PHOENIX CONTACT | The flexible I/O marshalling system

PHOENIX CONTACT | The flexible I/O marshalling system - VIP I/O-Marshalling

Contents Universal solutions for the marshalling and interface level Project Manager, Automation Maintenance Lead Instrumentation Engineer Greenﬁ eld: Reducing project times Brownﬁ eld: Fit for the future Universal I/O: Intelligence in the ﬁ eld Universal for every application Order overview 4 5 6 7 8 10 12 14 16 Into the future with VIP I/O-Marshalling 20 Everything from a single source 22 PHOENIX CONTACT 3

Project Manager, Automation Responsible for the complete project from a technical and commercial perspective. The challenge We decided early on to adopt the Universal I/O approach. The advantages in project handling and in the overall project costs were compelling. We were particularly impressed by the additional ﬂ exibility during the planning phase and also that tasks can be processed in parallel. Moreover, the approach also makes it possible to react ﬂ exibly to changes during the course of the project. In the ﬁ eld of interface and marshalling technology, we were on the lookout for a specialized one-stop service provider off ering a suitable solution for the Universal I/O system. Solution with VIP I/O-Marshalling VIP I/O-Marshalling from Phoenix Contact is the right choice for us. The system off ers a suitable base element for our I/O system, the appropriate system cable, and also a broad range of function modules. This covers all our requirements, and we only need one supplier. At the same time, it is an open, independent system, meaning that we are also able to react ﬂ exibly to changes at the control system level. In the long term, this increases availability and reduces dependence on individual suppliers. Project team “In the ﬁ eld of interface and marshalling technology, we were on the lookout for a specialized one- stop service provider of a suitable solution for the Universal I/O system. In the case of VIP I/O-Marshalling, Phoenix Contact is the right choice for us.” PHOENIX CONTACT 5

Maintenance Maintenance personnel are responsible for the maintenance and repair of all system areas. The challenge We constantly face the challenge of ensuring a particularly high system availability while, at the same time, keeping the costs of repairs and maintenance work as low as possible. A system that provides maximum availability and that is quick and easy to maintain and repair in the event of a malfunction is therefore required. Moreover, the ﬂ exibility off ered by the Universal I/O system also has to be retained at the interface and marshalling level. Solution with VIP I/O-Marshalling With VIP I/O-Marshalling from Phoenix Contact, we have found the ideal solution. The plug-in function modules (IOAs) allow changes to be easily made without any wiring work. This eliminates the need for repeated, expensive loop checks. This saves a huge amount of time during maintenance and repair work. The system is also incredibly ﬂ exible, because the function modules can be combined in practically any way, and we are able to ﬂ exibly adapt to the particular application. Our Universal I/O system therefore remains ﬂ exible. Maintenance engineer in action “We needed a system that provides maximum availability and that is quick and easy to maintain and repair in the event of a malfunction. With VIP I/O-Marshalling from Phoenix Contact, we have found the ideal solution.” 6 PHOENIX CONTACT

Lead Instrumentation Engineer Responsible for the selection of instrumentation/control engineering technology and for compliance with standards and regulations. The challenge We constantly face the challenge of saving costs, being technologically up-to-date, and having the highest level of ﬂ exibility in the planning and implementation of our systems. Moreover, my team and I have to ensure that our systems comply with all relevant standards and approvals, and that all signal types from the ﬁ eld can be transmitted reliably and accurately to the control level. We have only done a good job if the connection between the control system and instrumentation is secure, reliable, and ﬂ exible. To achieve maximum system availability, every single component must be designed to be easy to maintain and future-proof. Solution with VIP I/O-Marshalling Universal I/O is a fantastic help in meeting the daily demands on our systems. With VIP I/O-Marshalling from Phoenix Contact, we have found a solution that now also makes our system truly Universal-I/O-capable between the control system and instrumentation. We can therefore exploit the full potential across all levels. VIP I/O-Marshalling enables us to process all signal types from the ﬁ eld decentrally with a very high degree of ﬂ exibility and reliably, and to transmit them to the control level. This means that our philosophy of processing signals in the ﬁ eld as close as possible to the sensors can also but put into practice without diffi culty. Process system “With VIP I/O-Marshalling, we have found a solution that ensures our systems now also truly Universal-I/O-capable between the control level and instrumentation.” PHOENIX CONTACT 7

Greenﬁ eld: Reducing project times Planners and operators of new systems ﬁ rst face the challenge of planning their costs and time as precisely as possible. A ﬂ exible solution for the connection and processing of all ﬁ eld signals is a decisive factor in keeping within the project budget and timing plans. Your advantages  Reduction of the project duration with Universal I/O  Changes to the I/O assignment are possible in every project phase with plug-in IOAs  Lower number of control cabinets, because additional marshalling cabinets are not necessary  Simpliﬁ ed planning – only the total number of I/Os needs to be known, rather than the individual signal types 8 PHOENIX CONTACT

Comparison of process automation projects The need to stock a multitude of diff erent components such as terminal blocks, relays, and ﬁ eld termination assemblies (FTAs) is eliminated, meaning that inventories are reduced and operations streamlined. Late assignment changes in the I/O plan do not require rewiring because the IOAs can be replaced easily, eliminating the need to reallocate cabinet space for additional hardware. FEED System design FAT Ship Installation SAT 18 months FEED System design 12 months FAT Ship FEED: Front-End Engineering Design FAT: Factory Acceptance Test SAT: Site Acceptance Test Installation SAT The average project duration of approx. 18 months can be reduced to 12 months with the Universal I/O approach. PHOENIX CONTACT 9

Brownﬁ eld: Fit for the future Operators of brownﬁ eld systems face the challenge of remaining competitive in relation to state-of-the-art systems. Moreover, system availability, which declines over the years, must continue to be guaranteed. This inevitably leads to the need for system modernization. Your advantages  Reduction of downtimes with modern signal processing and replaceable IOAs  Easy migration into existing systems with the compact solution of interface, marshalling, and system cabling combined into one module  Reduction of the wiring work with various system cabling solutions for connection to distributed control systems (DCS) 10 PHOENIX CONTACT

Comparison of topologies Classic signal marshalling In classic signal marshalling, the ﬁ eld signals arrive in any order and are sorted according to their signal type. The marshalling level is wired to the interface level, which in turn is wired to the I/O level. Marshalling level Interface level DCS and I/O level Distribution boxes Multi-core cables (two cables per signal) Marshalling System cables 64 I/Os = 128 cables Size control room Universal Remote Cabinet with VIP I/O-Marshalling With Universal Remote Cabinets, the need for large marshalling and interface cabinets is eliminated. The ﬁ eld signals are routed directly to the VIP I/O-Marshalling base elements in the cabinets. The connection to the Universal I/O system is then made using the system cable. The ﬁ nal connection to the control system is established via one ﬁ berglass cable. DCS Fiberoptic cable (one line for all signals) Marshalling, interface, I/O level 64 I/Os = 1 cable Size control room PHOENIX CONTACT 13

Universal for every application VIP I/O-Marshalling is a controller-independent solution comprising a base element and plug-in input-output accessories (IOAs) with various electrical functions. This enables the channels between the ﬁ eld and control level to be conﬁ gured individually. Web code: #2321 Base element • 8-channel or 16-channel Field connection • Up to 6 terminal points per channel (8- to 16-channel) • With screw or Push-in connection technology 14 PHOENIX CONTACT

Order overview Base elements For further product details visit phoenixcontact.com Type Description Channel marking Order No. Number of channels Controller connector Field connection I/O system Type Description Channel marking Order No. Number of channels Controller connector Field connection I/O system For further product details visit phoenixcontact.com Type Description Channel marking Order No. Number of channels Controller connector Field connection I/O system VIP/S/MC/BASE 1-8/L/EX VIP/S/MC/BASE 9-16/L/EX VIP/S/MC/BASE 17-24/L/EX VIP/S/MC/BASE 25-32/L/EX Base element for mounting up to eight function modules (IOAs) and MINI COMBICON connection 1 - 8 2906596 9 - 16 2906630 17 - 24 2907024 25 - 32 2907025 8 MC Screw Honeywell Experion PKS C300, Honeywell Safety Manager VIP/S/MC/BASE 1-8/L/C/EX VIP/S/MC/BASE 9-16/L/C/EX VIP/S/MC/BASE 17-24/L/C/EX VIP/S/MC/BASE 25-32/L/C/EX Base element for mounting up to eight function modules (IOAs) and MINI COMBICON connection, with protective coating 1 - 8 2907186 9 - 16 2907187 17 - 24 2907209 25 - 32 2907210 8 MC Screw Honeywell Experion PKS C300, Honeywell Safety Manager VIP/S/D25M/BASE VIP/MSTB/D50M/BASE/ BASE-MSTB/D37M/ 1-8/L/C/EX 16CH/CX/EX 16CH/EX Base element for mounting up to eight function modules (IOAs) and D-SUB 25 connection, with protective coating 1 - 8 2906595 8 D-SUB 25 Screw Base element for mounting up to 16 function modules (IOAs) and D-SUB 50 connection, with protective coating Base element for mounting up to 16 function modules (IOAs) and D-SUB 37 connection 1 - 16 2908788 16 D-SUB 50 Depending on connector kit 1065476 * 16 D-SUB 37 Screw, Push-in Screw, Push-in Schneider Electric Foxboro DCS Schneider Electric Triconex SIS Honeywell Experion PKS C300, Honeywell Safety Manager / Universal * Available at the end of 2020 at the latest 16 PHOENIX CONTACT

Passive modules For further product details visit phoenixcontact.com Type IOA FEED-THRU/EX IOA AI/AO/BFI/DS/0.5A/EX IOA-PR-DAI/DAO/F/DS/2A/EX Description 1:1 feed-through Fuse module with two 0.5 A fuses and Fuse module with 2 A fuse in the supply fuse-blow indicator path 2906598 AI/AO/DI/DO 2906599 AI/AO 1048208 * AI/AO/DI/DO Signal: max. 30 V DC/1 A PWR/signal: max. 30 V DC/0.5 A PWR/signal: max. 30 V DC/1 A Order No. Signal type(s) IN OUT For further product details visit phoenixcontact.com Type IOA DI/DO/BFI/DS/1.0A/EX IOA-PR-DAI/DAO/F/DS/0.25A/EX Description Order No. Signal type(s) IN OUT Analog IN For further product details visit phoenixcontact.com Type Description Order No. Signal type(s) IN OUT Fuse module with two 1 A fuses and fuse- Fuse module with 0.25 A fuse in the blow indicator 2906600 DI/DO supply path 1188706 * AI/AO/DI/DO PWR: max. 30 V DC/2 A Signal: max. 30 V DC/30 mA PWR: max. 30 V DC/0.25 A Signal: max. 30 V DC/30 mA IOA RPSS-I-I/HART/EX IOA MCR-RPSS-I-I IOA MCR-EX-RPSS-I-I 3-way repeater power supply 3-way repeater power supply 3-way repeater power supply Ex i 2908452 AI 1085774 * AI 1085761 * AI Isolator operation: 0 … 20 mA, 4 … 20 mA; Isolator operation: 0 … 20 mA, 4 … 20 mA; Isolator operation: 0 … 20 mA, 4 … 20 mA; repeater power supply operation: repeater power supply operation: repeater power supply operation: 4 … 20 mA 4 … 20 mA 4 … 20 mA * Available at the end of 2020 at the latest PHOENIX CONTACT 17

Order overview Digital IN For further product details visit phoenixcontact.com Type Description Order No. Signal type(s) IN OUT For further product details visit phoenixcontact.com Type Description Order No. Signal type(s) IN OUT Temperature For further product details visit phoenixcontact.com IOA REL 24V DI/BFI/1.0A/EX IOA REL 120V DI/1.0A/EX IOA REL 230V DI/1.0A/EX Input relay for 24 V DC signals Input relay for 120 V AC signals Input relay for 230 V AC signals 2910155 DI 24 V DC 2910157 DI 120 V AC 2910423 DI 230 V AC Floating switch contact N/O Floating switch contact N/O Floating switch contact N/O IOA LM-DI/R/RUSIO/EX IOA DAC-4DI/AI/EX Resistor combination for detecting line faults via Honeywell Safety System 4 DI to 1 AI signal converter 1048209 * DI 1145061 * 4 DI Floating switch contacts Up to 4 ﬂ oating switch contacts Honeywell-Safety-Manager-speciﬁ c signal level 4 … 20 mA Type IOA MCR-RTD-I IOA MCR-TC-I IOA MCR-EX-RTD-I IOA MCR-EX-TC-I Description RTD temperature transducer TC temperature transducer RTD temperature transducer TC temperature transducer Ex i Ex i Order No. Signal type(s) IN OUT 1007728 * Temperature Resistance temperature detector 4 … 20 mA 1007722 * Temperature Thermocouples 4 … 20 mA 1085764 * Temperature Resistance temperature detector 4 … 20 mA 1085766 * Temperature Thermocouples 4 … 20 mA * Available at the end of 2020 at the latest 18 PHOENIX CONTACT

Digital OUT For further product details visit phoenixcontact.com Type Description Order No. Signal type(s) IN OUT For further product details visit phoenixcontact.com IOA REL 24V DO/BFI/3.0A/EX IOA REL 120V DO/BFI/3.0A/EX IOA REL 230V DO/BFI/NO/3.0A/EX Output relay for 24 V DC signals Output relay for 120 V AC signals Output relay for 230 V AC signals 2910153 DO 24 V DC 2910154 DO 24 V DC 2910421 DO 24 V DC Floating switch contact N/C / N/O Floating switch contact N/C / N/O Floating switch contact N/O Type IOA REL 230V DO/BFI/NC/3.0A/EX IOA-PSR-PS22-1NO-1NC-24DC IOA FEED-THRU-DO/NI/EX Output relay for 230 V AC signals Safety output relay for 230 V AC signals 2910422 DO 24 V DC 2702971 DO 24 V DC Floating switch contact N/C Floating switch contact N/O Nonincendive impeding device for DO signals 1172189 * DO Max. 30 V/75 mA Description Order No. Signal type(s) IN OUT Accessories System cables Connector kits Partition plates Miscellaneous For VIP/S/MC/BASE... For VIP/S/MC/BASE... For VIP/S/... Cold junction compensation CAB-MSTB32/2XMC9/… …18/ 0,4M/C3/S …18/ 0,5M/C3/S …18/ 1,0M/C3/S …18/ 2,0M/C3/S …18/ 3,0M/C3/S …18/ 4,0M/C3/S …18/ 6,0M/C3/S …18/ 8,0M/C3/S …18/10,0M/C3/S …18/15,0M/C3/S …18/20,0M/C3/S 2908403 2908404 2908405 2908406 2908407 2908408 2908409 2908410 2908411 2908412 2908413 CAB-MSTB32/2XMC9/… …22/ 0,4M/C3/S …22/ 0,5M/C3/S …22/ 1,0M/C3/S …22/ 2,0M/C3/S …22/ 3,0M/C3/S …22/ 4,0M/C3/S …22/ 6,0M/C3/S …22/ 8,0M/C3/S …22/10,0M/C3/S …22/14,0M/C3/S …22/15,0M/C3/S …22/16,0M/C3/S …22/17,0M/C3/S …22/18,0M/C3/S …22/19,0M/C3/S …22/20,0M/C3/S 2908328 2906874 2906884 2906886 2906887 2906888 2906889 2907783 2907784 2910400 1065475 2910401 2910403 1013239 1013240 2907785 * Available at the end of 2020 at the latest VIP/S/MC/… …KIT 1-8 …KIT 9-16 …KIT 17-24 …KIT 25-32 2907031 2907267 2907268 2907269 VIP/U/RAIL 3L DIVIDER 2908555 VIP/S/BASE 3L DIVIDER 2907715 IOA MCR-CJC-PT100 1085776 For VIP/MSTB/D50M/BASE/16CH/CX/EX Marking material VIP/… …S/MVSTBR/KIT CX 2910416 …P/FKC/KIT CX 2910417 VIP/UM-PRO/BASE DIVIDER/CX 2910139 UC-TM 10 UC-TM 10 BU 0818069 0818441 For BASE-MSTB/D37M/16CH/ES PLUGKIT-GY/… …MSTB/16CH-1-16 1193570 …FKC/16CH-1-16 2910417 PHOENIX CONTACT 19

Everything for your universal I/O control box Universal Remote Cabinet In addition to marshalling and interface solutions, Phoenix Contact, as the long- serving partner to the process industry, provides further components and services for your control box solutions. 1 4 2 3 5 6 1 2 3 Universal I/O modules Easy connection to standard Universal I/O modules that are available on the market. Power supplies with outstanding functionality QUINT POWER for maximum system availability. Web code: #1513 Industrial Ethernet Industrial Ethernet has become a proven and established solution in automation because it is consistent, fast, and extremely ﬂ exible. Web code: #0956 4 5 6 Flexible I/O marshalling system Make Universal I/O truly universal with the ﬂ exible I/O marshalling system. Web code: #2321 Terminal blocks for process technology Innovative terminal blocks for the speciﬁ c requirements of process technology. Surge protection for MCR technology Powerful protective devices with low voltage protection levels provide optimum protection for your MCR applications. Web code: #0567 Web code: #0292 PHOENIX CONTACT 23

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