Emerson S-series Mass Connection Solutions

Emerson S-series Mass Connection Solutions

Core positioning and core advantages

The DeltaV S series large-scale connectivity solution is an efficient cabling system designed specifically for S series traditional I/O cards, enabling fast and reliable connections between field devices and DeltaV single redundant/redundant high-density I/O cards. Its core advantages can be summarized as seven key features:

Fast and error free cabinet wiring: Single redundant/redundant high-density I/O cards are connected to large-scale connection boards through ribbon cables, which can be completed within seconds without the need for tools, eliminating the need for additional cross wiring inside the cabinet and significantly reducing labor costs and wiring error risks.

Modular design enhances reliability: The connection board adopts modular signal splitting (up to 16 signals per block), which is more stable compared to traditional solutions, reduces the impact of single point failures on the overall system, and improves the reliability of the wiring system.

Reducing terminal footprint: Integrating all components required for cabinet wiring into a single connection board, combined with flexible installation methods (adapted to different cabinet layouts), significantly optimizes cabinet space utilization and reduces overall equipment footprint.

Significantly reduce manual workload: achieve flexible connection between I/O cards and connection boards based on 1:1 ribbon cables, without the need for additional cross wiring; On site equipment is directly connected to the connection board through screw terminals, simplifying the wiring process and shortening the construction period.

Significant cost reduction: Ready made ribbon cables (up to a maximum length of 3m) can be used inside the cabinet, and 6m standard circular ribbon cables can be used for cross cabinet connections, eliminating the need for customized special cables and reducing material costs; The reduction of labor and time costs further compresses overall investment.

Full signal type circuit disconnection function: The analog (AI/AO) connection board adopts a blade type disconnection design with 2mm test holes, which does not require interruption of the process when maintaining or calibrating 4-20mA circuit signals; The DI/DO connection board achieves on-site circuit power disconnection through replaceable fuses, facilitating maintenance operations.

Discrete signal terminal fault detection: When the DI/DO Plus connection board is paired with the new Plus I/O card, the DeltaV diagnostic function can detect power or cable faults; The onboard jumper supports disabling this function during process operation, facilitating rewiring and ensuring flexibility in troubleshooting and maintenance.

Core components and functional details of the product

（1） Core hardware components

Component Name Adaptation I/O Card Type Function Description Key Features

AI/AO Plus large-scale connection board S series Plus single redundant/redundant 16 channel AI/AO card connects 4-20mA HART field devices with 16 channels of I/O cards, supporting 2-wire/4-wire devices (3-row screw terminals, channel level optional); Circuit disconnection function with 2mm test holes per channel; Connect the I/O card through a 24 pin ribbon cable (≤ 3m) or a 48 pin special circular ribbon cable (>3m)

DI Large scale Connection Board (Single Redundancy) S Series Single Redundancy 32 Channel 24V DC Dry Contact DI Card Connection 24V DC Discrete Input Signal (Dry Contact/Isolation Signal) Each set includes 2 boards, each with 16 channels (2 rows of screw terminals); Yellow LED channel status indicator; Replaceable fuse (used to disconnect the on-site power supply during maintenance); Connect the I/O card through a 20 pin ribbon cable (≤ 3m) or a 20 pin standard circular ribbon cable (>3m)

DI Plus large-scale connection board (redundant) S series redundant 32 channel 24V DC dry contact DI Plus card connects 24V DC discrete input signals, supports fault detection. Each set includes 2 boards, each with 16 channels (2 rows of screw terminals); Equipped with all the features of DI large-scale connection board, and additionally integrated terminal fault detection function (detecting power/cable faults); Onboard jumper can disable fault detection (used for wiring during operation); The I/O card resource manager view contains 2 fault detection parameters, and when enabled, the diagnostic system automatically marks abnormal signals

The DO Plus large-scale connection board S series single redundant/redundant 32 channel 24V DC high side DO card connects discrete output devices (24V DC high side relay output/no voltage relay contacts). Each set contains 4 boards, and every 2 daisy chain connections achieve 16 channels (screw terminals); Yellow LED channel status indicator; Replaceable fuses (disconnect power during maintenance); Integrated terminal fault detection function (with redundant DO Plus card); Onboard jumper can disable fault detection; Connect the I/O card through a 20 pin ribbon cable (≤ 3m) or a 20 pin standard circular ribbon cable (>3m)

All connection plates of circular ribbon cables (in cross cabinet scenarios) enable long-distance connection of 20 pins (discrete signal, 6m) and 48 pins (analog signal, 6m) across cabinets; Supports working temperature range of -20~70 ° C, wire specification of 0.14mm ² (26 AWG), compliant with ISA-S71.04-1985 G3 anti-corrosion standard

（2） Key functional characteristics

Signal adaptation and connection flexibility:

Analog Channel: Supports 4-20mA HART signals, and 2-wire/4-wire devices can independently select wiring methods according to channels to meet different on-site instrument requirements.

Discrete channel: DI supports 24V DC dry contacts and isolation signals, DO supports 24V DC high side output and no voltage contacts, fuse position can be switched by jumper to output types, suitable for various discrete devices.

Maintenance convenience:

Circuit disconnection: The blade type disconnection design of the AI/AO board can be directly connected to the testing equipment, and the replaceable fuse of the DI/DO board is convenient for cutting off the on-site power supply without interrupting the overall process.

Status indication: The yellow LED displays the real-time on/off status of discrete channels, which can quickly locate the problematic channel in case of a fault and simplify the troubleshooting process.

Fault detection and safety design:

The terminal fault detection function of DI/DO Plus board, combined with Plus I/O card, can monitor the power and cable status in real time. When abnormal, the diagnostic system automatically marks it, reducing the time for troubleshooting.

Onboard isolation design: DI board on-site wiring and I/O card circuit optical isolation (1000VDC test for 2 seconds), DO board relay contacts are isolated from the system (250V AC, 3600VDC test) to ensure system safety.

Hardware specifications and compatibility

（1） Universal environmental specifications (all connection boards)

Category parameter details

Working temperature -20~70 ° C (when the DO board is above 60 ° C, it needs to be downgraded to 3A/channel)

Storage temperature -40~85 ° C

Relative humidity 5%~95% (no condensation)

Pollutant level ISA-S71.04-1985 G3 level (with conformal coating)

Protection level IP20

Anti impact 10g half sine wave (continuous for 11ms)

Vibration 2~13.2Hz (1mm peak to peak), 13.2~150Hz (0.7g)

（2） Core component dimensions and electrical specifications

Component type size (length x width x height, mm) Key electrical parameters

AI/AO Plus board 118.06 × 109.78 × 60.52 channel type: 4-20mA HART; 16 channels

DI board 102.82 × 110.05 × 44.1 channel type: 24V DC dry contact/isolation; Conduct detection>2mA, shutdown detection<0.25mA; input impedance 5k Ω; on-site power supply 24V DC ± 10% (typical 75mA, maximum 100mA)

DO Plus board 133.3 × 109.75 × 60.52 channel type: 24V DC high side/relay contact; Output rated 5A/channel (250V AC/24V DC), board maximum 10A; on-site power supply 24V DC ± 10% (maximum 10A)

Round ribbon cable with a length of 6m and a wire specification of 0.14mm ² (26 AWG); 20 needles (50 threads/25 pairs), 48 needles (50 threads/25 pairs); Working temperature -20~70 ° C

（3） System compatibility

I/O card adaptation: Only supports DeltaV S series traditional I/O cards, including single redundant/redundant 32 channel DI/DO cards, 16 channel AI/AO Plus cards, which need to be ordered together with the connection board (refer to the "S Series Traditional I/O Product Manual" to confirm the model).

Software requirements: The fault detection function needs to be paired with the DeltaV diagnostic system, and the I/O card parameter configuration is completed in the DeltaV resource manager. There are no additional software version requirements (compatible with mainstream DeltaV versions).

Ordering information and spare parts

（1） Core Product Order List (Some Key Models)

Product Category Description Model Remarks

Connection board kit AI/AO Plus large-scale connection solution (1 board) - needs to be ordered as a set with the S series 16 channel AI/AO Plus card, refer to the I/O card PDS to confirm the complete model

DI Large scale Connection Solution (2 boards) - To be ordered as a complete set with S series single redundant 32 channel DI card

DI Plus Large scale Connection Solution (2 boards) - To be ordered as a complete set with S-series redundant 32 channel DI Plus card

DO Plus Large scale Connection Solution (4 boards) - To be ordered as a complete set with S series single redundant/redundant 32 channel DO cards

Circular ribbon cable 20 pin circular ribbon cable (6m, 2 pieces/set) SE4000L6P20 discrete signal cross cabinet connection, needs to be ordered separately

48 pin special circular ribbon cable (6m, 1 piece) SE4000L6P48 analog signal cross cabinet connection, needs to be ordered separately

（2） Spare parts information

Spare parts description, model, and remarks

AI/AO Plus connection board KJ4007X1-BD1 single block replacement

DI connection board KJ4007X1-BA1 single block replacement

DI Plus connection board KJ4007X1-BB1 single block replacement

DO Plus Connection Board KJ4007X1-BC1 Single Block Replacement

DI board main fuse (125V AC/1A, 10 pieces/box) KJ4007X1-DB1 compatible with DI/DI Plus board

DI board channel fuse (125V AC/160mA, 10 pieces/box) KJ4007X1-DA1 compatible with DI/DI Plus board

DO board main fuse (125V AC/10A, 10 pieces/box) KJ4007X1-DD1 compatible with DO Plus board

DO board channel fuse (250V AC/5A, 10 pieces/box) KJ4007X1-DC1 compatible with DO Plus board

（3） Third party products (optional)

Describe Phoenix Contact model and product type

20 pin circular ribbon cable (0.5m) 2296391 FLK 20/EZ-DR/50KONFEK

20 pin circular ribbon cable (1.0m) 2296401 FLK 20/EZ-DR/100KONFEK

20 pin circular ribbon cable (3.0m) 2296498 FLK 20/EZ-DR/300KONFEK

20 pin circular ribbon cable (10.0m) 2296537 FLK 20/EZ-DR/1000KONFEK

48 pin circular ribbon cable (xm) - CABLE-50/2FLK24/2FLK24/xM/S