2865298

PI-EX-SD-24-48 Ex-i solenoid driver for Group IIC gases, loop-powered, pluggable INTERFACE Data sheet 103120_en_01 1 © PHOENIX CONTACT - 07/2009 Description The PI-EX-SD-24-48 solenoid driver connects a signaling device installed in the safe area to a device located in the Ex area. The block itself is installed outside the Ex area or in zone 2. Solenoid valves, alarm blocks or other intrinsically safe devices can be connected, and basic electrical equipment, such as LEDs, can be operated. The safety data is designed so that loads can be operated in an IIC group gas. 1.1 – – – – – – Properties Single-channel Loop-powered Output [Ex ia] IIC Installation in zone 2 2-way electrical isolation SIL 3 according to IEC 61508 The PI-EX-SD-24-48 solenoid driver does not require its own power supply; instead, it is simply looped into the circuit. WARNING: Explosion hazard The device is an associated item of equipment. It is designed for use in zone 2, if the specific conditions are observed. When installing and operating the device, the applicable safety directives (including national safety directives), accident prevention regulations, as well as general technical regulations, must be observed. WARNING: Explosion hazard Observe the safety regulations and installation notes on page 5. Make sure you always use the latest documentation. It can be downloaded at www.phoenixcontact.net/download. This data sheet is valid for all products listed on the following page: PI-EX-SD-24-48 Table of contents 1 Description.................................................................................................................................. 1 2 Ordering data.............................................................................................................................. 2 3 Technical data ............................................................................................................................ 2 4 Safety regulations and installation notes .................................................................................... 4 5 Structure ..................................................................................................................................... 6 6 Installation ................................................................................................................................. 6 7 Comparison of safety data.......................................................................................................... 7 8 Calculating a valve circuit ........................................................................................................... 7 9 Safety-related applications (SIL 3) ............................................................................................. 8 10 Appendix..................................................................................................................................... 8 2 Ordering data Ex solenoid driver Description Type Order No. Pcs./Pkt. Ex-i solenoid driver for Group IIC gases, loop-powered, pluggable PI-EX-SD-24-48 2865298 1 Accessories Description Type Order No. Pcs./Pkt. Motherboard See "INTERFACE" catalog Ex basic terminal block for intrinsically safe signals with knife disconnection and test connections PI-EX-TB 2835901 10 Intrinsically safe basic terminal block, with knife disconnection, test connections, and surge protection, for mounting on NS 35/7,5 TT-PI-EX-TB 2858386 10 Basic terminal block for non-intrinsically safe signals, with surge protection TT-PI-TB 2858373 10 Basic terminal block for non-intrinsically safe signals, without surge protection PI-TB 2835943 10 FBST-500-PLC-RD FBST-500-PLC-BU FBST-500-PLC-GY 2966786 2966692 2966838 20 20 20 Continuous plug-in bridge, 500 mm long, insulated, can be cut to length, for potential distribution, Imax = 32 A, color of the insulating material: Red Blue Gray For additional accessories, please refer to the Phoenix Contact "INTERFACE" catalog. 103120_en_01 PHOENIX CONTACT 2 PI-EX-SD-24-48 3 Technical data Input Input signal 20 V DC … 30 V DC Output Output characteristic curve (see Figure 1 on page 3) UV = 24 V (guaranteed voltage) Ri = 246 Ω (internal resistance) Output voltage, intrinsically safe 11.8 V at 48 mA Current limit At 48 mA Output characteristic curve Output voltage UV 24 V 20 11.8 V 10 0 0 10 20 30 40 50 60 Output current IV Figure 1 Output characteristic curve for PI-EX-SD-24-48 General data Supply voltage range (No separate supply voltage required) Maximum current consumption at 24 V DC 130 mA Maximum power dissipation at 24 V DC 1.7 W Electrical isolation (input/output) 375 V (peak value according to EN 50020) Housing material PBT and polyamide PA, non-reinforced Inflammability class according to UL 94 V0 Degree of protection IP20 Color Green Dimensions Without basic terminal block (width x height) With basic terminal block (width x height x length) 12.4 mm x 108.6 mm 12.4 mm x 147 mm x 145 mm Ambient conditions Ambient temperature (operation) -20°C ... +55°C (perpendicular mounting of DIN rail) -20°C ... +60°C (horizontal mounting of DIN rail) Average temperature according to IEC 61508 40°C Ambient temperature (storage/transport) -40°C … +80°C Permissible humidity (operation) 10% ... 95% (relative humidity, no condensation) Indicators Status indicators Yellow LED (switching state) Red LED (line fault) EC conformance EMC Directive 89/336/EEC Yes Ex Directive (ATEX) Yes 103120_en_01 PHOENIX CONTACT 3 PI-EX-SD-24-48 Safety data according to ATEX for intrinsically safe circuits Maximum output voltage Uo 27.7 V Maximum output current Io 101 mA Maximum output power Po 697 mW Gas group Maximum external inductance Lo Maximum external capacitance Co Maximum ratio Lo/Ro True r.m.s. value of maximum AC voltage Um Maximum DC voltage Um IIA IIB IIC 20 mH 0.44 μF 2 mH 0.29 μF 0.5 mH 0.067 μF 51.1 μH/Ω1 250 V AC 125 V DC 1 Please observe the technical data for the connecting cables used. Approvals ATEX X II (1) GD [EEx ia] IIC/IIB/IIA, TÜV 06 ATEX 553193 X II 3 G Ex nA II T4 X UL/CUL UL applied for 103120_en_01 PHOENIX CONTACT 4 PI-EX-SD-24-48 4 Safety regulations and installation notes 4.1 Installation and operation Follow the installation instructions. NOTE: Installation, operation, and maintenance may only be carried out by qualified specialist personnel. When installing and operating the device, the applicable safety directives (including national safety directives), accident prevention regulations, as well as general technical regulations, must be observed. NOTE: The circuits inside the device must not be accessed. Do not repair the device yourself, replace it with an equivalent device. Repairs may only be carried out by the manufacturer. NOTE: The device must be stopped and immediately removed from the Ex area if it is damaged, was subject to an impermissible load or stored incorrectly, or if it malfunctions. NOTE: The device is designed to meet IP20 protection when: – It is installed outside potentially explosive areas. – The environment around the device is clean and dry. In order to provide protection against mechanical or electrical damage, install the device in appropriate housing with a suitable degree of protection according to IEC 60529. 4.2 Safety regulations for installation in potentially explosive areas Regulations for intrinsically safe circuits WARNING: Explosion hazard When carrying out measurements on the intrinsically safe side, observe the relevant regulations regarding the connection of intrinsically safe equipment. Only use devices approved for use in intrinsically safe circuits. WARNING: Explosion hazard If the device has been used in nonintrinsically safe circuits, it must not be used again in intrinsically safe circuits. The module must be clearly labeled as nonintrinsically safe. For the safety data, please refer to the operating instructions and certificates (EC-type examination certificate, other approvals, if necessary). Installation in zone 2 WARNING: Explosion hazard The device is an associated item of equipment with "intrinsically safe" explosion protection and is designed for installation in zone 2. Observe the specified conditions for use in potentially explosive areas. WARNING: Explosion hazard Install the device in suitable approved housing with IP54 protection, minimum, that meets the requirements of EN 60079-15. Observe the requirements of IEC 60079-14/EN 60079-14. WARNING: Explosion hazard Disconnect the block power supply before: – Snapping it on or disconnecting it. – Connecting or disconnecting cables for nonintrinsically safe circuits. WARNING: Explosion hazard Only use category 3G PI EX modules (ATEX 94/9/EC). 103120_en_01 PHOENIX CONTACT 5 PI-EX-SD-24-48 Installation in areas with a danger of dust explosions WARNING: Explosion hazard The device is not designed for use in areas with a danger of dust explosions. Connection to the intrinsically safe circuit in areas with a danger of dust explosions (zone 20, 21, and 22) is only permitted if the equipment connected to this circuit is approved for this zone (e.g., category 1D, 2D or 3D). 4.3 Use in safety-related applications (SIL 3) When using the PI-EX-SD-24-48 in safety-related applications, observe the instructions in Section 9, as the requirements differ for safety-related functions. 103120_en_01 PHOENIX CONTACT 6 PI-EX-SD-24-48 5 Structure 6 Installation NOTE: Electrostatic discharge 9 The device contains components that can be damaged or destroyed by electrostatic discharge. When handling the device, observe the necessary safety precautions against electrostatic discharge (ESD) according to EN 61340-5-1 and EN 61340-5-2. IN OUT PI-EX-TB basic terminal block + - - +- + + - UB+ UB- 10 10 UB- 11 3 5 Cables of non-intrinsically safe circuits must only be connected and disconnected when the power is disconnected. ERR STAT 8 WARNING: Explosion hazard When used as equipment in zone 2, the electronic module must not be disconnected from the base element when connected to the power supply. UB+ UB- UB+ 1 20...30 V DC PI-EX-SD-2x-xx PI-EX-SD-24-48 6 2 7 4 The PI-EX-SD-24-48 can be installed in safe areas or in zone 2. 6.1 Figure 2 1 2 3 4 5 7 8 9 0 ! Structure Output "+" Output "–" Input signal "+" Input signal "–" 1 - 4 Terminal block screw with integrated test socket 6 Not used Isolating connectors Test sockets Locking clips Keying pin Status indicators Dimensions Base elements The device is designed for installation in the control cabinet and must be plugged into a base element (basic terminal block, electronics base or motherboard). Incorrect connection of the electronic module is prevented by a keyway in the base element and bars in the housing. A locking clip 9 is provided to prevent accidental removal of the device. To remove the electronic module, gently press the locking clip towards the housing; it can then be removed. WARNING: Explosion hazard If the device has been used in nonintrinsically safe circuits, it must not be used again in intrinsically safe circuits. The module must be clearly labeled as nonintrinsically safe. PI-EX-SD-24-48 Connection cross-section (solid/stranded): Tightening torque: 0.2 mm2 ... 2.5 mm2 0.5 Nm ... 0.6 Nm Basic terminal block Figure 3 103120_en_01 Dimensions (in mm) PHOENIX CONTACT 7 PI-EX-SD-24-48 Automatic keying of electronic modules 8 Calculating a valve circuit The base element is not keyed by default upon delivery. The user-friendly keying is located in the electronic module and consists of four plastic parts, which are joined together. When the electronic module is first removed, the bottom part of the keying pins (0 in Figure 2 on page 7) remains in the base element. In this way, it is automatically keyed to the relevant electronic module. If an electronic module is accidentally inserted in the wrong place, any plastic parts remaining in the base element can be removed using a screwdriver. RI UV Electronic module Base element View from below (locking clip to the right) View from above (isolating connector to the left) Input Output Input Solenoid driver NOTE: Compare the safety data before connecting a device located in the Ex-i area to the PI-EX-SD-24-48. Also observe the internal capacitance and inductance of the base elements. Safety data for: Ui, Ii, Pi, Li, Ci Uo, Io, Po, Lo, Co LiB, CiB, For the values for Uo, Io, Po, Lo, and Co, please refer to "Safety data according to ATEX for intrinsically safe circuits" on page 4. Capacitance and inductance of base elements LiB CiB PI-EX-TB PI-EX-TB/T 1 μH 1 nF TT-PI-EX-TB TT-PI-EX-TB/T 1 μH 3 nF Ex-i requirements: Ui ≥ Uo Ii ≥ Io Pi ≥ Po For IIB Li + Lc + LiB ≤ Lo and and IIA: Ci + Cc+ CiB ≤ Co For IIC: Li, Ci = 0 and Lc/Rc ≤ Lo/Ro 103120_en_01 Equivalent circuit In order to connect a solenoid valve to the device, it is necessary to compare the safety data and calculate the measurements. Ri: UV: Comparison of safety data Field devices: Solenoid driver: Base elements: Valve Output PI-EX-SD-24-48 7 RC USV Figure 4 Automatic keying ISV R SV 6.2 Motherboards Electronics base 0 μH 0 nF Internal resistance of the solenoid driver. Guaranteed voltage of the solenoid driver without load. Maximum current that can be supplied by the IV: solenoid driver. RC: Maximum permissible cable resistance when connecting the solenoid driver and valve. RSV: Effective coil resistance of the solenoid valve (the copper resistance of the coil depends on the temperature). ISV: The current required by the solenoid coil so that the valve can close tightly. USV: The voltage which is present at the coil with ISV. RSV and USV are determined by the copper resistance, which depends on the ambient temperature. The values for RSV and ISV must be obtained from the valve manufacturer. The values for Ri and UV can be found in the technical data under "Output" on page 3. The permissible cable resistance can be determined according to the following formula: Recommendation: RC = UV ––– ISV – Ri – RSV For RC, an actual cable resistance of +25 Ω should be calculated. In the event of a negative resistance, it is no longer guaranteed that the connection will function. (Lc and Cc or Lo and Ro are dependent on the cables/lines used.) Requirements for operation: IV ≥ ISV and RC > 0 Ω. A list of suitable valves can be found in the Download Center at www.phoenixcontact.net/download. PHOENIX CONTACT 8 PI-EX-SD-24-48 9 Safety-related applications (SIL 3) 9.1 Installation Failure limit Use one of the following base elements: – PI-EX-TB... basic terminal block – TT-PI-EX-TB... basic terminal block – PI-EX-MB... motherboard 9.2 The operating mode is based on low demand mode. The percentage of the device at PFH/PFD for the entire safety loop is less than 10%. Response times Following a state change at the input, the output enters the safe state in ≤ 40 ms. 9.3 Operating mode of the safety function Actuator control Actuator 35% 15% « 10% 40% 9.4 – Failure behavior and required response The safe state is entered in the event of an input voltage failure. The safe state is reached by removing the device from the base element. – – – 9.5 Safety loop Conditions – 2. Processing Figure 5 Operating mode according to IEC 61508: "Low demand mode". 1. Sensor and switching amplifier Safety integrity requirements The failure rates of the components used remain constant throughout the period of use. Propagation of errors by the device in the system is not taken into consideration. The repair time (= replacement) should be eight hours. The failure rates of the external signaling device are not taken into consideration. The average temperature at which the device is to be used is +40°C. This is based on standard industrial conditions. Error rates 9.6 – – Type A device (according to IEC 61508-2) Safety integrity level (SIL) 3 λSAFE 284 FIT3 λDANGEROUS 0 FIT SFF1 100% DCS2 0% 1 SFF = Safe Failure Fraction 2 DC = Diagnostic Coverage (safe or dangerous) 3 FIT = Failure in Time (1 FIT = 1 failure/109 h) DCD2 0% PFDAVG values T[PROOF] = PFDAVG1 = 1 1 year 0 5 years 0 10 years 0 Proof test Even where the PFDAVG value is 0, it is still recommended that you check the function of the valve burner in conjunction with the entire safety loop. 1. Take appropriate steps to prevent incorrect use. Prevent other areas of the system from being affected by the proof test (e.g., set the control system to test mode). 2. When a voltage of between 20 V and 30 V is applied at the input, check whether a voltage > 0 can be measured at the output terminal blocks. The field device must switch at the same time. 3. Restore the safety circuit to full functionality. 4. Return to normal operation. PFD = Probability of Failure on Demand Since the PFDAVG value is 0, it is not necessary to perform regular proof tests. This is, however, still recommended (see Section 9.6). 103120_en_01 10 Appendix Exida assessment summary (3 pages) PHOENIX CONTACT GmbH & Co. KG • 32823 Blomberg • Germany • Phone: +49 - 52 35 - 30 0 PHOENIX CONTACT • P.O.Box 4100 • Harrisburg • PA 17111-0100 • USA • Phone: +717-944-1300 www.phoenixcontact.com 9 Failure Modes, Effects and Diagnostic Analysis Project: Solenoid Driver with Motherboard Customer: Phoenix Contact GmbH & Co. KG Blomberg Germany Contract No.: Phoenix Contact 06/06-05 Report No.: Phoenix Contact 06/06-05 R004 Version V2, Revision R0, January 2008 Philipp Neumeier The document was prepared using best effort. The authors make no warranty of any kind and shall not be liable in any event for incidental or consequential damages in connection with the application of the document. © All rights on the format of this technical report reserved. Management summary This report summarizes the results of the hardware assessment carried out on the solenoid drivers type PI-EX-SD-**-** with a corresponding motherboard and on the solenoid drivers with top hat rail design, MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EX-SL-SD-**-**-LP-SP. Table 1 gives an overview of the different devices. Within each type the different devices have the same circuit diagram. Table 1: Device overview Motherboard type: Top hat rail type: PI-EX-SD-21-25 PI-EX-SD-21-40 PI-EX-SD-21-45 PI-EX-SD-24-48 PI-EX-SD-21-60 Output values: MACX MCR-EX-SL-SD-21-25-LP / MACX MCR-EX-SL-SD-21-25-LP-SP MACX MCR-EX-SL-SD-21-40-LP / MACX MCR-EX-SL-SD-21-40-LP-SP MACX MCR-EX-SL-SD-21-45-LP / MACX MCR-EX-SL-SD-21-45-LP-SP MACX MCR-EX-SL-SD-24-48-LP / MACX MCR-EX-SL-SD-24-48-LP-SP MACX MCR-EX-SL-SD-21-60-LP / MACX MCR-EX-SL-SD-21-60-LP-SP 21 V / 25 mA 21 V / 40 mA 21 V / 45 mA 24 V / 48 mA 21 V / 60 mA The hardware assessment consists of a Failure Modes, Effects and Diagnostics Analysis (FMEDA). A FMEDA is one of the steps taken to achieve functional safety assessment of a device per IEC 61508. From the FMEDA, failure rates are determined and consequently the Safe Failure Fraction (SFF) is calculated for the device. For full assessment purposes all requirements of IEC 61508 must be considered. The failure rates used in this analysis are the basic failure rates from the Siemens standard SN 29500. According to table 2 of IEC 61508-1 the average PFD for systems operating in low demand mode has to be ≥10-4 to < 10-3 for SIL 3 safety functions. However, as the modules under consideration are only one part of an entire safety function they should not claim more than 10% of this range, i.e. they should be better than or equal to 1,00E-04. The solenoid drivers type PI-EX-SD-**-** with a corresponding motherboard and the solenoid drivers with top hat rail design, MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EX-SL-SD-****-LP-SP are considered to be Type A1 components with a hardware fault tolerance of 0. For Type A components the SFF has to be 90% to < 99% according to table 2 of IEC 61508-2 for SIL 3 (sub-) systems with a hardware fault tolerance of 0. The solenoid drivers PI-EX-SD-**-** and MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EXSL-SD-**-**-LP-SP are operated in passive mode, and can therefore be regarded as loop powered modules. Because loop powered modules are directly driven from the digital output of a safety PLC there is no additional power supply which can keep the output energized in case of an internal fault. Thus all internal faults have either no effect on the safety function or lead to a safe state. 1 Type A component: © exida.com GmbH Philipp Neumeier “Non-complex” component (all failure modes are well defined); for details see 7.4.3.1.2 of IEC 61508-2. phoenix contact 06-06-05 r004 v2r0.doc, January 18, 2008 Page 2 of 3 Results for solenoid drivers PI-EX-SD-**-** with Motherboard: The following table shows how the above stated requirements are fulfilled. Table 2: Summary for PI-EX-SD-**-** with Motherboard – IEC 61508 failure rates 2 λSAFE 284 FIT λDANGEROUS 0 FIT 3 SFF PFDAVG 100% 0,00E+00 Results for top hat rail type solenoid drivers MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EX-SL-SD-**-**-LP-SP: The following table shows how the above stated requirements are fulfilled. Table 3: Summary for MACX MCR-EX-SL-SD-**-**-LP / MACX MCR-EX-SL-SD-**-**-LP-SP – IEC 61508 failure rates 2 λSAFE 282FIT λDANGEROUS 0 FIT 3 SFF PFDAVG 100% 0,00E+00 The above results show that the solenoid drivers PI-EX-SD-**-** with Motherboard and MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EX-SL-SD-**-**-LP-SP - both when loop powered can be used for all safety applications. The calculations are based on the assumption that the devices are mounted in an environment that is IP 54 compliant (e.g. housing, control cabinet or control room). The failure rates are valid for the useful life of the solenoid drivers PI-EX-SD-**-** and MACX MCR-EX-SL-SD-**-**-LP and MACX MCR-EX-SL-SD-**-**-LP-SP (see Appendix 1). 2 It is assumed that practical fault insertion tests can demonstrate the correctness of the failure effects assumed during the FMEDAs. 3 In order to deal with the excluded faults in the quantitative analysis it might be reasonable to consider a dangerous failure rate of 0.1 FIT, leading to a SFF of 99,97% and a PFDAVG of 4,38E-06 for a proof time of 10 years. © exida.com GmbH Philipp Neumeier phoenix contact 06-06-05 r004 v2r0.doc, January 18, 2008 Page 3 of 3