General Information

• Brand: Emerson
• Model: KJ2005X1-SQ1
• Product Type: I/O Interface Module (for DeltaV DCS)
• System Compatibility: Exclusively compatible with Emerson DeltaV DCS (supports DeltaV software versions v13.3 and later). Works with DeltaV controllers (M-series, S-series) and DeltaV I/O racks (e.g., Electronic Marshalling Chassis).
• Core Function: Converts industrial field signals (analog/digital) into a format readable by DeltaV controllers; enables bidirectional data exchange between field devices and the DCS. Provides signal isolation and surge protection to ensure stable communication.

Technical Specifications

1. Signal & I/O Configuration

• Supported Signal Types:
  • Analog Input (AI): 4–20 mA DC (two-wire/four-wire), 0–10 V DC.
  • Analog Output (AO): 4–20 mA DC, 0–10 V DC (configurable per channel).
  • Digital Input (DI): 24 V DC wet contact, dry contact (NO/NC).
  • Digital Output (DO): 24 V DC transistor output (max 1 A per channel).
• Channel Count: 8 universal I/O channels (each channel can be independently configured as AI/AO/DI/DO via software).
• Signal Isolation: 2.5 kVrms isolation between channels, between channels and backplane (per IEC 61010-1) – prevents ground loops and voltage surges from damaging the module.

2. Power Supply

• Backplane Power: 5 V DC (supplied by DeltaV I/O rack), typical current draw: 0.4 A.
• External Isolation Power: 24 V DC (required for field signal circuits), typical current draw: 0.6 A (full load).
• Protection: Reverse polarity protection (up to 36 V DC) and overcurrent protection (1 A self-resetting fuse).

3. Communication

• Protocol: DeltaV proprietary communication protocol (via backplane) – ensures high-speed data transmission (up to 100 Mbps) with low latency.
• HART Compatibility: Supports HART 7.0 protocol (optional) – enables bidirectional communication with HART-enabled field devices for configuration and health monitoring.

4. Physical & Environmental Specifications

• Dimensions: 101.6 mm (W) × 152.4 mm (H) × 38.1 mm (D) [4.0” × 6.0” × 1.5”] – fits DeltaV standard 1U I/O racks.
• Mounting: 19-inch rack-mounted (installs into DeltaV I/O chassis; no additional brackets needed).
• Operating Temperature: -40°C to +70°C (-40°F to 158°F) – suitable for extreme industrial environments (e.g., outdoor cabinets, high-temperature process areas).
• Storage Temperature: -40°C to +85°C (-40°F to 185°F).
• Humidity: 5%–95% RH (non-condensing) – resistant to moisture in chemical or offshore facilities.
• Vibration Resistance: 5 g (10–500 Hz) per IEC 60068-2-6 (sinusoidal); 10 g (100–2000 Hz) per IEC 60068-2-27 (random).
• Shock Resistance: 25 g (11 ms half-sine wave) per IEC 60068-2-27 (transient).
• Protection Class: IP20 (front panel) – designed for enclosed control cabinets (prevents dust ingress; not waterproof).

5. Safety & Compliance

• Certifications:
  • CE (EN 61326-1 for EMC immunity/emissions, EN 61010-1 for safety) – no interference with DeltaV system components.
  • UL 508 (industrial control equipment) – compliant for North American markets.
  • CSA C22.2 No. 14 (Canadian safety standard) – meets Canadian electrical codes.
  • ATEX/IECEx (variant-dependent: KJ2005X1-SQ1-EX) – for use in explosive environments (Zone 2/22).

Key Features

1. Universal I/O Flexibility: Each of the 8 channels can be independently set to AI/AO/DI/DO via DeltaV software (no hardware jumpers) – eliminates the need for multiple dedicated modules, saving rack space and reducing inventory costs.
2. High Signal Integrity: 2.5 kVrms channel isolation and surge protection prevent electrical noise (from motors, power lines) from disrupting signal transmission – critical for accurate data acquisition in harsh industrial settings.
3. Advanced Diagnostics:

• Built-in Self-Test (BIST): Automatically checks module hardware (ADC, power, isolation circuits) on startup; sends fault alerts to the DeltaV controller for remote monitoring.
• Field Signal Monitoring: Detects overrange/underrange signals, open/short circuits in field wiring, and HART communication errors (if HART-enabled) – triggers configurable alarms for quick troubleshooting.
• Status LEDs: Dedicated LEDs for power (green), communication (yellow), and channel faults (red) – enable visual identification of module health without accessing software.

4. Hot-Swappable Design: Supports hot swapping in DeltaV redundant I/O racks – allows module replacement without shutting down the DCS, minimizing downtime for 24/7 operations (e.g., refineries, power plants).
5. Electronic Marshalling Support: Works with DeltaV Electronic Marshalling (EM) chassis – simplifies wiring by allowing remote configuration of signal routing, reducing installation time and wiring errors.
6. Long-Term Reliability: Industrial-grade components and a rugged enclosure ensure a Mean Time Between Failures (MTBF) of >500,000 hours – reduces maintenance frequency and lifecycle costs.

Applications

• Oil & Gas: Connects pressure transmitters (4–20 mA) and valve actuators (DO) in wellhead control systems; monitors pipeline flow rate and temperature via analog inputs.
• Chemicals & Petrochemicals: Interfaces with reactor temperature sensors (RTD/thermocouple) and chemical dosing pumps (AO); provides digital inputs for emergency shutdown (ESD) switches.
• Power Generation: Links turbine vibration sensors (AI) and cooling fan controllers (DO) in thermal power plants; monitors boiler feedwater pressure via analog signals.
• Pharmaceuticals: Connects pH sensors (AI) and agitator motors (DO) in bioreactors; ensures compliance with GMP standards via accurate signal transmission and fault logging.
• Water & Wastewater: Interfaces with flow meters (AI) and pump starters (DO) in treatment plants; monitors tank level via analog inputs and triggers alarms for high/low levels.

Documentation & Support

• Technical Manual: Emerson DeltaV KJ2005X1-SQ1 I/O Interface Module Installation & Configuration Guide (Document No. D301010X015) – available for download via Emerson’s official Support Center portal. It includes wiring diagrams, software configuration steps, and troubleshooting flowcharts.
• Software Tools: Configured using DeltaV Explorer (DeltaV v13.3+) – enables channel type selection, alarm setup, and HART device management (if applicable).
• Spare Parts: Compatible with Emerson’s DeltaV spare kits (e.g., KJ2005X1-SQ1-KIT), which include replacement fuses, terminal blocks, and isolation components.

Ordering Information

• Base Model: KJ2005X1-SQ1 (8-channel universal I/O interface module, standard non-hazardous version).
• Variants:
  • KJ2005X1-SQ1-EX: Explosion-proof variant (ATEX/IECEx Zone 2/22) for hazardous environments.
  • KJ2005X1-SQ1-H: HART-enabled version (pre-configured for HART 7.0 devices).
• Optional Accessories:
  • Terminal Block Kit (KJ2005X1-SQ1-TB): For field wiring termination (compatible with 12–24 AWG wires).
  • Isolation Power Supply (24 V DC, Model: PS24-5A): For standalone testing and commissioning.
  • EMC Shielding Kit (KJ2005X1-SQ1-EMC): For high-noise environments (e.g., near large motors or variable frequency drives/VFDs).
• Lead Time: Typically 3–5 weeks for standard orders; 1–2 weeks for emergency spares (via Emerson’s authorized DeltaV distributors).