3.

Signal Cable Connection to Input/Output Modules (For FIO)

An I/O module can be connected in two ways: either directly connected via the terminals
of a field device or connected via a terminal board through dedicated cables. In addition, it
is possible to connect by MIL cables, which should be provided by the user.
This chapter explains how to use the I/O modules together with the pressure clamp
terminal blocks and connection cables provided as accessories, and shows the
corresponding terminal connection diagrams.
3.1 Configuration of Input/Output Module Connections
In this chapter, how to connect field devices to the I/O modules is explained.
 Various Signal Cable Connection Methods
For saving the wiring space or for standardizing the instrumentation style, the following methods
can be applied.
• Use Pressure Clamp Terminal Blocks
When connecting field device signal cables directly to the I/O modules, use pressure clamp
terminal blocks.
• Use Terminal Board
When connecting field devices to I/O modules via terminal boards with specific cables, KS
cable interface adapters are required.
• Use MIL Cables
Use MIL Cables (prepared by user) to connect to I/O modules directly.
In the following figure, the parts within the dotted line are provided by Yokogawa

 Combinations of Input/Output Module and Terminal Block

There are various methods for connecting cables to I/O modules, such as single/dual-redundant
operation, isolated/non-isolated, and directly coupled/via a terminal board. In each case, it is
possible to combine an I/O module with adapters or terminal blocks according to the purpose.
The table below lists the model names of the different combinations of I/O modules and terminal
blocks that can be used.
 l Analog I/O Modules
Table Combinations of Analog I/O Module and Terminal Block

 Digital I/O Modules

Table Combinations of Digital I/O Module and Terminal Block

 Communication Modules
When connecting to serial communication modules (RS-232C), different types of cables are used
depending on whether a modem connection or a null-modem connection is used, as well as the
type of device to be connected.
Serial communication modules (RS-422/RS-485) can be directly connected to multiple devices
through multiple cables.
It is possible to connect to a FOUNDATION fieldbus (FF-H1) either via pressure clamp terminals
or by the connectors via a terminal board.
Table Combinations of I/O Module and Terminal Block

 Compatible Module for Replacement

Existing terminal boards and KS cables can be utilized when replacing I/O parts of old Electric-made
CENTUM models with I/O modules for FIO.
Table Combinations of I/O Module and Terminal Board

The compatible modules other than the modules listed in the above table are shown in the table
below. Generally, the MIL connector should be used for connection.
The cables listed in the table below can also be used.
Table Combinations of I/O Module and Terminal Board

3.2 How to Connect Signal Cables

The following methods for connecting signal cables are available:
• Direct-coupled connection using pressure clamp terminals
• Connector connection using dedicated cables via terminal boards
• MIL connector connection

3.2.1 Direct-Coupled Connection Using Pressure Clamp Terminals

The interface part of an I/O module basically consists of a connector (male). Connect the
pressure clamp terminal block to the front section.
Pressure clamp terminals are available for single and dual-redundant operation.
 Signal Cables for Pressure Clamp Terminal

 Cables Used
• 600 V polyvinyl chloride isolated wires (IV); JIS C3307
• Polyvinyl chloride isolated wires for electrical apparatus (KIV); JIS C3316
• 600 V grade heat-resistant polyvinyl chloride isolated wires (HIV); JIS C3317
• Heatproof vinyl isolated wires VW-1 (UL1015/UL1007)
• Control cables (vinyl isolated vinyl sheath cable) (CVV); JIS C3401
 Recommended Cable Thickness
Pressure clamp terminals
• Without sleeve: 0.5 mm2 to 2 mm2 (AWG20 to 14)
• With sleeve: 0.5 mm2 to 1.5 mm2 (AWG20 to 16
 Connecting to Pressure Clamp Terminals (Without Sleeves)
Table Wiring to Pressure Clamp Terminals without Sleeves

 Connecting to Pressure Clamp Terminals (With Sleeves)

Table Wiring to Pressure Clamp Terminals with Sleeves

 Types of Pressure Clamp Terminal Blocks

Table Types of Pressure Clamp Terminal Blocks

 Pressure Clamp Terminal Blocks for Single Operation

It is possible to install one single pressure clamp terminal block per one I/O module.

 Pressure Clamp Terminal Blocks for Dual-Redundant Operation

It is possible to install one dual-redundant pressure clamp terminal block per two adjacent I/O
modules beginning from an odd number in dual-redundant operation. The width of the terminal
block for dual-redundant operation is twice that of the terminal block for single operation.
Connect the flat cables coming out from the backside of the pressure clamp terminal block to the
two I/O modules, as appropriate.

 Pressure Clamp Terminal Blocks for Digital Input/Output Modules

The figures below show an example of external appearance when digital pressure clamp
terminal blocks are connected to digital I/O modules.

3.2.2 Connection via Connectors

I/O modules and field equipment can be connected via terminal boards. For this kind of
connection, use dedicated cables to connect to the connectors of the I/O modules or KS
cable interface adapters.

 Input/Output Modules Connected via Connectors

The figures below show examples of the external appearance of the I/O modules connected via
connectors.

 Cables between an Input/Output Module and a Terminal Board

Table List of Signal Cables.

 Type of Signal Cable

 Type of Communication Cable

 Signal Cable Connection

 Type of Communication Cable (ALR121)

 Signal Cable Connection

The terminals for connecting the field devices on the terminals board are the M4 screw terminals.
 Cable termination
If the process I/O signals are connected through the terminals, the wires connected to the
terminals should use the isolated solderless lugs.
 Solderless lug specifications
The specifications of the solderless lug to use are determined by the nominal cross
sectional are of the power cable for which the lug is to be used, the lug screw, dimensions
and so on.

3.2.3 Connection via MIL Connector

 MIL Cable Connection

The MIL cable should be provided by the user.
A cable connector cover (model: ACCC01) is provided in order to prevent the MIL cable from
being pulled out.
3.3 Signal Cable Connection to Analog Input/Output Modules

There are three ways of connecting input/output signal cables to Analog I/O modules: by
connecting via a pressure clamp terminal block, by using a dedicated cable to connect
to the connectors via a terminal board, or by direct connection using a MIL cable. This
section shows wire connection diagrams and tables showing the input/output channel
numbers.
 Channel Numbers and Pin Numbers
 Pressure Clamp Terminal Blocks
The terminal numbers of a pressure clamp terminal block are arranged in the order from A1, A2
and so on to A18 starting from the top of the left column and from B1, B2 and so on to B18 from
the top of the right column on the front of the terminal block.
The terminal number layout of a dual-redundant pressure clamp terminal is the same.

 MIL Connector
The pin numbers of MIL connector are shown as follows.

 Correspondence of Pin Numbers between Pressure Clamp Terminals and MIL Connectors
The figure below shows how the input/output channel numbers correspond to the terminal
numbers of a pressure clamp terminal block and the pin numbers of a MIL connector.
Only pressure clamp terminals are shown in the cable connection diagrams from the next page;
use the correspondence shown in the figure below for the corresponding MIL connectors.

 Signal Connecting to Analog I/O Module

Vary with the model of analog input/output modules and vary with devices connected, the
terminals for connecting the signal cables are different. Refer to the following table and connect
the cable to the proper terminals.
Table Input Terminal Types for Analog Input/Output Modules

3.3.1 Analog Input Module, 16-Channel (AAI141, AAI143,AAV141, AAV142, AAV144)

 AAI141, AAI143 (4 to 20 mA Input)

 AAV141 (1 to 5 V DC Input), AAV142, AAV144 (-10 to 10 V DC Input)

3.3.2 Analog Input/Output Module, 8-Channel Input/8-Channel Output (AAI841,

AAB841)

 AAI841 (4 to 20 mA Input/4 to 20 mA Output)

 AAB841 (1 to 5 V DC Input/4 to 20 mA Output)

3.3.3 Analog Output Module, 16-Channel (AAV542, AAI543, AAV544)

 AAV542, AAV544 (-10 to +10 V DC output), AAI543 (4 to 20 mA DC output)

 3.3.4 Thermocouple/mV Input Module, 16-Channel, Isolated (AAT141)

3.3.5 RTD Input Module, 12-Channel, Isolated (AAR181)

3.3.6 Analog Input Module, 8-Channel Isolated (AAI135)

3.3.7 Analog Input/Output Module, 8-Channel Isolated (AAI835)

3.3.8 Pulse Input Module, 8-Channel Isolated (AAP135)

 Connecting Signal Cables with Pulse Input Module AAP135

The AAP135 receives contact ON/OFF, voltage pulse and current pulse. Refer to the figures
below for details on how to connect signal cables since the items to be set by the system
generation builder depend on the input pulse types.
 l When Receiving No-Voltage Contact Signals (1)
For the relay contacts or transistor contacts, connect as follows.
Pulse input frequency should be 0 to 800 Hz. Max. frequency differs due to the wiring effect, etc.

 When Receving No-Voltage Contact Signals (2)

Carry out connection as follows if a current is needed to flow to the relay contacts or transistor
contacts.
When receiving transistor output signal with higher frequency of above, the wiring is as follows.

 When Receiving Voltage Pulse Signals

 When Receiving Current Pulse By Using the Internal Power to Drive the Transmitter (2-wire
power supply type)

This method supplies power to the transmitter, and receives the transmitter output signals as
the current pulse signals. By using the input load resistance (select from Term. None, Term. 200
ohm, Term. 500 ohm, Term. 1 k ohm), the current signal is converted to the voltage level pulse
and receives it.

 When Receiving Voltage Pulse By Using the Internal Power to Drive the Transmitter (3-wire
power supply type)

3.3.9 Terminal Board Connections (Analog Input/Output Module)

 Connection between AEA4D and an I/O module

The terminal N.C. in the figure is an unused terminal; wiring is not required.
  When connecting AAI141, AAI143
 When connecting AAV141, AAV142, AAV144
 When connecting AAI841
 When connecting AAB841
 When connecting AAV542, AAI543, AAV544
 When connecting AAI135
 When connecting AAI835
 When connecting AAP135

 Connection between AEA3D and an I/O module

 When connecting AAI135 or AAP135 (2-wire transmitter, 2-wire input fixed connection)
 When connecting AAI835 (2-wire transmitter, 2-wire input fixed connection)

 Connection between AET4D and an I/O module

 When connecting AAT145

 Connection between AER4D and an I/O module

 When connecting AAR145

 Connection between MRT and an I/O module

 When connecting AAR145

3.4 Signal Cable Connection to Digital Input/Output Modules

Similar to Analog I/O modules, there are three ways of connecting a signal cables to
digital I/O modules: by connecting via a pressure clamp terminal block, by using a
dedicated cable to connect to the connectors via a terminal board, or by direct connection
using a MIL cable.

 Channel Numbers and Pin Numbers

 Pressure Clamp Terminal

 MIL Connectors
MIL connectors for digital input/output have 50 pins

 Correspondence between Pressure Clamp Terminal Numbers and MIL Connector Pin Numbers
The figure below shows how the input/output channel numbers correspond to the terminal numbers of
a pressure clamp terminal block and the pin numbers of a MIL connector.

3.4.1 Digital Input Module, 32-Channel (ADV151, ADV157)

ADV151 and ADV157 have the same specifications, but ADV157 is used with pressure
clamp terminal blocks for digital signals.
 3.4.2 Digital Input Module, 16-Channel (ADV141, ADV142)

In the case of ADV141, the input signal is 100 to 120 V AC. In the case of ADV142, the input
signal is 200 to 240 V AC.

3.4.3 Digital Output Module, 32-Channel (ADV551, ADV557)

ADV551 and ADV557 have the same specifications, but ADV557 is used together with
pressure clamp terminal blocks.

3.4.4 Digital Input Module, 64-Channel (ADV161)

3.4.5 Digital Output Module, 64-Channel (ADV561)

3.4.6 Digital I/O Module, 16-Channel Input/16-Channel Output (ADV851)

3.4.7 Relay Output Module, 16-Channel (ADR541)

3.4.8 Connection with a Terminal Board (Digital Input/Output Module)

The figures below show the signal names and terminal numbers of a terminal board, as
well as the connection from a terminal board to a digital I/O module.

 Connection between AED5D and an Input/Output Module

The terminal N.C. in the figure is an unused terminal; wiring is not required.

 Connecting to ADV151 (Voltage Input)

 When Connecting ADV151 (Dry Contact Input) 24 V DC required
 When Connecting ADV551 (Voltage Output) 24 V DC required
 When Connecting ADV551 (Transistor Output) 24 V DC required

 Connection between AEC4D and an Input/Output Module

 When Connecting ADV141, ADV142
 When Connecting ADR541

3.5 Signal Cable Connection to Communication Modules

This section explains how to connect signal cables to the communication modules
ALR111, ALR121, ALE111 and ALF111.

 Cables for Communication Modules

Yokogawa Electric Corporation provides communication cables in the range shown in the table
below. Any necessary cables other than these should be prepared by the user.

3.5.1 Signal Cable Connection to RS-232C Communication Module

The communication cables that can be used in this case have connectors for the D-sub 9 pin:
modem cables AKB131 and AKB135, null-modem cables AKB132, AKB133, AKB134, and
AKB136.

 Communication Module Signal Circuits

The ALR111 and ALR121 communication modules isolate the communication circuit signal lines
to prevent noise from entering the FCS from the partner AC line, frame ground (FG) connecting
cables and communication cables. Because of this, it is necessary that cable shielding wires
be connected to the FG at the partner side. The partner terminal requires that its FG and signal
ground (SG) be connected to each other, providing the same potential between them.

 ALR111 FG Connection
The ALR111 communication module isolates the RS-232C interface circuit functionally. This
prevents noise from entering the FCS from the subsystem, thereby improving noise resistance.
To use this function effectively, satisfy the following requirements:

Connect the shielding wires of the RS-232C communications cable to the FG at the partner
equipment (subsystem or modem side) so that with a maximum of 100 ohms can be attained.
Check that pin No. 1 (for the D-sub25 frame ground) and pin No. 7 (for the D-sub25 signal
ground) of AKB135 or AKB136 on the RS-232C communications connector at the partner
equipment are connected to each other. Also check that pin No. 1 is connected to the grounding
terminal at the partner equipment. A AKB133 cable connector with a red mark (CN1 side) has
shielding wires connected to connector shell. Connect this side of the AKB133 cable connector to
the subsystem or modem.

 AKB136 Cable Connection

For the partner equipment, jumper J1 should be provided (see the figure below) upon shipment.
(If it is not, provide jumper 1 for short-circuiting.) To meet the above requirement, the FG and SG
may be directly connected.

If the SG and FG signals in the partner equipment RS-232C communications circuit are not
connected floated signal grandings of the communication circuits at both the ALR111 and partner
equipment will result, in lowering noise resistance. To prevent this, use an AKB131 or AKB132
cable. Connect pin No. 1 (for the frame ground) and pin No. 7 (for the signal ground) together
at the partner equipment. In addition, as a means of grounding the shielding wires of this cable,
Figure below illustrates that the shielding wires can be connected to the FG terminal at the
partner equipment in cases where pin No. 1 is disconnected at the partner equipment.

 Connection to Partner Equipments

The ALR111 and partner equipment are connected by a cable up to 15 meters in length. If the
ALR111 is connected to a subsystem, the subsystem requires frame grounding with a grounding
resistance of up to 100 ohms. If the cable is longer than 15 meters, always use a modem that its
frame is grounded.

3.5.2 RS-422/RS-485 Communication Module

 ALR121 External Connection

When connecting Model ALR121 with external equipment, two methods for 1 to 1 and 1 to n (n:
up to 32) are available. The figure below shows the configuration.
  ALR121 FG Connection
Set up the RS-422/RS-485 shield as shown below.
Grounding for the FG must be grounding (with resistance up to 100 ohm) on the connected side
(subsystem side).
The cable shield between Model ALR121 and the subsystem side must be connected to the FG
on the subsystem side, not to the FG on Model ALR121.

 Connection with External Equipment

Four-wire and two-wire types are provided for the connection of Model ALR121 with external
equipment. Each type has 1 to 1 and 1 to n connections.

 1 to 1 Connection in 4-wire Type

 1 to 1 Connection in 2-wire Type

When ALR121 is specified for 2-wire connection by the builder, “Tx+ and Rx+” and “Tx- and Rx-”
are automatically connected within the module.

 1 to n Connection in 4-wire Type

 1 to n Connection in 2-wire Type

When ALR121 is specified for 2-wire connection by the builder, “Tx+ and Rx+” and “Tx- and Rx-” are
automatically connected within the module.

3.5.3 Signal Cable Connection to Ethernet Communication Module

The signal cables used for connecting Ethernet communication modules are 10BASE-T
twisted-pair cables.
Subsystems can be put in dual-redundant configuration by using two Ethernet
communication modules.

3.5.4 Signal Cable Connection to FOUNDATION fieldbus Communication Module

There are two ways of wiring signal cables to FOUNDATION fieldbus communication
modules: using pressure clamp terminal blocks (ATF9S) or connecting to ALF111 by
AKB336 cable via a connector and receiving signals from the field equipment via a
terminal board (AEF9D).

 Connection with Field Equipment (When Using Pressure Clamp Terminal Blocks)
The signal cables from the field device should be connected to the + and - terminals of the
pressure clamp terminal block (ATF9S).
Do not connect anything to terminals for channels that are not used.
Use shield lines for cables from the field device to the FG terminal. If two or more channels are
in use, no more than two shield lines can be connected to one FG terminal. When installing the
wiring on a control station using a pressure clamp terminal block, do not connect the shield lines
of the cables to the FG terminal of ATF9S but to the ground bar of the cabinet (isolated from the
cabinet itself).
The power unit should be placed as close as possible and using a cable shorter than 1 meter to
connect.
Use a type A cable and connect the cable shield to the same potential as the FG terminal of the
I/O node if the distance exceeds 1 meter.
Note that, when installing wiring within the cabinet, the shield line should be connected to the
shield ground bar within the cabinet as well.

 Single Operation
 Dual-Redundant Operation

 Connection with Field Devices (When Using Terminal Boards)

The terminal board (AEF9D) and ALF111 should be connected using AKB336 cables.
The shield line of the AKB336 cable should be connected to the FG terminal of ALF111.
The shield lines of the cables from the field device should be connected to the ground bar of
the cabinet (isolated from the cabinet itself). Connect only signal cables to the upper side of the
screw terminals of the terminal board (AEF9D). The power supply unit should be connected to
the lower side of the screw terminal board.
The wiring length between the power supply unit and the terminal board should be within 1 meter.

Make sure to install a terminator (YCB138) if ALF111 terminates the network, e.g. if the network is
not terminated by a power supply unit with terminator.

 Setting Elements
If a pressure clamp terminal block is used and ALF111 is terminating the network, the terminator
should be turned “ON.” Move the sockets of J1 and J4 (Ch1 and Ch4) in the front of ALF111 to
the “ON” side in order to turn the terminator “ON.” Remove the plastic panel when changing the
setting.
The terminator is set to “OFF” when the terminal block is shipped from the factory.

3.5.5 Connection with Terminal Boards

The figures below show the signal names and terminal numbers of a terminal board, as
well as the connection from a terminal board to a FOUNDATION fieldbus communication
module.
 Connection between AEF9D and FOUNDATION fieldbus Communication Module
 When Connecting ALF111

 Example of Implementation of FOUNDATION fieldbus Communication Module ALF111

To make fieldbus connection using the ALF111, the power supply unit for the fieldbus must be
prepared as shown below.
The following shows an example of ALF111 implementation (1U=44.45 mm).
Confirm each device specification as to temperature before mounting.

3.5.6 Signal Cable Connection to PROFIBUS-DP Communication Module

3.6 Signal Cable Connection to I/O Module with Built-in Barrier

A drawing and a table for describing the wiring of the I/O module with built-in barrier and
the I/O channels numbers are shown as follows.
The I/O module with built-in barrier can be connected only with the pressure clamp
terminals.

 Cautions Regarding to I/O Module with Built-in Barrier

Before pulling out modules or doing the similar maintenance works in the hazardous areas (Zone
2), it is necessary to confirm that explosive gases are not presented in the ambient atmosphere.
Moreover, the maintenance work must be performed by the professional personals who have
been educated and trained with the knowledge of explosive products and skill of explosive
prevention.

 Installation of Isolating Partition

When applying the intrinsically safe I/O modules to compact type FCS (FFCS), the isolating
partition needs to be installed between the intrinsically safe I/O modules and non-intrinsically safe
modules (Power Supply Modules, Processor Modules, Bus Interface Modules and so forth) to
isolate the two areas.

 Installing Isolating Partition to Field Control Unit (Models: AFF50S/AFF50D)

The component number of the Isolating Partition Kit is T9083ND.
An Isolating Partition Kit consists of the following parts:
- Partition A : For isolating the areas of intrinsically safe I/O modules and non-intrinsically safe
modules.
- Partition B : For isolating the cables of intrinsically safe I/O modules and V net.
- Mounting Screws: Two pieces for fixing Partition B.

How to install the isolating partition is illustrated in the following figure.

1. Put the Partition B on the cable tray, and use the two mounting screws to fix it.
2. Insert the Partition A to the slot in between the areas of intrinsically safe I/O modules and
non-intrinsically safe modules (One slot will be occupied).
3. Make sure that the cables of the I/O modules in the intrinsic safe area and the cables of the
modules in the non-intrinsic safe area are completely isolated by the isolating partition kit.

 Isolating Partition to Node Unit (Models: ANB10S/ANB10D, ANR10S/ANR10D)

The component number of the Isolating Partition is T9083NA.
This component is for isolating the intrinsically safe I/O modules and non-intrinsically safe
modules.
How to install the isolating partition is illustrated in the following figure.
Insert the isolating partition T9083NA to the slot in between the areas of intrinsically safe I/O
modules and non-intrinsically safe modules (One slot will be occupied).
And then, make sure that the cables of the I/O modules in the intrinsic safe area and the cables of
the modules in the non-intrinsic safe area are completely isolated by the isolating partition.

Cautions Regarding to Maintenance of I/O Module with Built-in Barrier

The following procedure should be observed when maintaining the I/O modules
with built-in barriers.The LED displays are explained in the following style.
LED= [STATUS, ---, ---] only the STATUS lamp is lit.
LED= [STATUS, ACT, DX] all lamps are lit.
1. Replacing Modules
1.1 If the module to be replaced is not in dual-redundant configuration
1) Remove the terminal block of the module.
2) Loosen the screws that fixing the module, then pull out the module.
3) Install a new module, then tighten the screws to fix the module.
4) Restore the terminal block to the module.
1.2 If the module to be replaced is in dual-redundant configuration and standing by
1) Remove the terminal block of the module.
2) Loosen the screws that fixing the module, then pull out the module.
3) Install a new module, then tighten the screws to fix the module.
4) Confirm that the LED status is LED=[STATUS,---,DX].
5) Restore the terminal block to the module.
1.3 If the module to be replaced is in dual-redundant configuration and running
In order to replace a module running in dual-redundant configuration, it is necessary to
switch the module’s control right and to make the module into standing by status. Thus, the
replacement is performed with the following steps.
Step 1. : Switch the control right to the dual-redundantly configure module. (As described in
2, “Switching control right of dual-redundantly configured modules”)
Step 2. : Replace the module in the same procedure of replacing a standby module. (As
described in 1.2, “ If the module to be replaced is in dual-redundant configuration and
standing by“ )

2. Switching control right of dual-redundantly configured modules

There are two ways to switch control right from the running module to the standby module. It
is recommended to use the method a) when switching modules’ control right.
a) Perform IOM Download to the Running Module on HIS.
On FCS status display view of HIS, choose the module (which is running) then start
IOM load.
b) Pulling Out the Running Module from Backboard
1) Confirm that the LED status of the running module is LED= [STATUS, ACT, DX]
2) Confirm that the LED status of the adjacent standby module is LED= [STATUS, ---, DX]
3) Loosen the screws that fixing the running module, then pull out the module.
4) Confirm that the LED status of the adjacent module changes to LED= [STATUS, ACT,
DX].
5) Push the pulled out module back to connect to the backboard and tight the screws to fix
the module.
6) Confirm that the LED status of the module is LED= [STATUS, ---, DX]

 Cautions Regarding to Terminal Block Connector of I/O Modules with Built-in

Barriers
When connecting the connector of terminal block to the I/O modules, the following points need to
be noted.
- It is necessary to plug in and pull out the connector promptly so as to avoid the connector is
tilted and halfway connected.
- When the terminal block is removed from the I/O module, the connector pins of the I/O
module should be intact.
- If the connector is halfway plugged for more than one second, or if the pins of the
disconnected connector are touched, the diagnosis circuits and the safety protection circuits
 may treat this circumstance as a dangerous abnormality so as to shutoff the power supply to
the module. Thus the module failure will occur.
- When the module failure occurs, the LED lamp [STATUS] turns off. Under this situation, it is
necessary to remove the module from the backboard, and put it back after two or more
seconds

 Cautions on Removing I/O Modules with Built-in Barriers from Backboard

When removing the I/O modules from the backboard, and then install it to the backboard again,
the following points need to be noted.
1. When the I/O module is removed from the backboard, at least two-seconds wait-time
is required to installing the module back to the backboard. If the I/O module is in a dualredundant
configuration, at least five-seconds wait-time is required. And whether the
module function switches to the standby module also needs to be confirmed before
installing the removed module to the backboard.
2. When the module is revoked from the backboard for a while, the diagnosis circuits and the
safety protection circuits may treat this circumstance as a dangerous abnormality so as to
shutoff the power supply to the module. Thus the module failure will occur. However, the
standby module in dual-redundant configuration will not fail.
3. When the module failure occurs, the LED lamp [STATUS] turns off. Under this situation, it
is necessary to remove the module from the backboard, and put it back after two or more
seconds.

 Cautions on Using I/O Modules with Built-in Barriers

The FIO current output modules with built-in barriers are designed with the safety concept that
when the over-current or the over-voltage occurs in the external circuits, the I/O modules will be
forced to failure state to guarantee the safety. The I/O modules are forced to failure state under
the following circumstances:
1. Forced to Failure State by Current/Voltage Limiter
For ASI533, ASD533 and ASI133, when the output encounters abnormalities due to the
over-current or over-voltage caused by the internal error of the module or the short-circuit of
the wiring, the current/voltage limiter circuit in the module becomes active to stop the output,
the module will be forced to the failure state. This feature is necessary for satisfying the
standards of intrinsically safety and explosion protection.
2. Forced to Failure State by Read-back
Read-back is one of the diagnostic capabilities of the I/O modules. Read-back function of
ASI533 and ASD533 can detect the following abnormalities:
- Internal errors regarding the output in the module circuits;
- Abnormalities of the terminals and the field wirings.

For explosion protection, the intrinsically safety circuits must be prevented from the errors
caused by incorrect wirings, damaged cables or short circuits. For the FIO modules with
the built-in barriers, if a read-back error is found, it does not only indicate the abnormalities
occurred in the module but also indicate that the abnormalities may have occurred in the
field wirings that weakened the intrinsically safety and explosion protection capabilities.
Thus the module will be forced to the failure state so as to prevent the possible accident that
may result to an explosion.
For the above purpose, the read-back capability of the FIO modules will be set to ON by
default.
When a module is forced to failure state, take care of the following cautions:
1. For Non-Redundantly Configured Module
Replace the failed module with a new one. If the module starts working normally, it indicates
that the error was caused by module’s abnormality. Otherwise, if the new module becomes
failure state, it indicates that the failure was caused by other abnormalities such as wiring
short circuits. In this case, a thorough check should be preformed to the connection
terminals and field wirings so as to guarantee the intrinsically safety circuits for explosion
protection.
2. For Redundantly Configured Modules
If an active module fails and the activities are transferred to the standby module, the I/O
loop is working properly; it indicates that the problem is caused by the internal error of the
module. Replacing the abnormal module will solve the problem.
However, if both modules become failure state after transferring activities to the standby
module, it indicates that the problem may have occurred in the common circuits such as the
terminals used by both modules as well as the field wirings (for an example, the short-circuit
occurs between the channels). In this case, a thorough check should be performed to the
connection terminals and field wirings so as to guarantee the intrinsically safety circuits for
explosion protection.
For detailed information about the procedure for specific channels that caused the
abnormalities, please contact Yokogawa agents.
Before replacing the modules or doing similar maintenance works in the hazardous area
(Zone 2), it is necessary to turn off the power supply and to confirm that the explosive gases
are not present in the ambient atmosphere. Moreover, the maintenance works must be
performed by the personals who have been educated and trained with the knowledge of
explosive products and skill of explosive prevention.

 Combinations of Input/Output Module and Terminal Block

There are various methods for connecting cables to I/O modules, such as single/dual-redundant
operation, isolated/non-isolated, and directly coupled/via a terminal board. In each case, it is
possible to combine an I/O module with adapters or terminal blocks according to the purpose.
The table below lists the model names of the different combinations of I/O modules and terminal
blocks that can be used.
 Analog and Digital I/O Modules with Built-In Barrier

 Signal Wiring to I/O Module

Vary with the model of analog input modules and vary with devices connected, the terminals for
connecting the signal cables are different. Refer to the following table and connect the cable to
the proper terminals.

3.6.1 Analog Input Module, 8-Channel (ASI133)

3.6.2 Analog Output Module, 8-Channel (ASI533)

 3.6.3 Thermocouple/mV Input Module, 16-Channel (AST143)

 Cautions Regarding to Wiring of AST143 Field Cable

To fulfill the requirements of EMC according to IEC 61000, it is necessary to use screened cable.
(shielded multicore cable with one shield for all channels is sufficient).
 Cautions Regarding to the Thermocouples Connected to AST143
The thermocouples connected to AST143 must be ungrouneded type. If you desire to use the
grounded type thermocouples, you need to consult to Yokogawa agents for advices.

3.6.4 RTD/POT Input Module, 8-Channel (ASR133)

 Cautions Regarding to Wiring of ASR133 Field Cable

To fulfill the requirements of EMC according to IEC 61000, it is necessary to use screened cable.
(shielded multicore cable with one shield for all channels is sufficient).

3.6.5 Digital Input Module, 16-Channel (ASD143)

3.6.6 Digital Output Module, 16-Channel (ASD533)