Product Overview
The Honeywell 51305896-200 is a high-performance analog input Field Termination Assembly (FTA) engineered exclusively for Honeywell’s Experion PKS (Process Knowledge System) and TDC 3000 distributed control systems (DCS). Designed to serve as a critical interface between industrial analog sensors (e.g., pressure transmitters, level sensors, flow meters) and Process Managers (xPM/PM), this FTA terminates, isolates, and conditions low-level analog signals, ensuring accurate, reliable data transmission for real-time process monitoring and control.
As an upgraded successor to legacy analog input FTAs (e.g., 51304477 series), the 51305896-200 integrates advanced solid-state technology (eliminating obsolete mechanical components like mercury-wetted relays) and enhanced diagnostic capabilities to improve operational reliability and reduce maintenance costs. It is CE-compliant, conformally coated, and certified for hazardous locations, making it suitable for harsh industrial environments—including oil & gas refineries, power generation plants, chemical processing facilities, and pharmaceutical manufacturing sites.
The FTA supports multiple analog input types (e.g., 4–20 mA current loops, 0–10 V DC voltage signals) across 16 fully isolated channels, enabling flexible integration with diverse field devices. It is optimized for both new Experion PKS installations and retrofits of existing TDC 3000 systems, offering drop-in compatibility with standard FTA mounting infrastructure and Process Manager I/O (PMIO) modules.
Key Features
High-Density, Isolated Analog Inputs
16 Fully Isolated Channels: Each channel features independent isolation (channel-to-channel, channel-to-Process Manager, channel-to-power supply), eliminating cross-talk and common-mode voltage (CMV) interference. This isolation is critical for maintaining signal integrity in electrically noisy industrial environments (e.g., near high-voltage motors or variable-frequency drives).
Multi-Signal Compatibility: Supports a wide range of analog input types, including 4–20 mA (2-wire/4-wire transmitters), 0–5 V DC, 0–10 V DC, and ±5 V DC signals. This flexibility allows integration with diverse field instruments, reducing the need for multiple FTA types.
Enhanced Signal Conditioning & Measurement Accuracy
Per-Channel Signal Processing: Each channel includes dedicated signal conditioning circuitry (filtering, amplification) and a high-resolution analog-to-digital (A/D) converter, ensuring precise measurement with a resolution of 16 bits. This design minimizes measurement latency and drift compared to legacy FTAs with shared A/D converters.
Common-Mode Rejection: Boasts a Common-Mode Rejection Ratio (CMRR) of 120 dB (min) at 50/60 Hz, effectively suppressing noise from ground loops and industrial electrical interference. Normal-Mode Rejection Ratio (NMRR) of 60 dB (min) further filters out differential noise, ensuring stable, accurate readings.
Solid-State Reliability & Environmental Durability
Mercury-Free Design: Replaces legacy mercury-wetted relays with solid-state switching components, eliminating environmental hazards, reducing mechanical wear, and extending the FTA’s operational lifespan (MTBF: >200,000 hours).
Conformal Coating: The printed circuit board (PCB) is coated with a moisture- and chemical-resistant conformal layer (per IPC-CC-830 standards), protecting against dust, humidity, and corrosive industrial atmospheres. This enables reliable operation in environments with 10–90% non-condensing humidity and temperatures ranging from 0°C to 50°C.
Hazardous Location Certification: Complies with CSA Class I, Division 2 (Groups A–D) and UL Class I, Division 2 (Groups A–D) standards, making it safe for installation in potentially explosive environments (e.g., oil refineries, chemical plants) when paired with an IP54-rated enclosure.
Advanced Diagnostics & Maintenance Ease
On-Board LED Status Indicators: Features three LEDs (green, red, yellow) for real-time health monitoring:
Green: Confirms power is applied and the FTA is operational.
Red: Alerts to critical errors (e.g., firmware mismatch, power supply fault, channel short circuit).
Yellow: Indicates normal communication with the Input/Output Link Processor (IOLP) or active calibration.
Remote Diagnostics Integration: Transmits diagnostic data (e.g., channel fault status, signal integrity metrics) to the Experion PKS system via the PMIO module, enabling remote troubleshooting and reducing the need for on-site inspections.
Drop-In Replacement: Retains the same mounting footprint and connector pinout as legacy analog input FTAs, allowing seamless retrofits without modifying existing wiring, cabinets, or Process Manager configurations. This minimizes downtime during system upgrades.
Flexible Power & Cabling Options
Wide Power Supply Range: Operates on 24 V DC nominal power (15–30 V DC range), compatible with standard industrial power supplies. Low current draw (180 mA at 24 V DC) reduces power consumption and heat generation.
Long-Distance Cabling Support: Compensates for signal attenuation in long cable runs (up to 1000 feet using 16 AWG twisted-pair cable), enabling installation of field devices far from the control room without sacrificing measurement accuracy.
Technical Specifications
The Honeywell 51305896-200 is manufactured by Honeywell International Sàrl, classified as an enhanced analog input FTA for Experion PKS (Release 516+) and TDC 3000 DCS. It is optimized for terminating, isolating, and conditioning analog signals from industrial sensors to Process Managers (xPM/PM).
Core Functional Specifications
Input Channels: 16 independent analog input channels, fully isolated (channel-to-channel, channel-to-PM, channel-to-power).
Supported Input Types:
Current: 4–20 mA (2-wire/4-wire), 0–20 mA.
Voltage: 0–5 V DC, 0–10 V DC, ±5 V DC, ±10 V DC.
Input Scan Rate: 1 second (fixed by IOLP to ensure synchronization with Process Manager data acquisition).
Signal Resolution: 16 bits (analog-to-digital conversion), ensuring precise measurement of small signal variations (e.g., 0.01 mA increments for 4–20 mA signals).
Measurement Accuracy & Signal Integrity
Gain Error: ±0.05% full scale (max) for all input types, ensuring consistent accuracy across the entire signal range.
Temperature Stability: ±20 ppm per °C (max) for gain and offset, minimizing drift in variable-temperature industrial environments.
Long-Term Drift: 500 ppm (max) per year, reducing the need for frequent recalibration.
Common-Mode Voltage (CMV): ±250 V DC/Vac rms (with respect to PM common, DC to 60 Hz), enabling operation in high-noise environments.
Common-Mode Rejection Ratio (CMRR): 120 dB min (50/60 Hz, 1000 Ω source impedance).
Normal-Mode Rejection Ratio (NMRR): 60 dB min (50/60 Hz), filtering out differential noise from power lines.
Electrical & Power Specifications
Power Supply: 24 V DC nominal (15–30 V DC range); Current draw: 180 mA at 24 V DC (typical), 220 mA (max).
Surge Protection: IEEE C37.90.1 compliant (±2 kV surge protection for sensor terminals), safeguarding against voltage transients from lightning or power grid fluctuations.
Input Impedance: 100 Ω (current inputs), 1 MΩ (voltage inputs), ensuring compatibility with standard industrial transmitters.
Environmental & Mechanical Specifications
Operating Temperature: 0°C to 50°C (32°F to 122°F).
Storage Temperature: -40°C to 80°C (-40°F to 185°F).
Relative Humidity: 10–90% non-condensing (max operating temperature 40°C).
Mechanical Resistance:
Shock (operating): 30 g peak acceleration (11 ±1 ms pulse width).
Shock (non-operating): 50 g peak acceleration (11 ±1 ms pulse width).
Vibration: 0.5 g (10–60 Hz) or 0.1 inches displacement (peak-to-peak).
Dimensions: 63.5 mm (depth) × 124.5 mm (width) × 307.3 mm (length) (2.5 × 4.9 × 12.1 inches), conforming to standard FTA rack-mount dimensions.
Weight: ~350 g (0.77 lbs) (typical, including connectors).
Compliance & Certifications
Regulatory: CE Mark (EU EMC Directive 89/336/EEC, Low Voltage Directive 2014/35/EU); UL Listed (UL 508); CSA Certified (CSA C22.2 No. 142).
Hazardous Locations: CSA Class I, Division 2 (Groups A–D); UL Class I, Division 2 (Groups A–D); ATEX Zone 2 (Group IIC) compatible when installed in a certified enclosure.
Environmental: Conformally coated (IPC-CC-830) for moisture, dust, and chemical resistance.
Compatibility & Included Components
Compatible Systems: Experion PKS (Release 516+), TDC 3000, xPM Process Managers, PMIO modules, High-Performance Process Managers (HPPM).
Replaced Legacy Models: 51304477-100, 51304477-150, 51309218-125 (analog input FTAs).
Included Parts: 1× 51305896-200 FTA, 16× 3-pin compression terminals (51190771-403) for sensor wiring, 1× 6-pin connector (51195776-100) for PMIO connection, mounting screws, and installation guide.
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