 Analog Inputs : 4-20mA (2/4 wires) protected by fuse 250mA

female lock and shielded suitable cables Analog Outputs : 4-20mA protected by fuse 250mA

Connector P1 (37 pin) : 16 Channels > 101/102 to 801/802 RTD Analog Inputs : 3 wires

Connector P2 (25 pin) : 8 Channels > 103 to 803 Thermocouple Analog Inputs : 2 wires

Analog Outputs : Remark : For thermocouples, the cold junction compensation (CJC) was

By one SUBD25 pin male connector UNC 4-40 female lock managed in the existing RS3 marshalling panel using an RTD

and shielded suitable cable compensator using one channel among the 16 available.

Connector P3 : 8 Channels > 103 to 803 With the BC-FIC-AIAO-01-1, the DCS or PLC I/O structure must be in

RTD and Thermocouple Analog Input signals : Accordance with such I/O functionality (mix of RTDs and TH)

By two SUBD25 pin male connector UNC 4-40 female lock Pulse Outputs : DCs or PLC card has to be in accordance with the

and shielded suitable cable existing connected field device

Connector P4 : 8 channels > 101/102 to 401/402 Remark : The existing RS3 card had the following capabilities :

Connector P5 : 8 channels > 501/502 to 801/802 Output range : 0 – 1KHz

Pulse Output signals : Output voltage : 21 to 24Vdc

By one SUBD25 pin male connector UNC 4-40 female lock Max current : 20mA

and shielded suitable cable Pulse Count Inputs : Free contact or voltage input

Connector P6 : 16 Channels > 101/102 to 801/802 1°) Free contact : Supplied by internal power supply 12Vdc

Pulse Count Input signals : (see section “Power supply” here above)

By four SUBD9 pin male connector UNC 4-40 female lock 2°) Voltage input : DCs or PLC card has to be in accordance with the

and shielded suitable cable existing connected field device

Connector P7 : 4 Channels > 101/102, 201/202

Connector P8 : 4 Channels > 301/302, 401/402

Connector P9 : 4 Channels > 501/502, 601/602

Connector P10 : 4 Channels > 701/702, 801/802

FIRELEC provides cables with suitable connectors or

free labelled wires in accordance with DCS or PLC I/O cards

used.

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BC-FIC-AIAO-01-1/-2

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Bulletin Rev : 2016_01 View 1 : BC-FIC-AIAO-01-1 without power supply for Pulse Count Inputs

1 x SUBD 37 pin connector for Analog Inputs : P1 : 16 Channels 101/102 to 801/802

4 x SUBD 9 pin connector for Pulse Count Inputs : P7 : Channels 1 to 4 / 101/102/201/202 P8 : Channels 5 to 8 / 301/302/401/402 P9 : Channels 9 to 12 / 501/502/601/602 P10 : Channels 13 to 16 / 701/702/801/802 Not used for option -1 of the BC-FIC-AIAO-01 -1

AI / AO / PCI / PCO / RTD configuration area

PCI Configuration jumpers for Dry Contact or Voltage Inputs

1 x SUBD 25 pin connector for Analog Inputs : P2 : 8 Channels 103 to 803

Jumpers T101 to T803 for 2W / 4W analog input configuration. 2W (2 wires) : The DCS or PLC card supply the transmitter 4W (4 wires) : The transmitter is supplied externally See Page 7

AI Fuses

AI Fuses

AO Fuses

1 x SUBD 25 pin connector for Analog Inputs : P3 : 8 Channels 103 to 803

HE1050 I/O connector used for the connection of the existing I/O cable (from the field)

2 x SUBD 25 pin connector for RTD Inputs : P4 : 8 Channels 101/102 to 401/402 P5 : 8 Channels 501/502 to 801/802

1 x SUBD 25 pin connector for Pulse Out puts : P6 : 16 Channels 101/102 to 801/802

Power supply area not used for option -1 of the BC-FIC-AIAO-01 -1

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BC-FIC-AIAO-01-1/-2

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Bulletin Rev : 2016_01 View 2 : BC-FIC-AIAO-01-2 with power supply for Pulse Count Inputs

1 x SUBD 37 pin connector for Analog Inputs : P1 : 16 Channels 101/102 to 801/802

4 x SUBD 9 pin connector for Pulse Count Inputs : P7 : Channels 1 to 4 / 101/102/201/202 P8 : Channels 5 to 8 / 301/302/401/402 P9 : Channels 9 to 12 / 501/502/601/602 P10 : Channels 13 to 16 / 701/702/801/802

AI / AO / PCI / PCO / RTD configuration area

PCI Configuration jumpers for Dry Contact or Voltage Inputs

1 x SUBD 25 pin connector for Analog Inputs : P2 : 8 Channels 103 to 803

Jumpers T101 to T803 for 2W / 4W analog input configuration. 2W (2 wires) : The DCS or PLC card supply the transmitter 4W (4 wires) : The transmitter is supplied externally See Page 7

AI Fuses

AI Fuses

AO Fuses

1 x SUBD 25 pin connector for Analog Inputs : P3 : 8 Channels 103 to 803

HE1050 I/O connector used for the connection of the existing I/O cable (from the field)

2 x SUBD 25 pin connector for RTD Inputs : P4 : 8 Channels 101/102 to 401/402 P5 : 8 Channels 501/502 to 801/802

1 x SUBD 25 pin connector for Pulse Out puts : P6 : 16 Channels 101/102 to 801/802

Power supply used for option -2 of the BC -FIC-AIAO-01-2 Redundant Power Supplies are to be installed in order to supply Pulse Count Inputs in “Dry Contact” versions. A : Primary PS (18 to 36Vdc) B : Secondary PS (18 to 36Vdc) RTN : Return / Signal Common J2 : Connector for new PS, if J949 / J950 not used. J949 / J950 : Connector for existing PS RS3 connector J1 : Free voltage contact for PS monitoring

Note : PS has to be applied either on J2 or on J949/J950 (never on both of them)

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BC-FIC-AIAO-01-1/-2

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Bulletin Rev : 2016_01 1. CONFIGURATION PROCEDURE OF BC-FIC-AIAO-01-1/-2:

1.1. INPUT/OUTPUT TYPE CONFIGURATION USING DOUBLE-J UMPERS

According to the existing RS3 MPC Analog Card Cage, each channel has to be configured using suitable jumpers. As indicated here below, the hardware configuration is divided into 8 groups of I/Os matching with 8 I/O cards of the existing RS3 MPC Analog Card Cage. The jumpers are clearly indicated by screen printing on the PCB. As default, the BC-FIC-AIAO-01-1 is provided with all I/Os configured in AI mode. It user has to take care of the right/wrong way of jumpers. Refer to the indications here below for I/O configuration :

1.2. ANALOG INPUT TYPE CONFIGURATION USING SINGLE-J UMPERS

Each analog input channel has to be defined as a 2W or 4W transmitter.

• 2W (Two wire transmitter) : Transmitter is supplied by the input card of the DCS or PLC

• 4W (Four wire transmitter) : Transmitter is supplied by an external source located at the field or in the marshalling cabinets

Refer to the indications here at the right for configuration using the jumpers T101 to T803.

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Bulletin Rev : 2016_01 1.3. PCI TYPE CONFIGURATION USING DOUBLE-JUMPERS

To manage existing PCI, the option -2 (with redundant power supply) of the BC-FIC-AIAO-01-2 is required. Each Pulse Count Input channel has to be defined as a “Dry Contact Input” or “Voltage Input”.

• Dry Contact Input : Field Dry Contact is powered by the input of the redundant PS of the BC-FIC-AIAO-01-2 • Voltage Input : Input is directly applied to the DCS or PLC input card of through the BC-FIC-AIAO-01-2

Refer to the indications here below for configuration using the jumpers K101 to K802.

2. INSTALLATION PROCEDURE :

2.1. REMOVING OF THE EXISTING CABLES : Disconnect the I/O cable from its connector J453. Disconnect all communication cables and remove them, as there are not to be used anymore in the new architecture. Power cables connected on the existing J949 and J950 have to be managed as follow :

• The existing RS3 MPC analog card cage had no Pulse Count Input cards : Power cables connected on the existing J949 and J950 have to be removed. In that case, the BC-FIC-AIAO-01-1 doesn’t require any power supply.

• The existing RS3 MPC analog card cage had Pulse Count Input cards : Power cables connected on the

existing J949 and J950 have to be kept and reconnected on same connectors similarly labelled of the BC-FIC-AIAO-01-2

2.2. MECHANICAL OPERATIONS :

• Remove the fixing screws and remove the existing RS3 analog card cage. • Install in the same location the BC-FIC-AIAO-01-1/-2 and secure it.

2.3. ELECTRICAL AND WIRING OPERATIONS :

• In accordance with the input / output configuration, install the required I/O cables. • Route and connect them to the DCS or PLC I/O cards. • Connect the power cable in connector J949 and J950 if necessary.

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Bulletin Rev : 2016_01

Description of Analog Input Configuration with 2W transmitter supplied by PLC or DCS card.

Description of Analog Input Configuration with 2W transmitter powered from PS connected on the Marshalling panel.

Description of Analog Input Configuration with 3W/4W transmitter with external Power Supply (self powered transmitter).

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Bulletin Rev : 2016_01

3. CONFIGURATION EXAMPLES :

3.1. EXAMPLE 1 - ONLY HIGH LEVEL (4-20MA) AI AND AO :

Analog Inputs Analog Outputs Group of 3 I/Os

Existing RS3 - Address 101-102-103 Yes : 101-102 Yes : 103 1

Existing RS3 - Address 201-202-203 Yes : 201-202 Yes : 203 2

Existing RS3 - Address 301-302-303 Yes : 301-302 Yes : 303 3

Existing RS3 - Address 401-402-403 Yes : 401-402 Yes : 403 4

Existing RS3 - Address 501-502-503 Yes : 501-502 Yes : 503 5

Existing RS3 - Address 601-602-603 Yes : 601-602 Yes : 603 6

Existing RS3 - Address 701-702-703 Yes : 701-702 Yes : 703 7

Existing RS3 - Address 801-802-803 Yes : 801-802 Yes : 803 8

No card required on connector P2

PLC or DCS Analog Input Card 16 channels

PLC or DCS Analog Output Card 8 channels

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Bulletin Rev : 2016_01

3.2. EXAMPLE 2 - ONLY HIGH LEVEL (4-20MA) AI AND AO :

Analog Inputs Analog Outputs Group of 3 I/Os

Existing RS3 - Address 101-102-103 Yes : 101-102-103 No 1

Existing RS3 - Address 201-202-203 Yes : 201-202-203 No 2

Existing RS3 - Address 301-302-303 Yes : 301-302 Yes : 303 3

Existing RS3 - Address 401-402-403 Yes : 401-402-403 No 4

Existing RS3 - Address 501-502-503 Yes : 501-502 Yes : 503 5

Existing RS3 - Address 601-602-603 Yes : 601-602-603 No 6

Existing RS3 - Address 701-702-703 Yes : 701-702 Yes : 703 7

Existing RS3 - Address 801-802-803 Yes : 801-802 Yes : 803 8

PLC or DCS Analog Input Card 16 channels

PLC or DCS Analog Output Card 8 channels

PLC or DCS Analog Input Card 8 channels