Emerson CHARM I/O Modules: KL2101X1-BA1 12P4987X162

Technical Dossier

Product Details And Specifications

Emerson CHARM I/O Series Technical Notes

The Emerson CHARM (Characterization Module) I/O system is a core component of the DeltaV distributed control system (DCS) platform, deployed extensively across global heavy industries including petrochemical refineries, nuclear power facilities, LNG terminals, offshore platforms, and pharmaceutical manufacturing plants. The CHARM architecture enables field-level intelligence by embedding signal characterization directly at the I/O terminal, eliminating the need for traditional marshalling cabinets and reducing wiring complexity by up to 40% compared to conventional DCS I/O designs.

The KL2101X1-BA1 12P4987X162 is a CHARM I/O card (CIOC) that serves as the primary interface between CHARM modules and the DeltaV controller network. It provides the backplane infrastructure for mounting individual CHARM modules and manages the high-speed serial communication bus connecting field signals to the DeltaV controller tier.

The Evolution of CHARM I/O Architecture

Emerson introduced the CHARM I/O concept as part of the DeltaV S-series platform expansion in the early 2010s, addressing the industry demand for electronic marshalling. The architecture has evolved through three distinct generations:

Generation 1 (2012–2015): Initial CIOC hardware with 96-channel capacity per carrier, supporting HART-enabled analog and discrete CHARM types. Limited to DeltaV v12.x and above. Compatibility constraints existed with legacy DeltaV M-series controllers without firmware upgrades.

Generation 2 (2015–2019): Revised CIOC backplane with improved bus arbitration, support for SIS (Safety Instrumented System) CHARM types, and expanded redundancy options. Introduced the CHARM SIS carrier for IEC 61511 SIL 2 applications. DeltaV v13.x and v14.x compatibility baseline.

Generation 3 (2019–present): Current production CIOC hardware with enhanced cybersecurity features (IEC 62443 alignment), support for wireless CHARM adapters, and compatibility with DeltaV v15.x and DeltaV Live. Backward-compatible with Generation 1 and 2 CHARM modules at the field terminal level.

The KL2101X1-BA1 12P4987X162 belongs to the Generation 2 / transitional Generation 3 product family. Units from this part number range are confirmed compatible with DeltaV v13.3 through v15.LTS. Operators running DeltaV v12.x must verify firmware revision before installation.

CHARM I/O Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly stocked components within the Emerson CHARM I/O ecosystem. All part numbers are cross-referenced against Emerson DeltaV hardware catalogs and field service documentation.

CIOC / Carrier Cards:

KL2101X1-BA1 12P4987X162: CHARM I/O Card (CIOC), 96-ch backplane carrier, DeltaV bus interface.
KL2101X1-BA2: CIOC redundant pair module, hot-swap capable, DeltaV v13+ required.
KL2101X1-BA3: CIOC with extended temperature rating (-40°C to +70°C), hazardous area variant.

Analog Input CHARM Modules (AI):

KJ3221X1-BA1: 4–20 mA HART AI CHARM, single-channel, SIL 2 rated, loop-powered.
KJ3222X1-BA1: 4–20 mA HART AI CHARM, single-channel, externally powered, NAMUR NE43.
KJ3223X1-BA1: 1–5 VDC AI CHARM, single-channel, high-impedance input, process analyzer interface.
KJ3224X1-BA1: RTD/Resistance AI CHARM, 2/3/4-wire PT100/PT1000, thermocouple compensation.
KJ3225X1-BA1: Thermocouple AI CHARM, J/K/T/E/R/S/B types, CJC integrated.

Analog Output CHARM Modules (AO):

KJ3241X1-BA1: 4–20 mA HART AO CHARM, single-channel, 750 Ω max load, HART pass-through.
KJ3242X1-BA1: 4–20 mA AO CHARM, non-HART, high-drive 1100 Ω max load, valve positioner interface.

Discrete Input CHARM Modules (DI):

Discrete Output CHARM Modules (DO):

KJ3011X1-BA1: 24 VDC DO CHARM, single-channel, 2 A max, short-circuit protected, status feedback.
KJ3012X1-BA1: 120/240 VAC DO CHARM, single-channel, solid-state relay, 0.5 A max, zero-crossing switch.
KJ3013X1-BA1: 24 VDC SIS DO CHARM, IEC 61511 SIL 2, de-energize-to-trip logic, internal diagnostics.

Power & Communication:

KL2102X1-BA1: CHARM Power Supply Module, 24 VDC, 10 A, redundant-capable, DIN rail mount.
KL2103X1-BA1: CHARM Ethernet Switch Module, managed, 8-port, DeltaV network segment isolation.

Sourcing Hard-to-Find & Obsolete CHARM I/O Parts

For end-users operating DeltaV systems on extended lifecycle support contracts (post-standard support), DriveKNMS provides multi-year spare parts reservation programs. This service is specifically structured for facilities that cannot execute a full DCS migration within a 3–5 year operational window and require guaranteed access to CIOC and CHARM module inventory.

Quality Control for the CHARM I/O Range

CHARM I/O modules present specific testing challenges due to their integrated backplane bus architecture and embedded HART modem circuitry. DriveKNMS applies the following test protocol to all CHARM I/O inventory prior to dispatch:

CIOC Backplane Verification: Each CIOC card is powered in a live DeltaV test rack running v13.3 or v14.3 firmware. The CIOC must enumerate correctly on the DeltaV controller network, pass self-diagnostics, and achieve READY status within 90 seconds of power-on. Backplane slot continuity is verified across all 96 channel positions using a custom bed-of-nails fixture.

CHARM Module Functional Test: Individual CHARM modules are inserted into a verified CIOC test carrier. AI CHARMs are tested with a calibrated 4–20 mA source (Fluke 725) across 0%, 25%, 50%, 75%, and 100% of span. AO CHARMs are loaded with a precision 250 Ω resistor and output verified against DeltaV setpoint commands. DI CHARMs are tested for wet/dry contact detection and NAMUR threshold compliance. DO CHARMs are tested for switching response time and short-circuit protection activation.

HART Communication Validation: All HART-capable CHARMs are tested using a HART communicator (Emerson 475 Field Communicator) to verify device descriptor (DD) loading, variable mapping, and burst mode operation.