Pepperl+Fuchs FB Remote I/O User manual

FB Remote I/O
Hardware
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 lectrical Indus-
try, published by the Central Association of the lectrical Industry (Zentralverband
lektrotechnik und lektroindustrie (ZV I) e.V.) in its most recent version as well as the
supplementary clause: " xpanded reservation of proprietorship"
FB Remote I/O

FB Remote I/O
3
1 Introduction 5
1 1 Content of this Document 5
1 2 Target Group, Personnel 5
1 3 Symbols Used 6
2 Product Specifications 7
2 1 Prerequisites for Operating the FB Remote I/O Unit 7
2 2 Introduction 7
2 3 System Components 8
2 4 Field Units (Surrounding Enclosures) 9
2 5 Backplanes 11
2 5 1 Function........................................................................................... 11
2 5 2 Design and Dimensions................................................................... 12
2 5 3 Backplane and Module Compatibility............................................... 15
2 6 I/O Modules, Com Units, Bus Termination Modules,
Power Supplies 16
2 6 1 Layout .............................................................................................. 16
2 6 2 Function........................................................................................... 17
2 6 3 Design and Dimensions of the Modules........................................... 20
2 7 Accessories 21
2 7 1 Field Wiring...................................................................................... 21
2 7 2 Cordsets .......................................................................................... 26
2 7 3 FB Removal Tool for x-d Modules.................................................. 27
3 Installation 28
3 1 Field Unit (Surrounding Enclosure) 28
3 2 Backplanes 29
3 3 Connections for FB9262BP* 30
3 4 Maximum Number of I/O Modules 32
3 5 Inserting and Removing Modules 33
3 6 Field Wiring 41
3 6 1 I/O Modules with Front Socket ......................................................... 43
3 6 2 I/O Modules with Cable Tail.............................................................. 46

4
FB Remote I/O
3 7 Coding 48
3 8 Line Fault Detection 49
3 9 Cold Junctions in Thermocouples 49
3 10 Line Resistance in Resistance Thermometers 50
3 11 Strain Gage Measurement 51
3 12 Status Monitoring of the Output Shutdown 52
3 13 Redundancy in PROFIBUS Communication 52
3 13 1 Basic Principles................................................................................ 52
3 13 2 Media Redundancy .......................................................................... 53
3 13 3 Application Redundancy .................................................................. 53
3 14 Fieldbus Connection 54
3 14 1 RS-485-Based Fieldbuses ............................................................... 54
3 14 2 thernet-Based Fieldbuses ..............................................................56
3 14 3 Cable Gland for Prefabricated Cables to thernet Gateways ............58
3 15 Potential Equalization and Shielding 60
3 15 1 Sources of Noise.............................................................................. 60
3 15 2 Wiring............................................................................................... 61
3 16 System Expansion 62
4 Commissioning 63
4 1 Electrical Testing of Connections 63
4 2 Configuration of an RS-485-Based Bus System 64
4 3 Startup Phase 64
5 Operation 65
6 Troubleshooting 66

FB Remote I/O
Introduction
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1 Introduction
1.1 Content of this Document
This document contains information required to use the finished device or system in the
relevant phases of the product life cycle. This may include information on the following:
■ Product identification
■ Delivery, transport, and storage
■ Mounting and installation
■ Commissioning and operation
■ Maintenance and repair
■ Troubleshooting
■ Dismounting
■ Disposal
The documentation comprises the following parts:
■ This hardware manual
■ Software manual for the com units in use
■ Instruction manuals for the components in use
■ Datasheets for the components in use
In addition, the documentation may comprise the following parts, if applicable:
■ C-type-examination certificate
■ U declaration of conformity
■ Attestation of conformity
■ Certificates
■ Control drawings
■ Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation,
commissioning, operation, maintenance, and dismounting of the product. The personnel must
have read and understood the instruction manual and the further documentation.
nsure that you are familiar with the system and its components before use. Read the
documentation carefully.
Note!
This document does not replace the instruction manuals for the components in use.
The safety information for the components in use determines the specific safety instructions
that apply to the system. The instruction manuals for the components in use must have been
read and understood.
Note!
For complete information about the components in use, refer to the instruction manuals and
additional documentation available online at www.pepperl-fuchs.com.

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FB Remote I/O
Introduction
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
Warning Messages
You will find warning messages, whenever dangers may arise from your actions. It is mandatory
that you observe these warning messages for your personal safety and in order to avoid
property damage.
Depending on the risk level, the warning messages are displayed in descending order as
follows:
Informative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Note!
This symbol brings important information to your attention.

FB Remote I/O
Product Specifications
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2 Product Specifications
2.1 Prerequisites for Operating the FB Remote I/O Unit
2.2 Introduction
Remote I/O systems, consisting of I/O modules, gateways, bus termination modules, power
supplies, and a backplane, form the interface for signals to be transmitted from the explosion-
hazardous area ( x area), to the safe area (non-hazardous area). With appropriate surrounding
enclosures, remote I/O systems can be installed in Gas- x areas of Zone 1. Using remote I/O, a
wide range of digital and analog sensors and actuators can be connected to process control
systems over a fieldbus. Specific measures need to be taken to disconnect I/O modules with
x-e front connectors during ongoing operation. To do so, observe the safety notices in this
manual. The gateway is the interface between the I/O modules on the backplane and the
process control system. Power supplies are used to power the I/O modules and com
unit/gateway.
All components of the FB remote I/O with x-q protection meet the FB concept. This simplifies
the evaluation of modules from an explosion protection point of view.
This manual sets out how to work with the hardware. Refer to the software manual for the
gateway and the I/O modules for information on the configuration of the gateway and the I/O
modules.
Note!
Requirements for equipment protection level Gb
Components of the FB remote I/O system may be installed and operated in Zone 1 only if they
are installed in a surrounding enclosure that complies with equipment protection level Gb.
Note!
Certification required
Before commissioning, the components of the FB remote I/O must be certified by an
appropriate certification body together with the surrounding enclosure. nclosures from
Pepperl+Fuchs are supplied fully certified and with complete documentation so that they can
be easily installed straight away.

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FB Remote I/O
Product Specifications
2.3 System Components
System Overview
Figure 2.1 FB remote I/O system components
1Field Unit (Surrounding nclosure)
2Power supply
3Bus termination module
4Com unit
5I/O module
6Backplane
7Cable gland for field lines
8Cable gland for power supply and bus cables
9x-e-terminals and IP30 cover
123 4 5
678
9

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Product Specifications
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2.4 Field Units (Surrounding nclosures)
Field units serve to protect all electronic components against environmental influences and are
an integral part of explosion protection. The enclosures are made of glass fiber reinforced
polyester or stainless steel and are available in various versions. The surrounding enclosures
contain backplanes for the connection of modules. The modular concept allows multiple
surrounding enclosures to be flanged together to create the required expansion level. ach
surrounding enclosure contains x-e terminals for power and communication lines. For safety,
these are individually equipped with protective covers (IP30) and touch protection.
The surrounding enclosures are equipped with a rating plate listing all safety-relevant
information, e.g., type of ignition protection, temperature class, permissible ambient
temperature and permissible power.
Plastic enclosure
Figure 2.2 Field unit with plastic enclosure partially without cover and modules
Glass fiber reinforced polyester offers a high level of mechanical protection for both onshore
and offshore plants.
Stainless steel enclosure
Figure 2.3 Field unit with stainless steel enclosure without modules
The stainless steel enclosure ensures a high level of corrosion resistance for onshore and
offshore plants.

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FB Remote I/O
Product Specifications
Modular plastic and stainless steel enclosures are available in various sizes and designs, and
custom solutions are also available. Depending on the version, the device units comprise base,
redundancy, and expansion backplanes installed in the corresponding surrounding enclosures.
We also offer custom solutions for our customers. xperienced project engineers from our
Solution ngineering Center (S C) will assist you with designing your ideal FB remote I/O.
More information can be found at www.pepperl-fuchs.com.
Order designation
Type
Max. number of slots
Material
Field unit Redundant field unit Stainless steel Polyester
FB9210-PB0-0-0-0-0-0 X 10 X
FB9210-PB0-0-0-0-0-F X 5 X
FB9210-S50-0-0-0-0-0 X 10 X
FB9211-PB0-0-0-0-0-0 X X
FB9224-PG0-0-0-0-0-0 X 24 X
FB9224-PH0-0-0-0-0-0 X 24 X
FB9224-S60-0-0-0-0-0 X 24 X
FB9225-PG0-0-0-0-0-0 X 24 X
FB9225-PH0-0-0-0-0-0 X 24 X
FB9225-S70-0-0-0-0-0 X 24 X
FB9248-PG0-0-0-0-0-0 X 48 X
FB9248-PH0-0-0-0-0-0 X 48 X
FB9248-S70-0-0-0-0-0 X 48 X
FB9249-PG0-0-0-0-0-0 X 48 X
FB9249-PH0-0-0-0-0-0 X 48 X
FB9249-S80-0-0-0-0-0 X 48 X

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Product Specifications
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2.5 Backplanes
2.5.1 Function
The modules are plugged into the backplane, which in turn is installed in a plastic or stainless
steel enclosure. The backplane supplies the modules with energy and provides internal wiring.
Any I/O module can be inserted into any I/O slot, enabling a mixture of I/O functions in one field
unit. Power supplies, com units/gateways, and bus termination modules are installed in their
reserved slots. These are mechanically coded to avoid confusion.
Overview of backplanes
Backplane combination options
Type FB9262BP* backplanes can be used together as base and extension backplanes in the
following combinations:
Warning!
Risk of death as a result of using a damaged or tampered backplane.
Using a defective or tampered backplane means that explosion protection can no longer be
guaranteed.
n Do not use a damaged backplane.
n The backplane must not be tampered with.
n In the event of a fault, the backplane must always be replaced with an original backplane
from Pepperl+Fuchs.
Order designation Info
FB9262BP10220.1 n Universal backplane
n 10 slots
n Redundant: com unit and power supply
FB9262BP20220.1 n Universal backplane
n 20 slots
n Redundant: com unit and power supply
FB9262BP24110.1 n Base backplane
n 24 slots
FB9262BP24200.1 n xtension backplane
n 24 slots
xtension
FB9262BP10220.1 FB9262BP20220.1 FB9262BP24110.1 FB9262BP24200.1
Base
FB9262BP10220.1 x x - -
FB9262BP20220.1 x x - -
FB9262BP24110.1 - - - x
FB9262BP24200.1 - - - -

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FB Remote I/O
Product Specifications
2.5.2 Design and Dimensions
Universal backplane
The following backplanes are operated as a base backplane and extension backplane.
Connect the two backplanes using the backplane cordset.
FB9262BP10220 1
n Redundant configuration with slots for 2 com units, 2 bus termination modules, 2 power
supplies
n Slots for max. 10 narrow or 5 wide I/O modules
n For PROFIBUS DP, MODBUS RTU, MODBUS TCP, thernet
Figure 2.4 FB9262BP10220.1 dimensions
1Power supply
2Bus termination module when used as a base backplane
mpty slot when used as an extension backplane
3Gateway when used as a base backplane
mpty slot when used as an extension backplane
4Slots for 10 narrow or 5 wide I/O modules
5Redundant power supply
6Bus termination module for redundant gateway, when used as base backplane
mpty slot when used as extension backplane
7Redundant com unit when used as a base backplane
mpty slot when used as an extension backplane
85
511
212
1 2 3
5 6 7
1 2 3 4 5 6 7 8 9 10
4

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Product Specifications
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FB9262BP20220 1
n Redundant configuration with slots for 2 gateways/com units, 2 bus termination modules,
2 power supplies
n Slots for max. 20 narrow or 10 wide I/O modules
n For PROFIBUS DP, MODBUS RTU, MODBUS TCP, thernet
Figure 2.5 FB9262BP20220.1 dimensions
1Power supply
2Bus termination module when used as a base backplane
mpty slot when used as an extension backplane
3Com unit when used as a base backplane
mpty slot when used as an extension backplane
4Slots for 20 narrow or 10 wide I/O modules
5Redundant power supply
6Bus termination module for redundant gateway/redundant com unit when used as a base
backplane
mpty slot when used as an extension backplane
7Redundant com unit when used as a base backplane
mpty slot when used as an extension backplane
511
212 85
1 2 3
5 6 7
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
4

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FB Remote I/O
Product Specifications
Base and extension backplane
The following backplanes are available in non-redundant design. The base backplane can be
expanded with the extension backplane. Connect both backplanes using the cordset.
FB9262BP24110 1
n Base backplane
n Non-redundant configuration with slots for 1 com unit, bus termination modules (see
chapter 2.6) and 1 power supply
n Slots for max. 24 narrow or 12 wide I/O modules
n For PROFIBUS DP, MODBUS RTU, MODBUS TCP, thernet
Figure 2.6 FB9262BP24110.1 dimensions
1Gateway
2Bus termination module
3Slots for 24 narrow or 12 wide I/O modules
4Power supply
511
212 85
1 2 3
4
1 2 3 4 5 6 7 8 9 10
13 14 15 16 17 18 19 20 21 22
11 12
23 24

FB Remote I/O
Product Specifications
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FB9262BP24200 1
n xtension backplane
n xpansion unit for base backplane for 2 power supplies and termination modules (see
chapter 2.6)
n Slots for max. 24 narrow or 12 wide I/O modules
n For PROFIBUS DP, MODBUS RTU, MODBUS TCP, thernet
Figure 2.7 FB9262BP24200.1 dimensions
2.5.3 Backplane and Module Compatibility
In principle, FB backplanes are compatible with all FB modules. Narrow I/O modules occupy
one slot, while wide I/O modules occupy two slots. However, please be aware of the following
restrictions.
1Power supply
2Slots for 24 narrow or 12 wide I/O modules
3Redundant power supply
511
212 85
1 2
3
1 2 3 4 5 6 7 8 9 10
13 14 15 16 17 18 19 20 21 22
11 12
23 24
Warning!
Use the FB9262BP* backplane with the following power supplies only:
FB9206D
FB9215B2

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FB Remote I/O
Product Specifications
2.6 I/O Modules, Com Units, Bus Termination Modules, Power Supplies
2.6.1 Layout
Figure 2.8 Layout shown through the example of an I/O module
Position Module Description
1 x-q modules
(left)
The integrated removal device allows you to quickly install and
safely replace modules during ongoing operation if the module has
intrinsically safe front connections or no front connections.
x-d modules
(right)
The module is removed by means of a removal tool. See chapter
"FB Removal Tool for x-d Modules".
2 Both modules The status of each channel is displayed using an L D. This gives
your technician clear information about the status of the field device
directly on the device itself. For more information about the status
L Ds, please refer to the respective datasheets for the modules.
3 Both modules The sockets on the discharge side of the module offer 1, 2, 4 and 8
channels to connect x field devices.
Using the single-channel modules for controlling valves, including
feedback, two additional binary input signals can be transmitted
from the field. The portfolio is supplemented with 2-channel
modules with shutdown input for emergency shutdown.
When modules are replaced, the new module automatically adopts
the settings of its predecessor. This prevents errors when replacing
modules.
x-q modules
(left)
The 4-channel universal module processes analog inputs and
outputs depending on the setting. ach of the four channels can be
configured independently of the others.
1
3
2
Note!
All new I/O modules ( x q) are fully compatible with the existing FB remote I/O and are
therefore ideally suited for a plant expansion. The backwards compatibility offers you the
opportunity to combine old modules ( x d) and new modules ( x q) on one backplane.
The I C x certification only applies when x-q modules are used exclusively. The addition of
an x-d module nullifies the I C x certification. The AT X certification remains in place.

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Product Specifications
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2.6.2 Function
I/O modules
I/O modules are used to modify signals between field devices in explosion-hazardous areas
and controllers or control systems in the safe area. The slots for the I/O modules on the
backplane are equal, so you can use I/O modules with different functions next to each other.
The various I/O modules can be plugged in.
Com unit
Com units form the interface between the I/O modules and the process control system. The
com unit converts the protocol of the bus integrated in the backplane to the protocol of the
higher-level bus system.
Another com unit variant is the gateway. This is described in more detail below.

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FB Remote I/O
Product Specifications
Gateway
The gateway ( x-q) can be operated directly via the touch screen on the front, meaning it can
be configured directly in the field. In addition, the device status is displayed using the four L Ds
below the touch screen.
The two thernet interfaces on the front connect the device to the thernet network.
Warning!
xplosion hazard in Zone 1
When pulling out an M12 connector in Zone 1, a spark may form that ignites an explosive
mixture.
n Do not pull out M12 connectors in potentially explosive atmospheres.
n Use only original Pepperl+Fuchs cables.
Warning!
Property damage due to incorrect terminal assignment
Incorrect terminal assignment and incorrectly positioned plug-in jumpers can cause damage to
the x-q gateway.
n nsure that the terminal assignment of the x-q gateway is correct. Please refer to the
information in the datasheet for the respective backplane. Terminals 39 and 40 must be
inserted when using the x-q gateway.
n nsure that the plug-in jumper is correctly positioned. Please refer to the information in
the datasheet for the respective backplane.

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Product Specifications
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Bus termination modules
Bus termination modules prevent the reflection of signals at the end of the bus line. A bus
termination module is required in each final unit of a bus line.
Power supplies
The power supplies provide power to all components of the FB remote I/O. The slots for com
units are mechanically coded on the backplane and marked accordingly.
Place-holder module
Placeholder modules keep non-wired field circuits in position.

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FB Remote I/O
Product Specifications
This module has no electrical connection.
2.6.3 Design and Dimensions of the Modules
The FB remote I/O system is designed in such a way that each I/O module can be connected to
the I/O slot it requires on the backplane. The slots on the backplane are limited. Depending on the
size, for example, a base backplane can accommodate max. 24 narrow or 12 wide I/O modules.
Power supplies, com units and bus termination modules are assigned to fixed slots. To avoid
confusion, these are mechanically coded. Com units and power supply units are always wide
modules. Bus termination modules are narrow modules.
Both the I/O modules and the com units and power supplies are equipped with L Ds on the
front that display the device status.
The I/O modules have connections on the front to which the relevant field devices are
connected. On the back of the I/O modules there is a coding pin that prevents an I/O module
from being accidentally inserted into a slot that is intended for a com unit or a power supply.
Figure 2.9 Narrow module dimensions
Figure 2.10 Wide module dimensions
Warning!
xplosion hazard as a result of removing coding pins!
Removing the coding pins means explosion protection can no longer be guaranteed.
Never remove the coding pins from the module.
Narrow modules
Wide modules
139,8
28,5
106,6
139,8
57,5
106,6