Lb5004 Rtd Module

LB REMOTE I/O SYSTEMHARDWARE

PROCESS AUTOMATION

MANUAL

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 In-dustry, 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 supplementary clause: "Expanded reservation of proprietorship"

LB REMOTE I/O SYSTEM


1 Safety................................................................................................. 61.1 Validity ....................................................................................................................................6

1.2 Symbols used ........................................................................................................................6

1.3 System Operator and Personnel ..........................................................................................7

1.4 Pertinent Laws, Standards, Directives, and further Documentation ................................7

1.5 Declaration of Conformity.....................................................................................................7

1.6 Markings .................................................................................................................................8

1.7 Intended use...........................................................................................................................8

1.8 General mounting ..................................................................................................................91.8.1 Installation in Zone 2................................................................................................................9

1.8.2 Installation in Zone 22..............................................................................................................9

1.9 Enclosure .............................................................................................................................10

1.10 Ignition protection classes and protection measures .....................................................101.10.1 Ignition protection class "Ex i"................................................................................................10

1.10.2 Ignition protection class "Ex nA" ............................................................................................ 111.10.3 Ignition protection class "Ex nC"............................................................................................ 11

1.10.4 Ignition protection class "Ex iD" ............................................................................................. 11

1.11 Installation and commissioning ......................................................................................... 11

1.12 Operation..............................................................................................................................121.12.1 Plastic enclosure....................................................................................................................13

1.12.2 Stainless steel enclosure .......................................................................................................13

1.13 Maintenance.........................................................................................................................13

1.14 Delivery, Transport and Storage.........................................................................................14

1.15 Repair....................................................................................................................................14

1.16 Certificates of Compliance .................................................................................................14

1.17 Overview of com units and power supplies......................................................................15

1.18 Overview of backplanes, end pieces, connecting cables, and dummies.......................15

1.19 Appendix – IEC Ex Scheme ................................................................................................16

2 Product Specifications .................................................................. 172.1 Introduction..........................................................................................................................17

2.2 Backplanes...........................................................................................................................172.2.1 Function .................................................................................................................................17

2.2.2 Design and dimensions .........................................................................................................182.2.3 Backplane combinations........................................................................................................22

2.2.4 Backplane and module compatibility .....................................................................................22

2.2.5 Parts included........................................................................................................................24

2.3 Com units, I/O modules, power supplies ..........................................................................252.3.1 Function .................................................................................................................................252.3.2 Design and dimensions .........................................................................................................25

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3 Installation .......................................................................................263.1 Installation............................................................................................................................26

3.2 Installing the backplane ......................................................................................................27

3.3 Connectors...........................................................................................................................283.3.1 Connectors on the LB 9022 to LB 9029 backplanes .............................................................28

3.3.2 Connectors on the LB 9101 to LB 9121 segment backplanes ...............................................31

3.4 Output shutdown on the LB 9022 to LB 9029 backplanes...............................................333.4.1 Switch S1 and connector X3..................................................................................................33

3.4.2 Combining I/O modules that do, and do not, have the output shutdown ...............................36

3.5 Inserting and removing I/O modules, com units, and power supplies ...........................36

3.6 Labeling with TAG numbers ...............................................................................................39

3.7 Field wiring and coding.......................................................................................................40

3.8 Lead breakage detection.....................................................................................................44

3.9 Cold junction in thermocouples.........................................................................................46

3.10 Line resistance in resistance thermometers.....................................................................47

3.11 Redundancy .........................................................................................................................473.11.1 Basic principles......................................................................................................................473.11.2 Line redundancy ....................................................................................................................48

3.11.3 Application redundancy .........................................................................................................49

3.11.4 Com unit properties ...............................................................................................................493.11.5 Backplane-internal redundancy function................................................................................50

3.11.6 Power supply redundancy......................................................................................................51

3.11.7 Example of redundancy .........................................................................................................51

3.12 Line length............................................................................................................................523.12.1 Basic principles......................................................................................................................523.12.2 RS485 bus .............................................................................................................................53

3.13 Potential equalization and shielding..................................................................................533.13.1 Introduction ............................................................................................................................54

3.13.2 Sources of noise ....................................................................................................................54

3.13.3 Wiring.....................................................................................................................................553.13.4 Signal paths ...........................................................................................................................56

3.13.5 Shielding the bus cable..........................................................................................................56

3.13.6 Practical grounding designs...................................................................................................56

3.13.7 Typical industrial installations ................................................................................................57

3.14 System expansion ...............................................................................................................58

4 LB 9035 Backplane (Foundation Fieldbus Modular I/O)..............594.1 Connectors...........................................................................................................................59

4.2 Output shutdown .................................................................................................................624.2.1 Switch S1 and connector X3..................................................................................................62

4.2.2 Combining I/O modules that do, and do not, have the output shutdown ...............................63

4.3 Power supply redundancy ..................................................................................................64

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5 Commissioning .............................................................................. 655.1 Testing data transfer over the bus.....................................................................................655.1.1 Bus – electrical test of connections .......................................................................................65

5.2 Configuration .......................................................................................................................67

6 Operation ........................................................................................ 686.1 Availability and monitoring functions................................................................................686.1.1 Individual availability ..............................................................................................................68

6.1.2 Multichannel capability...........................................................................................................696.1.3 Self-monitoring.......................................................................................................................69

6.1.4 Common alarm ......................................................................................................................70

6.1.5 Functional safety....................................................................................................................70

6.2 LEDs on the com units and I/O modules...........................................................................70

6.3 Strain gage measurements.................................................................................................71

6.4 Valve circuit and connection to an LED ............................................................................72

7 Maintenance ................................................................................... 73

8 Troubleshooting ..............................................................................748.1 Service call ........................................................................................................................... 74

8.2 Communications errors ...................................................................................................... 74

8.3 Redundancy faults...............................................................................................................75

8.4 Faults indicated by LEDs ....................................................................................................76

8.5 Signal fault ...........................................................................................................................78

8.6 Faults and their effects .......................................................................................................80

9 Technical specifications................................................................ 839.1 Technical data LB backplanes ...........................................................................................83

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LB REMOTE I/O SYSTEMSafety

1 Safety

1.1 Validity

The chapter “Safety” is valid as instruction manual.

Specific process and instructions in this document require special precautions to guarantee the safety of personnel.

1.2 Symbols used

This document contains information that you must read for your own personal safety and to avoid property damage. The warning signs are displayed in descending order depending on the hazard category, as follows:

Safety-relevant symbols

Informative symbols

Action

This symbol marks an acting paragraph.

Danger!This symbol indicates a warning about a possible danger.

In case of ignoring the consequences may range from personal injury to death.

Warning!This symbol indicates a warning about a possible fault or danger.

In case of ignoring the consequences may cause personal injury or heaviest property damage.

Caution!This symbol warns of a possible fault.

In case of ignoring the devices and any connected facilities or systems may be interrupted or fail completely.

Note!

This symbol brings important information to your attention.

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1.3 System Operator and Personnel

The plant owner is responsible for its planning, installation, commissioning, operation, maintenance and disassembly.

Mounting, commissioning, operation, maintenance and dismounting of any devices may only be carried out by trained, qualified personnel. The instruction manual must be read and understood.

1.4 Pertinent Laws, Standards, Directives, and further Documentation

Laws, standards, or directives applicable to the intended use must be observed. In relation to hazardous areas, Directive 1999/92/EC must be observed.

The corresponding data sheets, declarations of conformity, EC Type-examination certificates, certificates and Control Drawings if applicable (see data sheet) are an integral part of this document. You can find this information under www.pepperl-fuchs.com.

Due to constant revisions, documentation is subject to permanent change. Please refer only to the most up-to-date version, which can be found under www.pepperl-fuchs.com.

1.5 Declaration of Conformity

All products have been developed and manufactured taking into consideration applicable European standards and regulations.

The following standards were taken into consideration: EN 60079-0:2009, EN 60079-11:2007, EN 61241-11:2006, EN 60079-15:2005.

The manufacturer of this product, Pepperl+Fuchs GmbH in 68307 Mannheim, Germany, has a certified quality assurance system in conformity with ISO 9001.

Note!

A Declaration of Conformity can be requested from the manufacturer.

ISO9001

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1.6 Markings

Manufacturer: Pepperl+Fuchs GmbH, Lilienthalstraße 200, 68307 Mannheim, Germany.

Marking on LB modules for associated apparatus used in hazardous areas:

• EC type examination certificate: PTB 03 ATEX 2042

• Associated apparatus:II (1) G [Ex ia] IIC/IIB or II (2) G [Ex ib] IIC/IIB or II (1) D [Ex iaD] or II (2) D [Ex ibD]

• Current circuits:Ex ia IIC or Ex ia IIB or Ex ib IIC or Ex ib IIB

Marking of LB modules for use in hazardous areas in Zone 2:

• EC declaration of conformity: PF 08 CERT 1234

• Category 3G apparatus:II 3 G Ex nA IIC/IIB T4 or II 3 G Ex nA [ic] IIC/IIB T4 or II 3 G Ex nA nC IIC T4

• Current circuits:Ex ic IIC/IIB

The permitted ambient temperature for all LB modules is -20°C Ta 60°C.

1.7 Intended use

Remote I/O modules (I/O modules, Bus coupler, Power Supplies) must only be used together with the respective backplanes.

Remote I/O modules act as an interface between signals from the hazardous area (Ex area) and the safe area (non-Ex area).

The equipment is not suitable for isolating signals in high current applications unless this is noted separately in the corresponding datasheet.

The devices are only approved for appropriate and intended use. Ignoring these instructions will void any warranty and absolve the manufacturer from any liability.

Protection of the operating personnel and the overall system is not ensured if the product is not being used according to its intended purpose.

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1.8 General mounting

Prior to mounting, installation, and commissioning of the device you should make yourself familiar with the device and carefully read the instruction manual.

The device must not be installed at locations where corrosive vapors may be present.

The installation instructions in accordance with IEC/EN 60079-14 must be observed.

The equipment is designed for use in degree of pollution 2 and overvoltage category II as per IEC/EN 60664-1.

If devices have already been operated in general electrical systems, they may subsequently no longer be installed in electrical systems used in combination with hazardous areas.

Input / Output modules with non-intrinsically safe circuits may be operated near modules with intrinsically safe circuits. Observe the isolation requirements in IEC/EN 60079-14.

Select an installation position that ensures the climatic limits specified in the technical data are observed.

1.8.1 Installation in Zone 2

Equipment identified as category 3G apparatus should only be installed and operated in Zone 2 if installed in a suitable enclosure with a minimum IP degree of protection of IP54 as per IEC/EN 60529.

The operator must ensure that the ambient temperature range of the modules installed in the enclosure does not exceed -20 °C Ta 60 °C,

even under unfavorable operating conditions.

The housing when energized may be opened for service in zone 2.

For maintenance purposes, modules with intrinsically safe circuits may be exchanged during operation. This does not apply to modules LB 6010 through LB 6015 and LB 6110 through LB 6115.

Connection or disconnection of energized non-intrinsically-safe circuits is only permitted in the absence of a hazardous atmosphere.

1.8.2 Installation in Zone 22

Equipment should only be installed and operated in Zone 22 if installed in an enclosure with a declaration of conformity for category 3D at least.

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1.9 Enclosure

If additional housings are needed for installation in hazardous areas, the following points must be considered / evaluated:

• Degree of protection as per IEC/EN 60529

• Light resistance as per IEC/EN 60079-0

• Impact strength as per IEC/EN 60079-0

• Chemical resistance as per IEC/EN 60079-0

• Heat resistance as per IEC/EN 60079-0

• Electrostatics as per IEC/EN 60079-0

Vacant openings must be closed off securely with sealing plugs to comply with the IP degree of protection. The seal kits for the relevant cable diameter should be used as well.

Applying excessive force to cable glands may compromise the IP degree of protection.

To ensure the IP degree of protection:

• all seals must be undamaged and correctly fitted

• all screws of the housing / housing cover must be tightened with the appropriate torque

• only cable of the appropriate size must be used in the cable glands

• all cable glands must be tightened with the appropriate torque

• all empty cable glands must be sealed with sealing plugs

If the seal on the enclosure cover or a seal on the cable or wire gland is damaged, they must be replaced with new seals provided by the manufacturer.

1.10 Ignition protection classes and protection measures

The following considerations relate to the risks posed by flammable gases, dust, or mist spray. The simultaneous presence of gas and dust must be prevented.

1.10.1 Ignition protection class "Ex i"

Circuits of type of protection "Ex i" (intrisically safe) which have been operated with circuits of other type of protections must not be used as "Ex i" circuits afterwards.

The intrinsically safe circuits of the associated apparatus may lead into hazardous areas. Make sure to observe all relevant distances (creepage distances, clearances) to all non-intrinsically safe circuits (e.g. clearance) in accordance with IEC/EN 60079-14.

The respective peak values of the field device and the associated apparatus with regard to explosion protection should be considered when connecting intrinsically safe field devices with intrinsically safe circuits of associated appartus (verification of intrinsic safety). Make sure to observe IEC/EN 60079-14 and IEC/EN 60079-25.

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1.10.2 Ignition protection class "Ex nA"

Apparatus marked with ignition protection class "Ex nA" (non-sparking) for installation in Zone 2 does not contain sparking circuits.

1.10.3 Ignition protection class "Ex nC"

Apparatus marked with the ignition protection class "Ex nC" (encapsulated) for installation in Zone 2 contains sparking circuits, e.g. encapsulated contact circuits.

1.10.4 Ignition protection class "Ex iD"

Associated apparatus marked with [Ex iaD] or [Ex ibD] (installation in safe area) may be connected to intrinsically safe sensors/actuators installed in hazardous areas.

1.11 Installation and commissioning

The device must be disconnected from the power supply prior to installation and maintenance. The power supply may be activated only after all the circuits required for operation have been fully assembled and connected.

The remote I/O station should only be connected to the power supply voltages as specified on the print plate. All non-intrinsically safe interfaces should be connected to low voltages only (SELV/PELV). The maximum effective value (Um) of those voltages must not exceed

60 V AC/DC for the power supply and 30 V AC/DC respectively for the bus connection. This limitation does not apply to modules that are explicitly designed for higher voltages according to the datasheet and the print plate .

The installation requirements specified in IEC/EN 60079-14 as well as directive 1999/92/EC and national regulations must be observed.

Only skilled electricians/qualified personnel are permitted to install equipment in Zone 2 or Zone 22 in accordance with applicable national standards.

Make sure to observe the explosion group specified on the enclosure, the temperature class, and special ambient conditions!

Changes and alterations to the device are not permitted. The device must be operated in a sound, undamaged condition in accordance with the intended purpose.

Only original parts from the manufacturer should be used as replacements.

Foreign bodies that have entered the device must be removed prior to commissioning!

Always observe all national safety and accident prevention regulations and the specially highlighted warning signs in these operating instructions when working on the device!

Observe applicable safety regulations for the installation and operation of associated apparatus specified in your country´s Health and Safety regulations as well as generally recognized codes of practice!

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Before commissioning the device, refer to the technical data to make sure that the operating requirements are met and that the polarity of all the connections is correct. Check the auxiliary power supply and the operating conditions as well.

1.12 Operation

The devices must not be repaired, changed or manipulated. If there is a defect, the product must always be replaced with an original device.

If the seal on the enclosure cover or a seal on the cable or wire gland is damaged, they must be replaced with new seals provided by the manufacturer.

The insulation must extend up to the terminal. The actual wire must not be damaged.Fine-wire cables should be secured with a terminal lug. If two cables are connected to the same terminal, a double terminal lug should be used. Only certified cable or wire glands and sealing plugs should be used as a general rule. Coiled screw connections or other suitable cable glands with additional strain relief should be used for moving cables. Observe the installation guidelines applicable for the cable or wire glands. When using cable or wire glands with a lower IP degree of protection than required for the device, the overall IP degree of protection for the device is reduced. Vacant openings must be closed off securely with suitable sealing plugs to comply with the minimum degree of protection. When installing the cable or wire gland, ensure that suitable seal kits are used for the cable diameter. If custom seal kits are used, ensure that the insert is adapted correctly to the cable diameter. All vacant cable or wire glands must be closed off with suitable sealing plugs for cable or wire glands.

Cable ducts

The cable or wire glands should be tightened securely to comply with the required minimum degree of protection.

Supply voltage

Number of ducts - 2 2

Duct diameter - M 20 M 20

Permitted cable diameter - 5.5 ... 13 mm 5.5 ... 13 mm

RS 485 bus line

Number of ducts - 2 2



Ex-e or Ex-I connections



Functional ground - permanently mounted connection

permanently mounted connection

Shield - permanently mounted connection

permanently mounted connection

Depending on the design of the installation, the functional ground and shield should be incorporated in the potential equalization.

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1.12.1 Plastic enclosure

Testing torques, plastic enclosures

1.12.2 Stainless steel enclosure

Testing torques, stainless steel enclosures

Overtightening may affect the degree of protection. When tightening the cap nut on the metal cable or wire gland (type E1WF/e), secure the gland with a suitable tool to prevent it from turning.

The device must only be operated in the ambient temperature range and at the relative humidity (non-condensing) specified.

The live enclosure may be opened for servicing in Zone 2 (with gas explosion protection).


1.13 Maintenance

The requirements specified in IEC/EN 60079-17 and IEC/EN 61241-17 apply to maintenance, servicing, and inspection of associated apparatus. Always observe these requirements!

Regular maintenance is not necessary if the devices are operated properly and if the installation instructions and ambient conditions are observed.

Inspection, servicing and maintenance must be carried out by qualified and experienced personnel only. Individuals must thoroughly study all the different explosion protection methods during their training. The individuals must also know the relevant rules and regulations regarding zoning. The appropriate national standards must be observed.The maintenance intervals required are user-specific and depend on the operating conditions, these are therefore to be defined by the user. During maintenance, checks of components that determine the degree of protection take top priority (e.g., the condition and tightness of the enclosure, condition of the seals, cable or wire glands, and required potential equalization).

Cover screws 2.50 Nm

Pressure screw for M12 KLE 1.65 Nm

Pressure screw for M16 - M20 KLE 2.50 Nm

Pressure screw for M25 KLE 3.50 Nm

Cover screws 2.5 Nm

Pressure screw for the metal Ex-e M16 KLE

7.5 Nm Type E1WF/e, (Ex-e)





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If during maintenance it becomes apparent that repair work is required, read the installation instructions (see chapter 1.8).


1.14 Delivery, Transport and Storage

Check the packaging and contents for damage.

Check if you have received every item and if the items received are the ones you ordered.

Keep the original packaging. Always store and transport the device in the original packaging.

Always store the device in a clean and dry environment. The permitted storage temperature (see data sheet) must be considered.

1.15 Repair


1.16 Certificates of Compliance

ATEX

• LB modules (safe area): PTB 03 ATEX 2042

• LB modules (Zone 2): PF 08 CERT 1234

IECEx

• LB modules (safe area): IECEx BVS 08.0011X

• LB modules (Zone 2): IECEx BVS 09.0037X

Note!

To view the certificates of compliance listed above and for further certificates, please visit www.pepperl-fuchs.com.

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1.17 Overview of com units and power supplies

• without explosion protection; for operating the LB I/O modules listed above

1.18 Overview of backplanes, end pieces, connecting cables, and dummies

• without explosion protection; for operating the LB I/O modules listed above

Type Type of apparatus Terminal assignment

LB 8101 … LB 8109 Com unit(48 ... 80 analog and144 ... 184 digital channels)

Connectors linked via backplane

LB 8110 FF com unit(20 analog or40 digital channels)


LB 9006 Power supply(for 12 single or6 dual modules)


LB 9104 Power supply(for 8 single or4 dual modules)


Type Type of apparatus Terminal assignment

LB 9022 ... LB 9023LB 9026 ... LB 9029LB 9035

Base backplane(for 8 ... 22 single or 4 ... 11 dual modules)

X1: Power supply 24 V X2: Redundant power supply 24 V X3: Control terminal for digital output with output disable input X4. Spare or primary bus X5: Redundancy bus X6:Service bus X7: Connection to base unit using cable (PIN assignment as per RS 485 standard)

LB 9024 ... LB 9025LB 9027

Extension backplane(for 8 ... 24 single or 4 ... 12 dual modules)

LB 9101 Backplane segment (for 8 single or 4 dual modules)

Used with LB 9102 (end piece, left) and LB 9103 (end piece, right) only

LB 9102 End piece (left) X1: 24 V power supply BUS 1: Primary bus BUS 2: Redundancy bus SERVICE BUS: Service bus

LB 9103 End piece (right) X1: 24 V power supply X2: for extension with LB 9153

LB 9153 Connecting cable with end connectors(left and right)

Connecting cable (1 m in length) connects the right end pieces LB9103 with LB9103 for shared use of the com unit on 2 backplanes

LB 9199 Dummy Accessories: Empty module (single-width module with blue terminals for marshalling Ex i circuits)

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1.19 Appendix – IEC Ex Scheme

Relevant laws, standards, guidelines, and other documentation

The laws, norms and guidelines applicable for the use or the intended purpose must be observed.

The corresponding data sheets and certificates, where applicable, (see data sheets) are integral components of this document.

In addition to the considerations specified in the ATEX guidelines (RL 94/9/EC), the devices have also been examined in accordance with IECEx. The following standards were taken into consideration:

• IEC 60079-0,

• IEC 60079-11,

• IEC 60079-15,

• IEC 60079-26,

• IEC 61241-0,

• IEC 61241-11.

Marking

The marking on the devices was extended as described in the IEC Ex scheme. The following additional markings were added:

• Device marking:Ex nAc [ia] IIC/IIB T4Ex nAc [ib] IIC T4Ex nAc [ic] IIC/IIB T4Ex nAc II T4Ex nAc nCc II T4

• Circuit marking:Ex ia IIC/IIBEx ib IICEx ic IIC/IIB

When connecting intrinsically safe circuits, IEC 60079-14 or IEC 60079-25 should be observed.

Maximum values for intrinsically safe circuits

The maximum values for intrinsically safe circuits listed in the tables also apply for IECEx applications (see chapter 1.16).

Intended use

All instructions in this chapter relating to the intended use, installation, and assembly also apply for IECEx applications.

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LB REMOTE I/O SYSTEMProduct Specifications

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2 Product Specifications

2.1 Introduction

The modular LB Remote I/O system economically connects field signals from hazardous areas and safe areas with the process control system by means of a field bus.

Different Com Units are available, enabling connection to different field busses. The I/O components can be used in any combination. In addition, a high modularity and the possibility of installation near the field devices allow for a cost-efficient implementation of I/O layers. The system stands out due to good functionality and easy handling.

The following bus systems are supported by LB Remote I/O:

This manual describes handling of the backplanes and modules and provides important safety instructions. Separate software manuals describe the configuration of modules and Com Units. There, you will also find solutions on how to change configuration without interrupting plant operation. Further information about the different bus systems can be found on the web pages of the respective user organizations:

• www.profibus.com

• www.fieldbus.org

• www.modbus.com

• www.standards.ieee.org/getieee802/802.3.html

There are various drivers and quick starts for integration of the Remote I/O system into process control systems. Our service engineers and consultants will be glad to advise you.

2.2 Backplanes

2.2.1 Function

Backplanes are used to hold I/O modules, com units and power supplies. The I/O modules act as an interface between signals from the hazardous area (Ex area) and the safe area (non-Ex area). The slots on the backplane have equal status, so that any functions can be installed side-by-side. The configuration is performed in software.Fixed slots are reserved on the backplane for the com unit and power supply.

Bus system Configuration Com Unit

Profibus DP/DPV1 GSD/GSE via master LB 8106

FDT/DTM or EDDL via master

LB 8109

Profibus DP/DPV1 with time stamp

FDT/DTM via master LB 8108

Modbus RTU FDT/DTM via servicebüs LB 8107

Modbus TCP (Ethernet) FDT/DTM via master LB 8111

Foundation Fieldbus DD via control system LB 8110

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http://www.profibus.com

http://www.fieldbus.org

http://www.modbus.com

http://www.standards.ieee.org/getieee802/802.3.html

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2.2.2 Design and dimensions

For the assignment of connector terminals on the LB 91xx backplanes see chapter 3.3.2. For the assignment of connector terminals on the LB 90xx backplanes see chapter 3.3.1.

LB 9101, LB 9102, LB 9103 backplane segments (not for new installations!)

• Description: A backplane can be built from one LB 9102 left-hand end piece, up to six LB 9101 backplane segments, and one LB 9103 right-hand end piece

• I/O module slots: 8 per LB 9101 backplane segment

Figure 2.1: Backplane segments, LB 9102 left-hand end piece, LB 9101 backplane segment, LB 9103 right-hand end piece (figures in mm)

LB 9121 backplane segment (not for new installations!)

• Description: backplane segment with integral left-hand end piece, for redundant com unit; can be used with LB 9101 and LB 9103

• I/O module slots: 6

LB 9023 base backplane

• Description: extendable base backplane including end pieces


Figure 2.2: LB 9023 base backplane (figures in mm)

Note!

The backplanes LB 9101, LB 9102, LB 9103, and LB 9121 have been succeeded by functionally compatible backplanes LB 9022 through LB 9035.Power supplies LB 9104, only to be used on backplanes LB 9101, LB 9102, LB 9103 und LB 9121, are only available as spares in limited numbers.Please check with your local Pepperl+Fuchs representative should you require advice.

55 165 55

119

LB 9101 LB 9103LB 9102

Bus

service

extension1 2 3 4 5 6 7 8

power 1

Netzteil 1

base unit - Basiseinheitcomm

unitBuskopplerX7

X6

X4

24V DC

24V DCbooster

X

X2

X1

X3shut down

S1 Schalter.........

...

275

110

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Figure 2.3: magnified view of connectors X - X3 and switch S1 on the LB 9023 - LB 9029 backplanes (right hand side)

LB 9025 extension backplane

• Description: extension backplane including end pieces; fits LB 9023 base backplane


Figure 2.4: LB 9025 extension backplane (figures in mm)


• Description: extendable base backplane including end pieces



24V DC

24V DCbooster

X

X2

X1

X3shut down


...

extension9 10 11 12 13 14 15 16

power 1

Netzteil 1

extension unit - Basiseinheit

X724V DC

24V DCbooster

X

X2

X1

X3shut down


...

275

110

Bus

service

extension1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

power 1

Netzteil 1

base unit - Basiseinheitcomm

unitBuskoppler

power 2

Netzteil 2X7

X6

X4

24V DC

24V DCbooster

X

X2

X1

X3shut down


...

440

110

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LB 9029 redundancy backplane

• Description: backplane including end pieces; cannot be extended; power supply and com unit redundancy


Figure 2.7: LB 9029 redundancy backplane (figures in mm)


• Description: extendable base backplane including end pieces; power supply and com unit redundancy


The LB 9022 base backplane is availavle in the following variants:


LB 9022 A Profibus or Modbus (redundant 9 pin SUB-D connector for RS485)

LB 9022 E Ethernet (redundant RJ45 connector)

LB 9022 F HDLC bus (redundant 9 pin SUB-D connector for HDLC bus)

extension17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

power 1

Netzteil 1

extension unit - Erweiterungseinheit power 2

Netzteil 2X7

24V DC

24V DCbooster

X

X2

X1

X3shut down


...

440

110

Bus

redundant

service

3 4 5 6 7 8 9 10 11 12 13 14

power 1

Netzteil 1

redundant unit - Redundanzeinheit

redundant comm

unitR

edundanzkoppler

comm

unitBuskoppler

power 2

Netzteil 2

power 3

Netzteil 3

X6

X5

X4

24V DC

24V DCbooster

X

X2

X1

X3shut down


...

440

110

Bus

redundant

service

extension3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

power 1

Netzteil 1

base unit - Basiseinheit

redundant comm

unitR

edundanzkoppler

comm

unitB

uskoppler

power 2

Netzteil 2

power 3

Netzteil 3X7

X6

X5

X4

24V DC

24V DCbooster

X

X2

X1

X3shut down


...

605

110

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Side view of LB 9022, 9023, 9024, 9025, 9026, 9027, 9029, and 9035 backplanes

Figure 2.10: Side view, LB 9022 ... LB 9035 backplanes (figures in mm)

1 Tag holder

2 I/O module

3 Front connector without cover

4 Front connector with cover

5 Field wire

6 Standard DIN rail

7 Bus connectors (number of bus connectors varies depending on the backplane type)

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

power 1

Netzteil 1

ext.

extension unit - Erweiterungseinheit power 2

Netzteil 2

power 3

Netzteil 3X7

24V DC

24V DCbooster

X

X2

X1

X3shut down


...

605

110

min. 195

1

2

3

4

5

6

7

min. 165

47

113

15

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2.2.3 Backplane combinations

LB 9022, ..23, ..24, ..25, ..26, ..27, ..29, ..35 backplanes (recommended for new installations)

A cable is included for connecting the base and extension backplanes together. This means that the com unit is only required on the base backplane.

There is no provision for different combinations.

LB 9101, LB 9102, LB 9103, LB 9121 backplane segments (not for new installations)

LB 9101, LB 9102, LB 9103 and LB 9121 Backplane segments are used for extending existing installations. They will eventually be removed from the product range, but will remain available for the time being.

2.2.4 Backplane and module compatibility

With the following exceptions, all LB backplanes can take all LB modules.

Combination max. no. of slots Redundancy

LB 9022 base backplane with LB 9024 extension backplane

46 yes


16 no


32 no

LB 9029 redundancy backplane, cannot be extended

12 yes

LB 9035 Foundation Fieldbus backplane, cannot be extended

5 (for dual-width I/O modules)

no

Table 2.1: Possible backplane combinations LB 9022, ..23, ..24, ..25, ..26, ..27, ..29, ..35

Combination max. no. of slots Redundancy

LB 9102 left-hand end piece, up to six LB 9101 center segments, LB 9103 right-hand end piece

48 no

Redundancy backplane including LB 9121 left-hand end piece, optionally up to five LB 9101 center segments, LB 9103 right-hand end piece

46 yes

Table 2.2: Possible combinations of backplane segments

Note!

The backplanes LB 9101, LB 9102, LB 9103, and LB 9121 have been succeeded by functionally compatible backplanes LB 9022 through LB 9035.Power supplies LB 9104, only to be used on backplanes LB 9101, LB 9102, LB 9103 und LB 9121, are only available as spares in limited numbers.Please check with your local Pepperl+Fuchs representative should you require advice.

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I/O modules with or without lateral guide groove

• I/O modules come with or without a lateral guide groove (see Figure 2.11 on page 23). I/O modules with a guide groove are compatible with all LB backplanes. I/O modules without a guide groove are only compatible with LB 9101 and LB 9121 backplane segments. Since August 2002, I/O modules have only been manufactured with a guide groove (single or dual width).

Figure 2.11: I/O modules with and without lateral guide groove

Figure 2.12: Backplane with guide rails

1 lateral guide groove

2 I/O module with lateral guide groove, compatible with all backplanes

3 I/O module without lateral guide groove, only compatible with backplanes LB 9101 and

LB 9121

1 Space for TAG numbers

2 Guide rails

1

2 3

1

2

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LB 9101, LB 9102, LB 9103, LB 9121 backplane segments (not for new installations)

• The LB 9101 to LB 9121 backplane segments can only be supplied with power from the LB 9104 power supply unit.

• The 4-channel digital outputs LB 6110 to LB 6115 cannot be used with the LB 9101 to LB 9121 backplane segments.

LB 9022, ..23, ..24, ..25, ..26, ..27, ..29 Backplanes (recommended for new installations)

• The LB 9006 power supply can only be used with LB 9022, ..23, ..24, ..25, ..26, ..27, ..29 backplanes.

• The 4-channel digital outputs LB 6110 to LB 6115 can only be used with the LB 9022, ..23, ..24, ..25, ..26, ..27, ..29 backplanes. Only these backplanes have a 24 V DC booster connection that is capable of supplying the specified digital outputs. The digital outputs LB 6110 to LB 6115 do not provide an output signal without this supply.

LB 9035 backplane

• The LB 9035 Foundation Fieldbus backplane can take up to 5 dual-width I/O modules. Do not use single-width I/O modules.

2.2.5 Parts included

The extension backplanes LB 9024, LB 9025 and LB 9027 come with a 1 m connecting cable for connecting the extension backplane to the base backplane.

No other parts are included with any other backplane.

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2.3 Com units, I/O modules, power supplies

2.3.1 Function

Com units work with the relevant I/O modules to transfer analog and digital signals from the hazardous area (Ex area) to the safe area (non-Ex area) via a range of standard buses. The com unit converts the protocol of the internal bus system into the protocol of the higher-level bus system. It sits at the left-hand end of the backplane.

I/O modules are signal conditioning components. Field signals from the hazardous area are conditioned for controllers or process control systems in the safe area. Integrated designs of complete installations can be achieved easily using a wide range of single-channel and multichannel I/O modules with Ex-i and Ex-e field connections. I/O modules can be located in any module slot on a backplane

Power supplies provide power for the I/O modules and their com unit on a backplane. The slots for the power supplies and com units on the backplanes are mechanically coded and marked with an information label.

2.3.2 Design and dimensions

Modules come in single or dual widths. Com units and power supplies are always dual-width, whereas I/O modules may be single or dual-width depending on the model.

Com units, I/O modules and power supplies have LEDs on the front panel to indicate the module status.

The I/O modules also have terminals on their front panel. These terminals are used for the field wiring.

Further details on field wiring: see chapter 3.7.

Figure 2.13: Dimensions of I/O modules (all figures in millimeters)

Further information and technical data on the com units, I/O modules, and power supplies are given in their operating manuals.

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LB REMOTE I/O SYSTEMInstallation

3 Installation

3.1 Installation

Always read the chapter on “Safety” before starting installation work.

Warning!Hazard because of electrostatic charges

If the remote I/O station is installed in the hazardous area, electrostatic charges of the plastic parts may cause a hazard.

• Electrostatic charges must be avoided. For example, never clean plastic parts with a dry cloth. Always use a damp cloth instead.

• A warning label must be placed clearly visible inside the enclosure of the backplane and the I/O modules. The warning label should say: "WARNING - Avoid electrostatic charges".

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3.2 Installing the backplane

Depending on the type, the backplanes are supplied as separate parts (see Figure 2.1 on page 18) or pre-assembled. In each case, the backplanes are mounted on an NS 35/15 rail.

Installing backplanes supplied as separate parts LB 9101, LB 9102, LB 9103, LB 9121

1. Attach the plastic parts of the backplane to a DIN rail.

2. Use end fixtures to secure the backplane firmly on the rail.

Pre-assembled backplanes LB 9022 to LB 9035 (recommended for new installations)

End fixtures are not needed for pre-assembled backplanes. Factory-assembled backplanes (for example see Figure 2.2 on page 18) are connected to the plastic parts by screws, which also make the connection to the metal plate. The metal plate makes optimum use of the protective measures taken for EMC.

Caution!Possible overheating of power supplies

If you fit the backplane vertically, the power supplies may overheat because of inadequate ventilation.

Depending on the power dissipation inside the enclosure the temperature will rise by 10-15 °C above the outside temperature. Given the same amount of installed power large free-standing enclosures are better suited than small densely packed ones. Low ambient temperatures improve the service life of the Remote I/O station.

• If you are using LB 9006A power supplies, vertical mounting of the backplane in Zone 2 is not permitted. In the safe area, however, vertical mounting is permitted.

• If you are using LB 9006C power supplies, backplanes may be mounted vertically or horizontally in Zone 2 and in safe areas.

• When mounting vertically, position the power supplies at the top to achieve good heat distribution.

• Do not exceed the 60°C maximum ambient temperature stipulated for the intrinsically safe I/O modules inside the enclosure.

• Ensure the power supplies are well ventilated.

Note!

Back-up fuses

Back-up fuses are required in 24 V power lines. We recommend using 4 A T back-up fuses.

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3.3 Connectors

3.3.1 Connectors on the LB 9022 to LB 9029 backplanes

The connectors of the backplanes LB 9022 (E/S), LB 9023, LB 9024 (S), LB 9025, LB 9026, LB 9027 and LB 9029 are described in the following.

Figure 3.1: Connectors on the right-hand side of the backplanes

Warning!Too high a voltage will damage equipment

Ensure that the supply voltage of the power supplies used in Zone 2 does not exceed DC 33.6 V (24 V x 1.4) even temporarily during a fault.

1 X40: 24 V DC booster; supplies extra auxiliary power for the 4-channel digital outputs LB

6110 to LB 6115.

2 S1: function switch (see chapter 3.4.1)

3 X3: connector used to control certain I/O modules with output shutdown (see chapter

3.4.1)

4 X2: connector for redundant 24 V supply (only with LB 9006 power supply)

5 X1: connector for 24 V supply

6 Backplanes LB 9022, ..23, ..24, ..25, ..26, ..27, ..29

7 Backplanes LB 9022 S and LB 9024 S

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Terminal assignment for supply connector X1

• X1.1 = 0 V supply connection

• X1.2 = + DC 24 V supply connection

• X1.3 = ground

Terminal assignment for redundant supply connector X2



• X2.3 = ground

Terminal assignment for the 24 V DC booster connector X

• X.1 = 0 V supply connection

• X.2 = + DC 24 V supply connection

• X.3 = ground

Terminal assignment for X3 connector/S1 switch settings

For the terminal assignment of the connector X3 and switch settings for the switch S1, please read the chapter "Output shutdown" (see chapter 3.4).

Figure 3.2: Connectors on the left-hand side of the backplanes

1 X4: primary SUB-D bus connector (not for LB 9025, LB 9027)

2 X5: redundant SUB-D bus connector (only LB 9022*, LB 9029)

3 X6: service bus connector (SUB-D) (not for LB 9025, LB 9027)

4 X7: extension connector; this connector connects the base backplane to an optional ex-

tension backplane (not for LB 9029)

5 X4: primary RJ45 Ethernet connector (only LB 9022 E)

6 X5: redundant RJ45 Ethernet connector (only LB 9022 E)

7 Backplanes LB 9022, ..23, ..24, ..25, ..26, ..27, ..29

8 Backplane LB 9022 E

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Ethernet connection of backplane LB 9022 E

• When connecting the backplane to the Ethernet, observe IEEE 802.3.

SUB-D connector pin-outs

• Pin 1: optional shield

• Pin 2:

• Pin 3: (B) RxD/TxD-P (+) receive/transmit data-P

• Pin 4: optional control signal-P

• Pin 5: DGND reference potential

• Pin 6: +5 V, only at end of line

• Pin 7:

• Pin 8: (A) RxD/TxD-N (-) receive/transmit data-N

• Pin 9: optional control signal-N

When installing the fieldbus, make sure that the transmit and receive line RTD-P(+) und RTD-N(-) are not swapped over. If the lines are swapped, this can result in the slave being inaccessible, while all others can be reached.If the lines have been swapped over at the terminals when looping through, all subsequent stations are also inaccessible.

Enabling the bus termination

In the last station of every bus line, enable the bus termination in the 9-pin bus connector (see accessories in catalog).

Caution!Check RJ45 plug (LB 9022 E)!

If the plug is damaged or if it does not click into place properly it may loose contact to the RJ45 connector during operation.

When commissioning, maintaining or repairing, always ensure that the RJ45 plug is not mechanically damaged and that it clicks into place securely.

Note!

If the station is installed in Zone 2 / Zone 22, the bus termination must be suitable for temperature class T4. Bus connectors with built-in bus terminations from the P+F accessories range satisfy this requirement (see Figure 5.2 on page 67).

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3.3.2 Connectors on the LB 9101 to LB 9121 segment backplanes

Connectors on LB 9102, LB 9103, LB 9121 (only for replacements)

The 24V supply is connected on the left-hand and right-hand end pieces LB 9102 and LB 9103. The extension cable kit LB 9153 can be used together with end pieces to split an LB Remote I/O station made up of individual LB 9101 segments into two sub-stations. Use a cable of maximum length 1 m to connect the two sub-stations.

The left-hand com unit on the backplane is connected to the primary bus.The right-hand com unit on the backplane is connected to the redundancy bus (LB 9121 only).

Figure 3.3: LB 9102 left-hand end piece



• Pin 2:





• Pin 7:



1 X4: primary-bus connector (SUB-D connector)

2 X5: redundancy-bus connector (LB 9121 only), not used on LB 9102 (SUB-D connector)

3 X6: service-bus connector (SUB-D connector)

4 connector for 24 V supply

2

1

3

4

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Figure 3.4: LB 9103 right-hand end piece

Enabling the bus termination

In the last station of every bus line, enable the bus termination in the 9-pin bus connector (see accessories in catalog).

1 connector for 24 V supply

2 connector for connecting to an extension (using cable LB 9153)

2

1

Note!

If the station is installed in Zone 2 / Zone 22, the bus termination must be suitable for temperature class T4. Bus connectors with built-in bus terminations from the P+F accessories range satisfy this requirement (see Figure 5.2 on page 67).

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3.4 Output shutdown on the LB 9022 to LB 9029 backplanes

3.4.1 Switch S1 and connector X3

On LB 9022 to LB 9029 backplanes and on the LB 9022/24 S backplanes, an external switch can be used to disable the outputs of certain I/O modules independently of the bus. For further information, please refer to the manuals of the com unit used.

Warning!The output shutdown can only be used with certain backplanes

The output shutdown can only be used with specially equipped backplanes (LB9022 to LB9029 and LB 9022/24 S). On other backplanes, the valve control output of I/O modules fitted with an output-disable input is always disabled.Be aware that the output shutdown function of the LB 9022/24 S backplanes works differently than the output shutdown function of the other backplanes LB9022 to LB9029, as described in the following.

Caution!Damage to backplane

The backplane may be damaged if you do not follow the instructions below.

• Backplanes LB 9022 S and LB 9024 S: Never apply a control voltage to connectors X3.x!All other backplanes: Never apply a control voltage to connector X3.2 when switch S1 is closed (=ON)!

• Always operate a group of connected backplanes from a common control voltage or a common contact to avoid equalizing currents (see Figure 3.6 on page 34, point 1)!

• The base and extension backplanes can be controlled in common (see Figure 3.6 on page 34, point 3).

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Output shutdown backplanes LB 9022 ... LB 9029

Figure 3.5: Backplanes LB 9022 to LB 9029

Terminal assignment for control input X3 (controls all slots)

• X3.1 = 0 V; control terminal for all I/O modules with output shutdown.

• X3.2 = +DC 12 V or 24 V; control voltage, galvanically isolated from supply (see Figure 3.6 on page 34, point 1); control current = n x voltage / 5.6 K (where n = number of I/O modules with output shutdown).

• X3.1 to X3.3 for external floating contact (contact galvanically isolated from other contacts on other backplanes (see Figure 3.6 on page 34, point 2). The status information on the external contact can be read via the LB 1x08 I/O module.

Figure 3.6: Connector X3

1 DIP switches S1.1 ... S1.4

2 Connectors X3.1 ... X3.3

DIP switches S1.1 ... S1.4

S1.1 S1.2 S1.3 S1.4

ON ON ON ON Output shutdown is not active, independent of X3.

OFF OFF OFF OFF Output shutdown is controlled via an external control voltage at X3.

ON OFF ON ON Output shutdown is controlled via an external, voltage-free contact at X3.

1 Voltage control for 1 remote I/O station

2 Control for 2 backplanes without external voltage

3 Base and extension backplane, controlled in common (without external voltage)

X 3.1 3.2 3.3 X 3.1 3.2 3.3

+–+– +–

X 3.1 3.2 3.3 X 3.1 3.2 3.3 X 3.1 3.2 3.3 X 3.1 3.2 3.3

1 2 3

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Output shutdown backplanes LB 9022 S and LB 9024 S

Figure 3.7: Backplanes LB 9022 S and LB 9024 S

Output shutdown can be configured separately for 5 different slot ranges (= segments) on the backplanes LB 9022 S (base) and LB 9024 S (extension):

Control of the segments

Output shutdown for backplane segment x is controlled with DIP switch S1.x and the voltage-free contact at X3.x:

1 DIP switches S1.1 ... S1.5

2 Connectors X3.1 ... X3.5

Segment 1 2 3 4 5

Slots LB 9022 S 3 ... 5 6 ... 10 11 ... 15 16 ... 20 21 ... 24

Slots LB 9024 S 1 ... 5 6 ... 10 11 ... 15 16 ... 20 21 ... 24

relevant DIP switch S1 S1.1 S1.2 S1.3 S1.4 S1.5

relevant contact X3 X3.1 X3.2 X3.3 X3.4 X3.5

Switch setting S1 Contact at X3 Effect

S1.x = ON X3.x = ON/OFF If the DIP switch S1.x is set to ON, output shutdown for segment x is not active, independent of X3.x.

S1.x = OFF X3.x = ON/OFF If the DIP switch S1.x is set to OFF, output shutdown of segment x is controlled via the voltage-free contact at X3.x. All outputs of segment x are shut down if S1.x = OFF und X3.x = OFF.

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3.4.2 Combining I/O modules that do, and do not, have the output shutdown

I/O modules with output shutdown can be combined with I/O modules without the output shutdown in the same Remote I/O station. I/O modules without an output shutdown are continuously controlled by the fieldbus controller irrespective of the position of the external output-disable contact. I/O modules with an output shutdown are only controlled via the fieldbus when the output-disable contact is closed.

3.5 Inserting and removing I/O modules, com units, and power supplies

Caution!Observe standards and regulations

Always comply with the relevant standards and regulations in safety-critical applications! See also EN 61508.





Caution!Damage to modules

Before inserting I/O modules, com units, or power supplies, check that the supply voltage and ground conductor have been connected correctly. The cables are printed with the polarity. (see Figure 3.1 on page 28 and see Figure 3.2 on page 29 for LB 9022 to LB 9029, see Figure 3.4 on page 32 and see Figure 3.3 on page 31 for LB 9102 and LB 9103 and see chapter 4.1 for LB 9035 ).

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Remote I/O stations have up to 48 slots for narrow I/O modules, or 24 slots for dual-width I/O modules. Any combination of these module formats is possible.

I/O modules containing intrinsically safe circuits and I/O modules containing non-intrinsically safe circuits can be installed side-by-side. However, it is essential to maintain the 50 mm clearance between the I/O modules with intrinsically safe circuits and I/O modules with non-intrinsically safe circuits (). To comply with the minimum clearance of 50 mm, you can fit covers over the front connectors on the I/O modules (see accessories in catalog). Fit the covers over the front connectors on the first two I/O modules containing non intrinsically safe circuits. These I/O modules are grouped beside the I/O modules containing intrinsically safe circuits (see chapter 3.7).

I/O modules can be plugged in or unplugged during operation without switching off the supply. Depending on the com unit or process control system used, the I/O modules can be configured and addressed automatically online (HCIR: Hot Configuration IN RUN). I/O modules can be hot swapped, i.e. replaced during operation without switching off the supply, whatever the process control system.

Observe the markings on the I/O module and LB backplane. Comply with all instructions and conditions that apply to the place of use.

Reserved slots: All backplanes contain reserved slots for com units and power supplies (see chapter 2.2.2). The slots on the backplane are mechanically coded for the power supplies, com units, and I/O modules. The power supplies and com units have mechanical coding pins on the underside of the module enclosure which prevent them being confused with I/O modules. If required, I/O modules containing intrinsically safe circuits can be coded (see chapter 3.7).

Empty slots: unwanted slots can be left empty. Dummy modules can be inserted to improve the appearance (see accessories in catalog). Alternatively, empty slots in the master can be pre-configured with deactivated I/O modules to allow later online expansion during operation, even for those process control systems not yet equipped with an automatic expansion function (see relevant com unit manual).Alternatively, special com units (e.g. LB 8x09) can be used that allow online expansion, irrespective of the properties of the process control system.

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Inserting I/O modules, com units, and power supplies in the backplane

1. Arrange the I/O modules in the Remote I/O stations in any order on the backplane, start-ing from the left.

2. LB 9022 to LB 9035 backplanes : push the I/O module into a spare slot backplane.

3. LB 9101 and LB 9121 backplanes : push the I/O module into a spare slot. When inserting the modules, make sure that the rear catches engage in the plastic retainer on the backplane (see Figure 3.9 on page 38).

Removing I/O modules, com units and power supplies from the backplane

1. LB 9022 to LB 9035 backplanes : With your thumb and index finger on the top and bot-tom of the module, pull firmly to remove the module (see Figure 3.8 on page 38).

Figure 3.8: Module removal on backplanes LB 9022 to LB 9029

2. LB 9101 and LB 9121 backplanes : Use a screwdriver to press on the catches to remove the module (see Figure 3.9 on page 38).

Figure 3.9: Inserting/removing a module in LB 91xx backplanes

Caution!Damage to connectors

The rear connectors on the modules can be damaged if you plug in the modules with too much force. Never force the modules into the backplane retainer.

1 Remove module by applying pressure to the catch

1

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3.6 Labeling with TAG numbers

A labeling area is provided on the I/O modules, com units, power supplies, and on the backplane for device identification and identifying the I/O assignment and terminals. Apply the TAG numbers here.

Labeling LB 9101 backplane

LB 9101 backplane is provided with a labeling comb (see Figure 3.10 on page 39).

1. Label the labeling comb with the TAG numbers.

Figure 3.10: Labeling comb for LB remote I/O

2. Slot the labeling comb onto the backplane.

The labeling comb is now fixed on the backplane (see Figure 3.11 on page 39).

Figure 3.11: LB 9101 backplane segment with affixed labeling comb

LB 9022 to LB 9035 backplanes have fixed plastic retainers for attaching labeling strips instead of the labeling combs.

TAG1

TAG2

TAG3

TAG4

TAG5

TAG6

TAG7

TAG8

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Labeling I/O modules, com units, and power supplies

Com units are labeled on the front face with firmware and software-status information. Code = barcode GHG127 06xx H 8106 = part number with firmware information (4-digits in front of the code letter H). GSD ID number

Apply the TAG numbers in the spaces provided on the front face of the I/O modules or com unit.

Figure 3.12: Example of an LB I/O module

3.7 Field wiring and coding

1 Space for TAG number

2 Coding slot containing coding strip

654321

LB 1101

1

2

Danger!Risk of explosion due to incorrect wiring

Incorrectly wired front connectors can result in dangerous mix-ups and explosions.

• Intrinsically safe current circuits must only be connected to the appropriate I/O modules with front connectors marked in blue.

• Use blue front connectors for intrinsically-safe current circuits.

• Connect non-intrinsically safe current circuits to approved Ex-e terminals. Cover the terminals with an IP 30 cover so that they are not accessible if the enclosure is opened when live.

• Lay the non-intrinsically safe current circuits separately from intrinsically safe current circuits. Protect loose wire ends using spiral tape to provide additional insulation or lay them in a suitable cable-duct.

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I/O modules have to be wired differently depending on their type and function. Block diagram and connection layout can be found on the corresponding datasheet on www.pepperl-fuchs.com. Enter the type designation into the search field, for example "LB1101". Alternatively, you may enter e.g. "LB11" to obtain a list of all intrinsically safe digital inputs (LB1101 ... 1108), or "LB10" for a list of all non-intrinsically safe digital inputs.

Figure 3.13: Screw-terminal connector and socket

Danger!Risk of explosion from unapproved test equipment

Explosions can be caused if installation requirements are not met and if unapproved test equipment is used.

Only make measurements on intrinsically safe circuits in accordance with EN 60079 installation requirements and using approved test equipment.

Danger!Risk of explosion from exposed metal parts

If wires are not installed correctly, exposed metal parts may cause explosions.

• When inserting wires into the connectors, ensure that no exposed parts protrude from the connectors.

• Also, when using wire end ferrules, select a ferrule version with a suitable insertion length; use insulated wire end ferrules e.g. contact length 8 mm, overall length 14 mm.

Danger!Risk of explosion or equipment damage if freewheeling diodes are not fitted

If freewheeling diodes are not fitted in relay circuits, there is a risk of explosions or damage to the relay contacts.

Fit freewheeling diodes in relay circuits containing inductive loads so as to avoid sparks.

1 Screw-terminal connector with coding lugs (left: side view, right: view from front)

2 Socket of the I/O module with coding slots (view from above)

1

2

41

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Connectors and sockets can be coded (optional)

Connectors and sockets can be mechanically coded. to avoid making wrong

connections(see Figure 3.13 on page 41). There are 26 = 64 possible combinations. Coding strips are available as accessories.

1. Insert the coding strip in the desired coding slot in the socket of the I/O module (see Fig-ure 3.14 on page 42).

2. Cut the relevant plastic lugs from the connector. Plastic lugs on the connector must be removed from those points where coding strips are located in the socket of the I/O module.

Figure 3.14: Coding strips for insertion in coding slot

The field wires are connected to the I/O modules via connectors from the PHOENIX COMBICON range (see Figure 3.13 on page 41). The manufacturer data states that each connector can take wires up to 1.5 mm² in cross-section. However, P+F recommends a maximum wire size of 0.75 mm².

There are a choice of connector versions available (see table "Different connector versions" on page 43). Front screw terminals or cage-clamp terminals are ideal for future expansions or for rewiring individual channels because the connectors can remain plugged in when new channels are added. These two connector versions also allow easy access for test probes when checking individual circuits.

Covers are available for screw-terminal connectors with side screws. The covers are designed to comply with the 50 mm minimum clearance specified by ATEX. They allow I/O modules containing intrinsically safe circuits and non-intrinsically safe circuits to be installed immediately adjacent to each other in Zone 2 (see Figure 3.16 on page 46).

Cage-clamp connectors may be used without wire end ferrules for non-intrinsically safe applications. In accordance with DIN EN 60999, class 5 conductors are suitable for this. Class 6 conductors are not suitable.

Note!

Applies to relay outputs LB 6101H and LB 6005 only:rated values Phoenix Combicon connector: 14 ... 18 AWG, copper wire, 4 lb-in.

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Different connector versions

Cage-clamp connectors Front-facing screw-terminal connector

Screw-terminal connector

Connection data (valid for the connectors pictured above)

Conductor cross section solid min. 0,14 mm2

Conductor cross section solid max. 1,5 mm2

Conductor cross section stranded min. 0,14 mm2

Conductor cross section stranded max. 1,5 mm2

Conductor cross section stranded, with ferrule without plastic sleeve min.

0,25 mm2

Conductor cross section stranded, with ferrule without plastic sleeve max.

1,5 mm2

Conductor cross section stranded, with ferrule with plastic sleeve min.

0,25 mm2

Conductor cross section stranded, with ferrule with plastic sleeve max.

0,5 mm2

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3.8 Lead breakage detection

The majority of I/O modules are equipped with lead breakage detection that can be switched on an off using the configuration software. For the I/O modules

• 1x01, 1x02, 1x03, 1x07, 1x08 as well as

• 21xx and 2002

the following applies:Each channel has a lead breakage detection function and can distinguish between a lead breakage and a short circuit (NAMUR input only). If you are using mechanical contacts, either deactivate lead breakage detection or connect the mechanical contact at the installation location with a NAMUR replacement resistor (see Figure 3.15 on page 44). The Namur replacement resistor replicates a NAMUR initiator. Using the NAMUR replacement resistor, the electronic circuit can distinguish between a closed switch and a short circuit. The NAMUR replacement resistor is available from P+F as an accessory.

Figure 3.15: NAMUR equivalent resistance

Please observe the additional information in the table below for the I/O modules listed above.

I/O module Information about lead breakage detection

1x03 When lead breakage detection is active: If you have selected direction detection, then also use the resistance circuit for the rotation direction input. Input 2 is ignored for devices without direction detection.

1x07, 1x08 24 V or 5 V inputs can only be used when lead breakage detection is disabled (Ex-e modules only).

2xxx The valve circuit is monitored by a current pulse that is so brief a connected valve does not respond. The I/O module is available in a version without an LFD pulse for use with LEDs and acoustic alarms. I/O modules delivered from 2007 onwards have a current pulse that can be disabled in the configuration software. It is not always possible to monitor the valve circuit when booster valves are used. These valves are equipped with a storage capacitor that acts like a short circuit when it is switched off. Depending on the valve, lead breakage detection can be activated in this case, also for booster valves, by connecting a shunt resistor of 10 k. If a lead breakage is still detected when the capacitor is off, even with the shunt resistor connected, disable the lead breakage detection function.

Table 3.1: Further information about lead breakage detection for specific I/O modules

2.2 KΩ10 KΩ

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Please observe the following for the remaining I/O modules:

I/O module Information about lead breakage detection

3x01, 3x02, 3x03, 3x04, 3x05

The lead breakage detection function is based on a current measurement. Depending on the version of the Com Unit, it is possible to set the switching point, e.g. < 1 mA > 21mA. In addition, the circuit provides live-zero monitoring (fault bit = 1 if the current drops below the minimum level of 3.6 mA or the lead breakage value).

4x01, 4x02, 4x05 D The lead breakage detection function is based on a current measurement. The minimum lead breakage detection current is 1 mA. The current also flows if the control system reads 0 mA (unsuitable for outputs of 0-20 mA). Currents < 0.1 mA are identified as lead breakages. The non-linear voltage behavior of modern HART actuators means that short circuits cannot be detected.

5x01, 5x04 The device has a lead breakage detection to signal a lead breakage (> 1 k) and short circuit (< 10 ) (values on Pt100). Wire resistances in this case have no effect on the measured values except in a 2-wire configuration. A broken wire delay function prevents measured values from being enabled after a line fault occurs in order to avoid constant toggling between OK/fault, e.g. if there is a loose contact.

5x02, 5x05 The device has a lead breakage detection function to signal a lead breakage. Short circuits are not signaled as it is not possible to detect the difference to 0 mV. A broken wire delay function prevents measured values from being enabled after a line fault occurs in order to avoid constant toggling between OK/fault, e.g. if there is a loose contact (0-250 x 160 ms for external VTS, 0-250 x 240 ms for internal VST). In addition, for internal reference junction compensation, you can set the ratio of temperature compensation measurements to actual thermocouple measurements to give an optimum measurement time.

6x08, 6110 - 6115 The circuit is monitored by a test current that is low enough not to activate a connected valve.

Table 3.2: Further information on lead breakage detection for specific I/O modules

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3.9 Cold junction in thermocouples

Only concerns I/O modules 5x02 und 5x05.

For thermocouple measurements, extension wires need to be connected from the thermocouple to the measurement input or to the junction with the copper wire. Since another thermocouple is created at the junction between the extension wire and the copper wire, the thermocouple measurement depends on the ambient temperature at the junction. Various methods can be used to compensate for this temperature dependency.

Cold junction thermostat: a thermostat is the standard option for external cold junction compensation. The thermostat keeps the temperature at the copper/extension wire junction at a constant 50°C, for example. This method delivers very accurate measurements but is quite costly. An alternative option is to measure the temperature at the cold junction, as described below.

Cold junction compensation CJC: measuring the cold junction temperature offers a good compromise between cost and accuracy. For the I/O modules, a Pt100 sensor is used to measure the temperature at the copper/extension wire junction. The junction temperature measured by the Pt100 sensor is used by the I/O module to correct for ambient temperature effects. The Pt100 sensor should therefore be mounted immediately next to the copper/extension wire junction. Locate the sensor externally to achieve the best possible accuracy. Suitable cold junction compensation modules are available in the accessories (Combicon male connector with Pt100 sensor as built-in cold junction for 5x02 I/O modules, see Figure 3.16 on page 46). A line resistance can be specified in the configuration software for systems using 2-wire cold junction compensation, to correct for the line resistance to the external cold junction.5x05 I/O modules (thermocouple transmitters) have a built-in internal cold junction that can be enabled by software. The software also gives the option to switch to an external cold junction.

Figure 3.16: Cover and cold junction compensation module for thermocouple measurements using 5x02 I/O modules

1 Pt100 cold junction compensation module

2 Combicon plug

3 Cover

1

2

3

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3.10 Line resistance in resistance thermometers

Only concerns I/O modules 5x01 and 5x04 in 2-wire configuration.

In a 2-wire circuit, the resistance of the measurement wire is in series with the sensor. It is therefore added to the sensor resistance and is included in the measurement result. This means that the line resistance must be measured and corrected. There are two possible ways of doing this.

Short-circuit the Pt100

1. Short-circuit the Pt100 sensor.

2. In the configuration software, change the measurement input of the I/O module to a resistance measurement.

3. Open the process-value window for the relevant measurement point.

4. Note the process value.

5. In the configuration software, change the measurement input of the I/O module to a 2-wire measurement using Pt100 sensor.

6. Enter the measured resistance in the parameter field for the line resistance. The maximum permitted line resistance is 50 .

Use a variable resistance.

Alternatively, you can opt to use the conventional procedure for measuring the line resistance instead of the method described above:

1. In this case, use a compensating terminal with integral variable resistor in the sensor line.

2. In the configuration software, change the measurement input of the I/O module to a 2-wire measurement using the Pt100 sensor.

3. Set the line resistance in the configuration software menu to 20 .

4. Replace the Pt100 sensor with a 100 measurement resistor at the measurement point.

5. To measure the resistance, open the process-value window for the relevant measurement point.

6. Use the variable resistor to adjust the displayed value to read 0 °C.

7. Then re-connect the Pt100 sensor.

3.11 Redundancy

3.11.1 Basic principles

Redundancy is used when you want to ensure that a bus station can continue to work even when there is a fault in a master, in a PROFIBUS line, or in a com unit.

P+F Remote I/O supports redundant buses, redundant com units, and redundant power supplies. If a bus line or com unit fails, the higher-level system switches over to the redundant com unit. Although the com units of the Remote I/O station perform this switchover automatically, the master must support this operation.

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The redundant com unit has the same configuration as the primary com unit and continuously receives all the data that is being processed in parallel by the primary com unit. This ensures a smooth switchover if the primary com unit or bus link fails. The primary com unit is normally the active com unit. The active com unit has write permission on the internal bus of the field station. The passive com unit (normally the redundant com unit) only has read permissions.

3.11.2 Line redundancy

A remote I/O station (slave) contains redundant com units and redundant power supplies. The Profibus is also implemented redundantly. The transmit lines from the master are connected to the active and passive com units via two bus lines. The master has a selector for the receive lines so that both bus lines can be accessed (see Figure 3.17 on page 48, see Figure 3.18 on page 48).

Figure 3.17: Principle of line redundancy: a master communicates with redundant slaves via a voter.

Figure 3.18: Bus with active primary com unit (BK): a master communicates with redundant slaves via a selector.

On the backplane-internal bus, only one com unit at a time is actively connected to the master and thus authorized to set outputs. The passive com unit continuously reads both the data traffic on the internal bus and also the traffic from the adjacent (active) com unit. If a com unit is replaced by a com unit configured for line redundancy, it automatically adopts the configuration of the primary com unit.

In line redundancy, the currently active com unit exchanges read and write information with the master. This does not depend on the bus line used. This method ensures master/slave communication even when several com units fail in different stations. In application redundancy, on the other hand, the whole bus line is switched over to the line of the active com unit.

The diagram below illustrates the principle of extended line redundancy (see Figure 3.19 on page 48).

Figure 3.19: Principle of (extended ) line redundancy: PLC with redundant master; master and redundant master communicate with redundant slaves via a voter.

RedundancymoduleRedundant bus

Power supply

Redundant power supply

PLCSlaveVoter

Master

Slave

Bus

I/O

BK

BK

BK

BK

BK

BK

redundancy bus

PLC

busvoter

master

RedundancymoduleRedundant bus

Redundant

master

Power supply

Redundant power supplyPLC

Voter

MasterSlave

Slave

I/O

Bus

Voter

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3.11.3 Application redundancy

A remote I/O station (slave) contains redundant com units and redundant power supplies. The Profibus is also implemented redundantly. The master has two redundant interfaces so that it can access both bus lines. Both com units are active on the two external buses. On the internal bus only one com unit is active and allowed to set outputs (see Figure 3.20 on page 49, see Figure 3.21 on page 49).

If a bus line or com unit fails, the system switches over to the redundant bus line. The com units can also be switched over by command, although the master must support this operation.

In application redundancy, the switchover makes the redundant bus line the active bus line. At the same time, all com units on this bus line become active com units with write permission on the internal bus of the field stations. In this case the faulty bus line or com unit must be repaired quickly, because this system cannot handle another fault on the bus line that is now active.

Figure 3.20: Principle of application redundancy: PLC with redundant master; master, and redundant master communicate with the redundant stations via the redundant bus.

Figure 3.21: Bus after the redundancy switchover with activated redundant com units (BK).

3.11.4 Com unit properties

In redundant systems, both com units are connected together and they both have the complete data set. In LB remote I/O stations, the com units are connected automatically via the backplane circuit board.

Active com units have flashing yellow LEDs on the front face. Passive com units can be recognized by the front yellow LEDs being off. Note: active = write permissions for outputs; passive = no write permissions.

Redundancymodule

Power supply

Redundant power supply

Redundant

master

PLC

Master Slave

Slave

Bus

Standby bus

I/O

BK

BK

BK

BK

BK

redundancy busredundancy

master

PLC

busmaster

Note!

When fault-free com units in LB remote stations are first put into operation, the active com unit is in the far left position on the backplane, beside the connectors.

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3.11.5 Backplane-internal redundancy function

The LB 9121, LB 9022, and LB 9029 backplanes are designed to work in redundant systems (both power supply and com unit redundancy). The LB 9024, LB 9026, and LB 9027 backplanes only have redundant power supplies. The LB 9023, LB 9025, and LB 9035 backplanes have no redundant com units and no redundant power supplies.

The com unit controls the I/O modules over an internal bus. The slots (up to 46 connected to the bus) are addressed via backplane segments. Redundant selectors are provided for this purpose, which connect the respective internal bus to the I/O modules.

On LB 9101 segment backplanes, a selector located in the power supply serves 8 slots. So if a power supply fails, then up to 8 I/O modules fail. A station containing 46 slots has 6 power supplies and hence 6 selectors (see Figure 3.22 on page 50).

Figure 3.22: LB 9101: 1 selector per segment

On LB 9022, LB 9024, and LB 9029 backplanes, for each com unit there is a separate selector serving 8 I/O modules each. A Remote I/O station containing 46 slots has 12 selectors (see Figure 3.23 on page 50).

Figure 3.23: LB 9022/LB 9024: 1 selector per com unit and for every 8 I/O modules

1 redundant station

BK Com unit

RK redundant com unit

SE selector

1 redundant station

BK Com unit

RK redundant com unit

SE selector

BK

RK

SE

.2

SE

.1

8 x6 x

1

BK

RK

SE

.1

SE

.2

SE

.1

SE

.2

8 x6 x1

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3.11.6 Power supply redundancy

In LB 9101 segment backplanes, the com units and I/O modules receive their auxiliary power from the LB 9104 power supplies. There is one power supply for each backplane segment. If one power supply fails, another power supply continues to supply the com units. A diagnostic message warns the process control system of the fault (see Figure 3.24 on page 51).

Backplanes LB 9022, LB 9024 and LB 9029 provide 2 out of 3 power supply redundancy. Two LB 9006 power supplies are enough to supply the whole backplane and the com units. The third power supply works in standby mode, so there is no interruption in supply if a power supply fails. A diagnostic message warns the process control system of the fault (version V6.x and above) (see Figure 3.24 on page 51).

Figure 3.24: Principle of the redundant power supply

3.11.7 Example of redundancy

An example of a ready-made redundancy station is shown below, illustrating the variety of assembly options (see Figure 3.25 on page 51).

Figure 3.25: Example of a redundant station

1 LB 9022 base backplane

2 LB 9121 base backplane plus 2 x LB 9101 segment backplanes

BK

Com unit

N Power supply

BK

BK

BK

BK

N NN

NN N

1

2

1 2 com units (primary com unit on left, redundant com unit on right)

2 Single-channel and multichannel I/O modules

3 3 power supplies

12

3

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3.12 Line length

3.12.1 Basic principles

comunits can be configured for a range of transmission speeds (bit rates). Interface standards specify the bus lengths possible for these bit rates when using shielded, twisted-pair cables for the bus. Follow the installation requirements given in EN 60079 when laying cables in the hazardous area.

RS485 standard hardware is generally used for buses. This provides an extremely reliable transmission link. Commercially available components enable the use of fiber optic communication or other transmission media (e.g., phone modem). Cables for standard applications should meet the cable type A specification given in IEC 61158 and IEC 61784. The table below relates to standard applications (see table "Bus lengths as specified in the RS485 standard" on page 52).

Bus lengths as specified in the RS485 standard

Commercial repeaters (amplifiers) can be used to extend the line length (see Figure 3.26 on page 52). Repeaters for installation in the hazardous area (e.g., by placing in a flameproof enclosure) are available on request.

Figure 3.26: Example of a bus topology

Bus Bit rate Max. line length

Modbus 1,2 ... 9.6 kbit/s 1200 m

19.2 kbit/s 1200 m

38.4 kbit/s 1200 m

115.2 kbit/s 1000 m

PROFIBUS 1.5 kbit/s 200 m

500 kbit/s 400 m

187.5 kbit/s 1000 m

93.75 kbit/s 1200 m

19.2 kbit/s 1200 m

9.6 kbit/s 1200 m

PROFIBUS PA, Foundation Fieldbus H1

31.25 kbit/s 1900 m

Service bus 9600 bit/s 1200 m

T bus termination

Master T

Slave 1

T

Slave 30 Repeater

Slave 31

Slave 2 Slave 1

T

T

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3.12.2 RS485 bus

RS485 compliant bus is used for the service bus and for communicating with the process control system or PLC. This bus must satisfy the following conditions specified by IEC 61158 and IEC 61784:

• Bus topology: line terminated at both ends by the bus termination without spurs;

• Length of spur to the bus stations < 0.3 m;

• Total length of spurs < 6 m;

• Transmission medium: shielded twisted-pair cable;

• Bus termination resistance 100 ... 130 ;

• Cross-section > 0.22 mm², approx. 60 pF/m;

• Line length:1200 m maximum, depending on bit rate;

• 32 active or passive bus stations including repeaters.

The line length can be extended using bi-directional repeaters (amplifiers). Up to 3 repeaters are allowed between 2 bus stations. The following limits are obtained for a bit rate of less than 93.75 kbit/s and with the lines connected in series: 0 repeaters: 1.2 km, one master plus 31 bus stations (Remote I/O stations) each with 48 I/O modules (1488 modules in total); 1 repeater: 2.4 km and 61 bus stations (Remote I/O stations) each with 48 I/O modules (2928 modules in total).

For LB remote I/O devices, the bus stations are connected to the bus by a 9-pin Sub-D connector to DIN 41652. The female connectors (sockets) are located on the backplane. The male connectors (containing pins) are fitted to the bus cable. Please refer to the "Connectors" section for the connector pin-outs (see chapter 3.3).

The bus cables are connected to the remote I/O stations via "T-pieces", which are formed by double terminals in the male connector.

Spurs must be no longer than 0.3 m to avoid reflections. The terminating resistor depends on the cable type and is specified in IEC 61158 and IEC 61784. For the different cable types: R = 220 for cable type A (< 12 Mbaud) or R = 150 for cable type B (< 0.5 kbaud). Cable type B should no longer be used if possible. (R = 120 for the Service bus).

3.13 Potential equalization and shielding

The following sections cannot provide a comprehensive picture of all grounding, shielding and lightning protection requirements. Please refer to the technical literature and relevant standards for further information.

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3.13.1 Introduction

Electromagnetic interference is extremely likely in technical installations. The aim of NAMUR recommendations NE21 is to establish EMC test criteria to be applied in conjunction with the EMC Directive for apparatus used in such an environment. Users can take numerous steps to minimize noise levels. The following information may be useful in reducing noise.

3.13.2 Sources of noise

Electromagnetic fields can induce noise in the signal path (see Figure 3.27 on page 54). The impact of such interference is reduced significantly just by using twisted-pair cable rather than parallel wires (see Figure 3.28 on page 54). The direction of the induced interference field reverses over short intervals in a twisted-pair cable. This means that the parasitic noise practically cancels out, whilst in parallel wires the noise acts over the entire surface.

Figure 3.27: Induced noise in parallel conductors

Figure 3.28: Induced noise largely compensated by twisted-pair conductors

A shield screens the signal path from noise (see Figure 3.29 on page 54).

Figure 3.29: A cable shield screens out interference fields

EMC filters are used in many pieces of equipment to divert any interference to ground (see Figure 3.30 on page 55). All lines are provided with a suitable capacitance for reasons of symmetry. Capacitively coupled high-frequency signals are effectively cancelled out by the symmetrical layout.

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Figure 3.30: EMC filters in signal paths

The same applies to DC isolated signals (see Figure 3.31 on page 55). Unexpected results may arise, however, in networks created by multichannel remote I/O systems that have no isolation. This is because the filter capacitors may even lie in parallel, depending on the configuration. Isolate the channels to eliminate any noise signals that may exist.

Figure 3.31: EMC filters in a network (simplified diagram)

3.13.3 Wiring

It is common practice to lay signal lines away from supply cables. You should also be aware that AC voltages and current spikes can induce parasitic voltages in neighboring lines. Screened cable should therefore normally be used, even for EMC tested equipment.

Warning!Hazardous area

In hazardous areas, always observe the regulations in EN 60079-14 (VDE 0165).

For example, potential equalization ensures that the resistance between different parts of an installation does not exceed 1 . This makes it easier to calculate the required cable cross-section for a given distance between the areas.

The grounding rails can be laid separately from the shielding (see diagram in EN 60079). In this case, the shielding is grounded at one point.

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3.13.4 Signal paths

Digital inputs are normally driven by NAMUR proximity switches with a low impedance signal. In this case, parasitic signals have a far lower impact than in circuits containing open switches that do not include a NAMUR equivalent resistance. Thus, do not connect inputs to open-ended wires.

The analog signals from resistive sensors or thermocouples are particularly susceptible to noise. The transducers have built-in filters to reduce this noise. The filters can be switched on if fluctuations in the process signal cannot be reduced sufficiently by other means.

Depending on the application, the cable shields are grounded at one point or at both ends. If possible, avoid grounding at both ends so that ground loops are prevented and the shield is not used as a return line.

Good results are obtained with grounding at one end if the cable is laid on a grounded metal cable support. With the metal surround immediately beside the conductor, only small surface areas are exposed to the interference field so that any noise is mainly eliminated.

3.13.5 Shielding the bus cable

Ground the bus-cable shield at both ends. Grounding at one end is sufficient if the bus cable is laid near a ground (e.g. on metal cable supports).

3.13.6 Practical grounding designs

It has recently been found that even installations with unscreened cables can produce satisfactory results, provided certain minimum requirements are met, e.g., standard practice for conventional equipment. So, do not lay signal cables close to powerful noise sources (such as frequency converters). All P+F I/O modules, comunits, and power supplies carry the CE mark following EMC type testing in accordance with the EMC Directive.

In addition, we have taken complete Remote I/O cabinets through EMC tests that go beyond standard practice for conventional installations. The test results are incorporated in the manufacturer declaration for certification.

If the CE mark is required for control cabinets and enclosures for unscreened cables, individual tests can be carried out. The test results would show the type of restrictions, if any, that apply. Control cabinets and enclosures from P+F carry the CE mark.

Note!

Please follow guidance in EN 60079-14.

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It is impossible to test every possible configuration. This means that although the recorded test results provide a high degree of certainty, they only apply to the actual test setup under standard test conditions. To obtain accurate results, it is necessary to perform tests on site under actual operating conditions. These complex tests are not normally performed in practice, as P+F components and various equipment combinations have already passed the relevant tests.

P+F believes that unscreened cables will yield signal quality results comparable to similar tests carried out on conventional systems and equipment employing Eurocards or equipment with DIN-rail mounting technology. Screened cables will result in far less interference from external noise sources. This is particularly true if there are powerful interference sources in the immediate vicinity.

3.13.7 Typical industrial installations

In a "typical industrial environment", there is normally no need for additional EMC protection to ensure reliable operation of Remote I/O devices. This even applies to unscreened field wiring to sensors and actuators.

A chemical plant can be seen as a "typical industrial environment" in which all electrical systems have been installed in accordance with the recommendations in NE 21 (particularly regarding emitted interference) or are working perfectly in NE 21-compliant equipment.

If surges or voltage peaks are likely in signal and supply lines, assume that the signals will contain a certain element of noise for the period of the interference. This still applies even if the interference lies within the values specified in NE 21. The reason for this is that in an unscreened system such noise signals are not diverted to ground. Noise consequently finds its way into the equipment. Examples of noise sources include

• mains cables laid in the same conduit as signal cables,

• frequency converters without sinusoidal filters,

• similar noise sources (non NE 21-compliant equipment).

Use screened cable in these cases.

Removing interference

If you cannot achieve a noise-free system by modernizing an installation, the following measures may help improve performance.

1. Fit filters in power supply lines.

2. Install transient suppression filters in signal lines.

3. Convert to DC isolated circuits.

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3.14 System expansion

To allow for a future need to install additional remote I/O stations during operation, attach empty stations at likely points on the bus, back at the installation stage. Additional remote I/O stations can then be connected at these points at a later date.

If the process control system has HCIR capability (can be configured online), you can add I/O modules to existing remote I/O stations during operation. If the process control system cannot be configured online (no HCIR capability), make suitable provisions at the initial installation stage by configuring spare slots or using suitable HCIR-compatible com units (e.g. UniCom 8x09).

To extend the bus during operation you need to remove the bus termination. In this case, correct operation can only continue reliably using redundant stations or in stations located after a repeater.

58

LB REMOTE I/O SYSTEMLB 9035 Backplane (Foundation Fieldbus Modular I/O)

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4 LB 9035 Backplane (Foundation Fieldbus Modular I/O)

The specifications in this chapter apply exclusively to the LB 9035 backplane.

The specifications in the remaining chapters (see list below) also apply to LB 9035 with limitations relating to redundancy and compatible I/O modules:

• Safety, see chapter 1

• Product specifications, see chapter 2

• Installation, see chapter 3

• Operation, see chapter 6

• Fault rectification, see chapter 8

• Technical data, see chapter 9.

Figure 4.1: LB 9035 Foundation Fieldbus backplane

The LB 9035 backplane is used to establish a connection to a Foundation fieldbus in combination with the LB 8110 comunit.

• Extensions: The backplane cannot be extended.

• Redundancy: The backplane is not suitable for com unit or power supply redundancy (only 1 com unit slot and 1 power supply slot).

• I/O module slots: 5 slots for dual-width multichannel I/O modules; not compatible with single-width I/O modules.

4.1 Connectors

The LB 9035 backplane is optimized for connecting to the Foundation fieldbus. All connectors are located on the left-hand side. Unlike the other LB backplanes, terminals are used for the bus connection to the Foundation fieldbus rather than a SUB-D connector. The service bus is connected via a SUB-D connector.

The 0 V lines from the X1, X3, and X40 connectors are connected together internally.

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Figure 4.2: Connectors on LB 9035 backplane

Terminal assignment for supply connector X1



• X1.3 = ground

Terminal assignment for X3 connector/S1 switch settings and bus termination

The switch S1 on the LB 9035 backplane controls not only the output shutdown but also disables/enables the bus termination. For the terminal assignment of the connector X3 and switch settings for the switch S1, please read the following section (see chapter 4.2).

Terminal assignment for bus connector X4

• X4.1 = - FF H1

• X4.2 = shield

• X4.3 = + FF H1

1 X4: primary-bus connector; this bus connector connects the comunit to the primary bus

(double terminals for incoming and outgoing bus)

2 X6: service-bus connector; this bus connector connects the comunit to the service bus

(SUB-D connector)

3 X40: 24 V DC booster; additional supply connector for the 4-channel digital outputs

LB 6110 to LB 6115.

4 S1: Function switch (see chapter 4.2.1)

5 X3: Connector used to control certain I/O modules with output shut down function (see

chapter 4.2.1)

6 X1: Connector for 24 V supply

2

1

3

4

6

5

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• Pin 2:





• Pin 7:




The service bus connector can be connected to a PC or laptop via a USB adapter (see Figure 4.4 on page 62).

Terminal assignment for the 24 V DC booster connector X40

The same supply voltage that is used for the X1 connector can be used for the X40 supply connector. A separate power supply can also be used.



• X40.3 = ground

Connecting the SUB-D service bus connector X6 to a PC or laptop

P+F recommends using a USB adapter to connect the service bus connector X6 to a PC or laptop (see Figure 4.4 on page 62).

1. Insert the USB adapter into the SUB-D connector on the LB 9035 backplane (see Figure 4.3 on page 61).

Figure 4.3: Connection of the USB converter

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2. Install the driver software for the USB adapter on the computer. The software is included with the USB adapter (see Accessories).

3. Then insert the USB adapter into the USB port of the computer.

4. Follow the instructions in the installation program.

Figure 4.4: USB-RS485 adapter from ICP CON

4.2 Output shutdown

4.2.1 Switch S1 and connector X3

On Foundation fieldbus backplane LB 9035, an external switch can be used to disable the outputs on certain I/O modules independently of the bus. For more information on the output shutdown, please refer to the operating manuals for the relevant I/O module (e.g. LB 4x02, LB 4x05, LB 6x08) and the com unit used.

Switch settings for switch S1 (output shutdown and bus termination)

• Switch S1 setting 1 to 2 ON (factory setting): outputs always enabled.

• Switch S1 setting 1 to 2 OFF: external voltage enables outputs.

• Switch S1 setting 1 =ON, setting 2 = OFF: all I/O modules with output shutdown are disabled via external floating contact.

• Switch S1 setting 4 =ON: bus termination enabled.

Caution!Damage to backplane

The backplane may be damaged if you do not follow the instructions below.

• Never apply a control voltage to X3.2 when switch S1 is closed.

• Always operate a group of connected backplanes from a common control voltage or a common contact to avoid equalizing currents (see figure below, point 1)!

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Terminal assignment for control input X3 (controls all slots)

• X3.1 = 0 V; control terminal for all I/O modules with output shutdown.

• X3.2 = +DC 12 V or 24 V; control voltage, galvanically isolated from supply (see Figure 3.6 on page 34, point 1); control current = n x voltage / 5.6 K (where n = number of I/O modules with output shutdown).

• X3.1 to X3.3 for external floating contact (contact galvanically isolated from other contacts on other backplanes (see Figure 3.6 on page 34, point 2). The status information on the external contact can be read via the LB 1x08 I/O module.

Figure 4.5: Connector X3

4.2.2 Combining I/O modules that do, and do not, have the output shutdown

I/O modules with output shutdown can be combined with I/O modules without the output shutdown in the same Remote I/O station. I/O modules without an output shutdown are continuously controlled by the fieldbus controller irrespective of the position of the external output-disable contact. I/O modules with an output shutdown are only controlled via the fieldbus when the output-disable contact is closed.

1 Voltage control for 1 remote I/O station

2 Control for 2 backplanes without external voltage

3 Base and extension backplane, controlled in common (without external voltage)

X 3.1 3.2 3.3 X 3.1 3.2 3.3

+–+– +–

X 3.1 3.2 3.3 X 3.1 3.2 3.3 X 3.1 3.2 3.3 X 3.1 3.2 3.3

1 2 3

Caution!Observe standards and regulations

Always comply with the relevant standards and regulations in safety-critical applications! See also EN 61508.

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4.3 Power supply redundancy

Note!

LB 9026 instead of LB 9035 for Foundation Fieldbus

The LB 9035 Foundation Fieldbus backplane has just one power supply slot. If you need a backplane that can be connected to a Foundation Fieldbus and can accommodate an additional redundant power supply, use the LB 9026 backplane instead of the LB 9035.

The LB 9035 is connected to the bus by screw terminals, whereas the LB 9026 is connected to the bus via a SUB-D connector. This means that a SUB-D adapter is needed to connect the LB 9026 to the Foundation Fieldbus (see Figure 4.6 on page 64).

If you connect the LB 9026 to a Foundation Fieldbus, you can insert a maximum of five dual-width I/O modules in the first five dual slots. The remaining I/O module slots must be left empty. Do not use any single-width modules. Do not connect an extension backplane.

Figure 4.6: SUB-D adapter

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5 Commissioning

5.1 Testing data transfer over the bus

5.1.1 Bus – electrical test of connections

The bus must have exactly 2 bus terminations per segment, one at the start and one at the end. A segment usually starts at the master, while the last Remote I/O station is the end of the segment. All Remote I/O stations on the bus are slaves.

Example(see Figure 5.1 on page 65): one line with 1 master, 4 slaves, one fiber optic link, 1 repeater (R), 3 segments, and 6 bus terminations (T): Master (T) – Slave (T) – OLM – fiber optic link – OLM (T) – Slave – (T) Repeater (T) – Slave – (T) Slave.

Figure 5.1: Example: bus segments with bus termination

Note!

Please refer to the relevant literature to obtain more detailed information.

Note!

A new copper segment also starts or ends at a repeater or OLM (Optical Link Module = fiber optic link)

T = bus termination

OLM = optical link module

R = repeater

T OLMMaster T

OLM

Slave

T

Slave

TRT

T Slave

Slave

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Testing the physical connection to the end of the segment

1. Remove the bus connector from the master (see Figure 5.2 on page 67).

2. Disable the bus termination on the bus connector (beginning of the bus).

3. Measure the voltage across A (pin 3) and B (pin 8) on the bus connector.

There should be a voltage of U = 220 / (220 + 2 * 390 ) * 5 V = 1.1 V across A and B. This voltage exists because of the bus termination at the field end.If a voltage of 1.1 V is not present, then one of these situations may be present: there is no bus termination connected at the end of the bus, the cable is faulty, or there is no termination voltage applied to the Remote I/O station.

4. Measure the current between A (pin 3) and B (pin 8) on the bus connector.

The current between A and B should measure I = 5 V / (2 * 390 ) ~ 6.4 mA. If the current is noticeably higher (by a factor of 2 or more), the bus is terminated with more than one termination. If the current equals ~0 mA, then one of these situations may exist: no bus termination is connected, the cable is faulty, or the termination voltage is not present. In this case, the resistance between A and B should measure 220 . If measurements show no current and no resistance, then either the termination at the end of the bus is missing or the cable is faulty.

5. Enable the bus termination on the bus connector of the master.

6. Plug the bus connector back into the master.

Tip

Perform all measurements from the control room!

If you do not have a multimeter available, hold an LED across B (+) (pin 8 on the bus connector) and A (-) (pin 3 on the bus connector). It should light up.

Danger!Risk of explosion

Measurements at the terminals of the Remote I/O stations are only permitted when there is no risk of explosion.

In Zone 2, during normal operation and servicing, it is generally unlikely that an explosion risk will exist while the measurements are made.

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Testing the physical connection to the Remote I/O station

1. Remove the bus connector from the master (see Figure 5.2 on page 67).

2. Disable the bus termination at the bus connector (beginning of the bus).

3. Measure the voltage across A and B at the bus connection to each Remote I/O station.

A voltage of U = 1.1 V should be present across A and B at every Remote I/O station.

4. Enable the bus termination on the bus connector of the master again.

5. Plug the bus connector back into the master.

Figure 5.2: Bus connector with built-in switchable bus termination

5.2 Configuration

The remote I/O system is configured using the configuration software. Please refer to the relevant com unit software manual.

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LB REMOTE I/O SYSTEMOperation

6 Operation

6.1 Availability and monitoring functions

6.1.1 Individual availability

Reliability is a major factor in industrial plant alongside explosion protection. Equipment should run smoothly, because any faults or breakdowns can result in huge costs. This means that I/O modules are expected to provide high availability and redundancy. In bus systems this means that the fieldbus stations used will contain redundant com units and redundant bus lines.

In addition, P+F provides single-channel I/O modules, which guarantee high availability by providing galvanic isolation of each signal circuit individually. This means that there is no need to worry that failure of one circuit will have repercussions for other measurement circuits. Also, when an I/O module is replaced, only its circuit is affected. Since a fault in one circuit has no impact on adjacent, possibly critical circuits, these circuits do not need to be incorporated in the fault strategy. The I/O modules offering individual availability, which are so useful in these applications, occupy more space per channel than multichannel I/O modules (see Figure 6.1 on page 68).

Figure 6.1: Comparison of single-channel and multichannel I/O modules

1 single-channel, high availability

2 multichannel, compact

1 8

Bus

1 8

Bus

1 2

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6.1.2 Multichannel capability

P+F is the first supplier to combine high-availability, single-channel I/O modules with multichannel I/O modules in one bus station. The com unit is able to automatically detect which modules are installed where, thereby simplifying design and commissioning.

Dual-width multichannel I/O modules have shared galvanic isolation and achieve a high packing density by sharing the use of certain circuits (see Figure 6.1 on page 68). Remote I/O stations fitted with multichannel modules can therefore almost double the number of signals per Remote I/O station compared with the high-availability, single-channel I/O modules. This is a particularly common requirement for digital circuits. Retrieving switch settings and controlling valves are among the most common signal processing functions in large engineering plants. Multichannel digital circuits are therefore particularly popular. A range of I/O modules are available here, which are designed for

• NAMUR signals,

• optocouplers,

• switches,

• active 5 V TTL levels and

• 24 V DC signals.

Intrinsically safe solenoid valves or flameproof valves can be operated on the output side.

4-channel analog inputs and outputs as well as 4-channel Pt100 and thermocouple inputs are also available.

All installations can be used both in hazardous areas within the relevant zone and outside of the Ex area. Even the eight-channel I/O modules are hot-pluggable, so that they can be fitted at any time during operation. Please observe the warning in section "Bus – electrical test of connections" (see chapter 5.1.1).

6.1.3 Self-monitoring

The I/O modules do not need redundancy because it is assumed, even in conventional technology, that one-channel to four-channel modules have high availability.

All I/O modules employ self-monitoring. Where technically feasible, field wires are monitored for open-circuits and short-circuits. If communication fails between an I/O module (output) and the com unit, the relevant output switches automatically to the safe "Off" state. The redundancy switchover time is set to give sufficient time for the redundant com unit to assume control. The failure criterion is faulty internal communication with the com unit or with both com units.

Manchester coding is used for internal data communication between the I/O modules and the com unit. If there are errors in the data from an I/O module, four attempts are made in consecutive read cycles to obtain correct information from the faulty I/O module. If all attempts fail, an error message is output. The selectors are designed to isolate faulty I/O modules from the internal bus in order to prevent faults in adjacent circuits.

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6.1.4 Common alarm

The com unit produces a common alarm when one of the following fault conditions exists:

• line fault in an I/O module,

• activated module slot contains incorrect module or no module,

• faulty I/O module,

• four successive communications errors between the com unit and an I/O module,

• internal error in the control processor of the PROFIBUS interface.

Please refer to the relevant com unit software manual for details on the error codes.

6.1.5 Functional safety

Applications where safety is crucial (e.g., functional safety loops) can be implemented with the Remote I/O components by taking signals through separate channels. Details available on request. SIL analyses are available for many output modules. Basic principles and more detailed information on the topic of functional safety and SIL (Safety Integrity Levels) are included in the P+F SIL handbook.

6.2 LEDs on the com units and I/O modules

Com unitsThe LEDs on the front of the com unit indicate bus activity on the transmit and receive lines, and help to locate faults. If no yellow LEDs are flashing when addressing a remote I/O station, the transmit line from the master is not connected (interface error in the master or cable fault). If communication cannot be established, the wrong station address may have been selected. Alternatively the bus termination may not be connected, or stubs have been connected that are not permitted.

Please refer to the relevant com unit operating manual for the exact meaning of the LEDs on a particular com unit.

I/O modulesFront-panel LEDs indicate the status of the I/O module. A green LED is on when the auxiliary power supply to the module is working properly and the module fuse has not blown. Red LEDs indicate the line fault detection status of the field wires. All leads to and from temperature sensors, transducer supply circuits, digital inputs, valve outputs etc. are monitored for open-circuits and/or short-circuits. Yellow LEDs indicate the control state of the digital inputs and outputs.

Please refer to the relevant I/O module operating manual for the exact meaning of the LEDs on a particular I/O module.

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Figure 6.2: LEDs on the front of an LB com unit

6.3 Strain gage measurements

The I/O modules 5x02 and 4x01 can be interconnected for strain gage readings. Use the 4x01 analog output to produce a constant current, and the measurement input of the 5x02 temperature input to process the millivolt signal from the voltage generated across the bridge. The measured value is tranmitted to the PLC or process control system via the fieldbus. A constant current of 20 mA is suitable for supplying a 350 bridge. This produces a bridge voltage of 7 V. If the bridge sensitivity is 2 mV/V, then the full-load voltage is 14 mV.

Intrinsic safetyBefore connecting intrinsically safe circuits to these I/O modules, establish the loop proofing document/entity parameter check. You can find the relevant data in the EC type examination certificate.

AccuracyCombining the two I/O modules results in the following total accuracy: Current source 4X01 has an accuracy of 0.1% Millivolt amplifier 5X02 has an accuracy of 0.1% Total accuracy equals approx. 0.2%

Figure 6.3: Example: Strain gage bridge

1

2

3

4

5

6

7

LB

Bus5X02

4X01

+

–

2+

5 -

6 -

5++–

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6.4 Valve circuit and connection to an LED

The follow section applies solely to digital outputs 2xxx, 6x08, and 6x1x.

Figure 6.4: Examples of output signals

Valve circuitA range of I/O modules (digital outputs) are available for controlling over 100 common models of intrinsically safe solenoid valves from a choice of manufacturers, including SAMSON, HERION, SEITZ, BÜRKERT, TELEKTRON, HONEYWELL, ASCO, and RGS. Perform a design analysis covering both instrumentation and safety issues when connecting the valve control module to the solenoid valve of one of the listed manufacturers.

Examples of possible device combinations can be found on the internet.

Connecting an LED indicator lamp LED indicators are mostly passive, intrinsically safe components as defined by IEC/EN 60079-14. These components do not require any special approval by authorized bodies if the intrinsic safety of the circuit is guaranteed. They are approved for connection to our digital outputs 2x04 and 2x13. The intrinsic safety data is specified in the certificates.

• The integral resistor in the indicator lamp limits the operating current to safe values.

• The data for the digital output can be used for the line length because the passive, intrinsically safe LED unit does not introduce any additional currents or voltages, or any inductances and capacitances into the circuit.

• The digital outputs 2x04 or 2x13 are suitable for the application.

Note:Digital outputs send a test pulse to check the line at one second intervals. This makes the dark LED flash briefly every second. This still happens even with line fault detection disabled. For this application, use the I/O module with the correct part number for no line fault detection. The test pulse is disabled in the factory for this module. I/O modules delivered from 2007 onwards have a test pulse that can be disabled in the configuration software. Special modules with a permanently disabled line fault detection function are then no longer required.Some solenoid valves draw a current > 50 mA, which is greater than the short-circuit current of the selected I/O module. This means that the supply voltage is disconnected by the short-circuit protection function. This can cause the valve to switch on and off continuously. Should this situation arise, select either a different solenoid valve or a different digital output.

1 Digital output with valve

2 Digital output with LED

RaUo

RaUo

1 2

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7 Maintenance

Regular maintenance is not necessary if the devices are operated properly and if the installation instructions and ambient conditions are observed.





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LB REMOTE I/O SYSTEMTroubleshooting

8 Troubleshooting

8.1 Service call

Before booking a service call, please check that the following actions have been taken:

• the customer has consulted the Service Center by phone to locate the problem,

• the customer has tested the installation against the checklists below,

• P + F Service staff have performed remote diagnosis using PC ANYWHERE.

8.2 Communications errors

If there is a communications error, work through the following checklist and take any relevant action.

Fault Action(s)

Errors in communication with the process control system or PLC

• Check that the cables are connected properly and not damaged.

• Check in the configuration software that the selected address matches the required station address.

• Check that the bus termination is enabled. The PROFIBUS must have exactly 2 bus terminations per segment, one at the start and one at the end.

• Check whether the bus stations have been connected to a branch in a star formation - this is not permitted. Choose a linear arrangement without branches

• Check that the master and slave have matching configuration strings. The slave address must be identical for master and slave on the fieldbus.

• Check that the correct GSD file is being used.

Communications error on the Service bus

• Check that the cables are connected properly and not damaged.

• Check in the configuration software that the selected address matches the required station address.

• Check that the bus termination is enabled. The Service bus must have exactly 2 bus terminations per segment, one at the start and one at the end.

• Check whether the bus stations have been connected to a branch in a star formation - this is not permitted. Choose a linear arrangement without branches.

• Check that the correct interface is set in the configuration software.

A new station will not work on a bus on which other stations are already working.

• Check whether the bus terminations are still located at the start and the end of the bus after the extension.

The software cannot find a com unit when establishing communication.

• Check that the yellow LEDs on the com unit come on when communication is being set up.

• Check that the bus address is in the chosen range. If necessary, enlarge the search range.

• Check that the com unit is plugged in correctly.

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8.3 Redundancy faults

If there is a redundancy fault, work through the following checklist and take any relevant action.

The com unit readout does not give the expected configuration.

• The required configuration has not been saved in the com unit. Select the "Write data to device" menu option to save the configuration in the com unit.

Communication error on the service bus after communication has been established

• Check that the Service bus is DC isolated.

• Use the laptop under battery power.

• Use a standard commercial RS232-RS485 interface converter with automatic detection of baud rate and transmission direction.

Data missing from station download

• Check that all the data was previously saved in the station.

No HART communication • Check whether the I/O module used supports the HART functionality.

• Make sure that the HART field devices are operating in the permitted range of 4 to 20 mA.

• Check that the correct address of the HART device has been used.

• Check that the HART software has a DTM for the field device used. If not, only HART basic functions are available.

Table 8.1: Communications error

Fault Action(s)

Fault Action(s)

Continuous switching between redundant systems

• Check that the correct type of redundancy is selected (line redundancy - application redundancy).

• Check that the switchover time been set to a sufficiently long period in the com unit.

• Check that the process control system is configured for this type of redundancy.

Does not switch to redundant system when a com unit is removed

• Check that redundancy has been configured at the com unit.

• Check that there is an electrical connection between the two com units. If not, connect them.

I/O modules are continuously changing the data

• Check whether one of the com units has not been configured for redundancy mode. If this is the case, both com units actively try to access the I/O modules and interfere with each other.

Table 8.2: Redundancy faults

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8.4 Faults indicated by LEDs

A number of LEDs on the com unit, the I/O modules and the power supply help to locate faults. If the LEDs indicate a fault, work through the following checklist and take any relevant action.

Incorrect error messages

An open-circuit in the output circuits may be indicated for certain loads, even though the I/O module is actually still working perfectly. For example this may happen sometimes with solenoid valves whose input impedance lies outside the lead breakage detection range. In this case, connect a large-value resistor in parallel with the output, which normally improves the situation.

With booster valves, the charging capacitor is often the culprit if the short-circuit detection activates. Connecting a small-value resistor in series usually rectifies the problem. If necessary, disable the line fault detection function.

LEDs on the com unit

Fault Action(s)

Red LED on com unit is on. There is a problem with an I/O module in one of the slots.

• Scan all slots for I/O modules displaying flashing red LEDs. All red LEDs must be off, otherwise the com unit will continue to indicate a fault.

Yellow LED on the com unit is flashing without the bus being connected.

• The com unit is operational and working with the I/O modules.

Yellow LED on the com unit is flashing at long intervals.

• The com unit is operational and working with the I/O modules. At least one I/O module is in simulation mode (manual operation).

Yellow LED on com unit is on.

• Check that a bus termination is being used and is enabled. The PROFIBUS must have exactly 2 bus terminations per segment, one at the start and one at the end.

Green LED on com unit is flashing.

• The com unit is active. As soon as this com unit is switched off in a redundant system, there will be a redundancy switchover.

• If possible, only remove the com unit whose green LED is permanently on.

Main bus

Yellow LEDs on com units do not flash while communication is being established.

• Check that the configuration cable and the adapter are connected properly.

Service bus

Yellow LEDs on com units do not flash while communication is being established on the service bus.

• Check that the configuration cable and the adapter are connected properly.

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LEDs on I/O modules and power supplies

Fault Action(s)

Red LED on an I/O module illuminated

• Check that the field wiring is connected correctly.

• Check that the sensor is working properly.

• Check that the field devices are working properly.

Red LED on an I/O module is flashing.

I/O module cannot communicate with the com unit.

• Check that the I/O module is plugged into the backplane properly.

• Make sure that none of the pins are bent in the connector.

• Plug a different I/O module into this slot. If the new module also does not work (red LED flashing), the fault may lie with the backplane.

Yellow LEDs on I/O modules illuminated.

• For digital inputs, the yellow LEDs provide various status indicators.

• For transmitter supply modules, the yellow LED indicates that operation is outside the normal range.

Green LEDs on all modules are off.

• Check that the supply is connected to the backplane correctly.

• Check that the power supply is working and is plugged into the backplane properly.

Green LED on one module is off.

• Check that the module is plugged into the backplane properly.

• If necessary, replace the module.

• If this does not rectify the problem, check that the backplane is working correctly.

Green LED on power supply is off.

• Check that the correct voltage is connected to the power supply unit.

• Check that the power supply is plugged into the backplane correctly and that it is making contact with the backplane.

• Check the supply voltage. Under maximum load, the 24 V DC voltage must not drop below 20 V including any ripple. If necessary, use an oscilloscope (fire permit may be needed).

• The fuse may have blown. For reasons of explosion protection, the fuses for I/O modules may only be changed by qualified personnel. Replace fuses with fuses of the same value.

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8.5 Signal fault

If there is a signal fault, work through the following checklist and take any relevant action.

Disabled I/O modules

Disabled I/O modules are often used for future expansions. Before disabling the I/O module, switch off its line fault detection function. This stops the I/O module from triggering an alarm every time the com unit polls the slot to see if an I/O module is installed.

Error Action(s)

The signal is not modified if the parameters are changed.

• Check that the I/O module is working.

• Check that the change has been saved in the slave station.

• Download the parameter settings to find out the latest parameters for the I/O module.

• Applies only to PROFIBUS Com Unit: Check whether HCiR is active. If so, then the new setting will not become active until the master has switched over to HCiR.

Erroneous signal • Check the circuit in case there is a short circuit or line break.

• Check that the field devices and sensors are working properly.

• Replace the I/O module.

• Check the bus signal path to the I/O module.

All the signals for a station are erroneous.

• Check that the power supply is working perfectly.

• Check the bus connection.

• Check the bus communication.

• Use a bus monitor.

Output module switches to substitute values.

• Check the watchdog time for monitoring the bus on the Com Unit. The watchdog time must be longer than the duration of a bus cycle.

One output module switches off.

Communication with the Com Unit is interrupted.


• If necessary, switch off the status bits for analog outputs.

Input module intermittently stops supplying measured values.

Communication with the Com Unit is interrupted.


I/O module works perfectly in one slot but not in another slot.

• Check that the connector in the faulty slot is OK and that the pins are not bent.

• If necessary, stop using that slot.

Measured values are sometimes wrong.

• Check whether the measured value can become corrupted by external interference.

• Check that the shielding is intact.

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Signal does not change. • Check whether simulation mode is enabled for the channel (does not apply to Com Unit 8x06) The signal is frozen in simulation mode.

• Check that the substitute value is active as there is no bus communication.

• Check for a line fault.

Module is not outputting any diagnostic messages.

• Check that line monitoring is enabled. If not, enable line monitoring.

• Check that the expected diagnostic information has been activated in the Com Unit (PROFIBUS: additional module diagnostics).

No input/output data • Check that the right I/O module is connected and ready for operation.

• Check that the scaling of the analog input/output corresponds to system requirements.

• Check that the wiring is in order.

I/O module is reported as not found.

• Check that the right I/O module has been connected.

• Check that the green LED on the I/O module is illuminated and that the I/O module is connected correctly.

Module fault • Check whether the green LED on the I/O module is illuminated. If not, either there is no contact with the backplane or the fuse is faulty. If all the I/O modules in a segment have failed, then the fault will be in either the power supply or the backplane.

• With the help of the measured value display for the I/O module concerned, check the diagnostic information for the I/O module (e.g., no module or wrong module, line fault, etc.)

Table 8.3: Signal fault

Fault Action(s)

6/8 LB modules fail simultaneously (LB 9121, LB 9101 backplane system).

• Check that the power supply for the segment is working correctly.

Table 8.4: Signal fault

Error Action(s)

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8.6 Faults and their effects

The table below shows what effect different faults will have.

Fault Diagnostics Effect

Power supply failure (redundant station)

• The master receives an error message in the global status register, provided this facility has been pre-configured (LB9022 and LB9024 backplanes only).

• Backplanes LB 9022, LB 9024 and LB 9029: 2-out-of-3 redundancy when using three LB9006 power supplies means full functionality is maintained even when a power supply fails.

• Backplanes LB 9121 and LB 9101: when using two LB9104 power supplies, 8 modules fail immediately if a power supply fails. The com units continue to be supplied from the working power supply, however, and communication is maintained.

Power supply failure (non-redundant station)

• The master receives 8 error messages in the global and module status register, provided this facility has been pre-configured.

• The master receives 8 module-specific and channel-specific error messages if module diagnostics have been enabled.

• Backplanes LB 9022, LB 9024 and LB 9029: in non-redundant use, normally just two power supplies are used. This means that if one power supply fails, the whole station may be adversely affected (depending on the number of modules used).

• Backplanes LB 9121 and LB 9101: when using two LB9104 power supplies, 8 modules fail immediately if a power supply fails. The com unit continues to be supplied from the working power supply, however, and communication is maintained.

Table 8.5: Faults and their effects


Bus communication failure • The master detects the failure.

• The outputs assume substitute values, provided this option has been programmed.

Com unit failure or voltage lost

• The master detects the faulty slave.

• No voltage at the outputs, unless system has redundant design.

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I/O module failure • The master receives an error message in the global and module status register, provided this function has been programmed.

• The master receives the message "module error" if module diagnostics have been enabled.

• No change in signal; the inputs assume substitute values, provided this option has been programmed.

• No voltage at the output.

• Usually the green LED is off. There are situations, however, where the green LED is still on despite a fault.

Incorrect I/O module • The master receives an error message in the global and module status register, provided this function has been programmed.

• The master receives the message "incorrect module" if module diagnostics have been enabled.


• No voltage at the output

• The red LED in the dual-width module flashes.

I/O module missing or removed.

• The master receives an error message in the global and module status register, provided this function has been programmed.

• The master receives the message "missing module" if module diagnostics have been enabled.

• The input is frozen.


module-specific faults

Line fault in input module • The master receives an error message in the global and module status register, provided this function has been programmed.

• The master receives an error message "data invalid" if module diagnostics have been enabled

• The red LED is on.


• Temperature inputs do not return to working normally until the fault has been rectified and the broken-wire delay has elapsed.

Input signal lies out of range for 3x01, 3x02, 3x03, 3x04, 3x05 analog input



• The yellow LED is on.

• The signal is kept within preset limits


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Line fault in output modules 2xxx, 4x01, 4x02, 6x08



• The red LED is on.


Table 8.6: Faults and their effects


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9 Technical specifications

9.1 Technical data LB backplanes

Electrical data

• Power supply: DC 24 V, Um = 60 V AC/DC

If other supply voltages are used, a suitable power supply unit for converting the given voltage to DC 24V must be employed. The maximum permissible supply voltage for this front-end power supply unit is AC 253 V.

• Bus connection: DC 5.4 V, Um = 30 V AC/DC

Mechanical data

• Weight: LB 9022 and LB 9024, approx. 1050 g eachLB 9101 approx. 350gLB 9023 ... LB 9025, 650g each LB 9026, LB 9027, LB 9029 approx. 850g each

• Dimensions: see chapter 2.2

Ambient conditions

• operating temperature: -20 °C ... +70 °Cfor explosion protection, max. operating temperature +60 °C

• storage temperature: -40 °C ... +80 °C

• relative air humidity (no condensation): max 95%, < 75% as yearly average

Warning!Voltage too high

Ensure that the supply voltage of the power supplies used in Zone 2 does not exceed DC 33.6 V ( 24 V x 1.4) even temporarily during a fault.

Subject to modificationsCopyright PEPPERL+FUCHS • Printed in Germany

www.pepperl-fuchs.com

Worldwide Headquarters

Pepperl+Fuchs GmbH68307 Mannheim · GermanyTel. +49 621 776-0E-mail: [email protected]

For the Pepperl+Fuchs representative closest to you check www.pepperl-fuchs.com/pfcontact

PROCESS AUTOMATION – PROTECTING YOUR PROCESS

536857 / TDOCT-1130GENG04/2011

Documents

Lb5004 Rtd Module