PI-EX-SD-21-60
Ex-i Solenoid Driver for Group IIB Gases,
Loop-Powered, Pluggable
INTERFACE
Data Sheet
103245_00_en
1
© PHOENIX CONTACT - 02/2008
Description
The solenoid driver PI-EX-SD-21-60 links a signaling
device installed in the safe area to a device located in the
hazardous area. The block itself is installed outside the
hazardous area or in Zone 2.
Solenoid valves, alarm modules, or other intrinsically safe
devices can be connected, and simple electrical equipment
such as LEDs can be operated.
The safety data allows loads to be operated in an IIB group
gas.
1.1
–
–
–
–
–
–
Properties
Single-channel
Loop-powered
Output [Ex ia] IIB
Installation in Zone 2
Electrical 2-way isolation
SIL 3 acc. to IEC 61508
The solenoid driver PI-EX-SD-21-60 does not require its
own power supply; instead, it is simply looped into the
circuit.
The device is associated equipment, which is suitable for use in Zone 2, provided that particular
conditions have been 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.
Observe the safety regulations and installation notes on page 4.
Make sure you always use the latest documentation.
It can be downloaded at www.download.phoenixcontact.com.
A conversion table is available on the Internet at
www.download.phoenixcontact.com/general/7000_en_00.pdf.
This data sheet is valid for all products listed on the following page:
PI-EX-SD-21-60
Table of Contents
1
Description.................................................................................................................................. 1
2
Ordering Data ............................................................................................................................. 2
3
Technical Data............................................................................................................................ 2
4
Safety Regulations and Installation Notes.................................................................................. 4
5
Structure ..................................................................................................................................... 5
6
Installation .................................................................................................................................. 5
7
Comparison of Safety Data ........................................................................................................ 6
8
Calculation of a Valve Circuit...................................................................................................... 6
9
Safety-Related Applications (SIL 3)............................................................................................ 7
10 Appendix..................................................................................................................................... 7
2
Ordering Data
Ex Solenoid Driver
Description
Type
Order No.
Pcs./Pck.
Ex-i solenoid driver for Group IIB gases, loop-powered, pluggable
PI-EX-SD-21-60
2865188
1
Accessories
Description
Type
Order No.
Pcs./Pck.
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 "INTERFACE" catalog from Phoenix Contact.
3
Technical Data
Input
Input signal
20 V DC - 30 V DC
Output
Output characteristic curve (see Figure 1 on page 3)
UV = 21.4 V (guaranteed voltage)
Ri = 136 Ω (internal resistance)
Output voltage, intrinsically safe
12.5 V at 58 mA
Current limit
At 58 mA
103245_00_en
PHOENIX CONTACT
2
PI-EX-SD-21-60
Output voltage UV
Output characteristic curve
21.4 V
20
12.5 V
10
0
0
10
20
30
40
50
60
Output current IV
Figure 1
Output characteristic curve for PI-EX-SD-21-60
General Data
Supply voltage range
(No separate supply voltage necessary)
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 indicator
Yellow LED (switching state)
Red LED (line fault)
EU Conformity
Complies with EMC directive 89/336/EEC
Yes
Ex directive (ATEX)
Yes
Safety Data According to ATEX for Intrinsically Safe Circuits
Maximum output voltage Uo
25.1 V
Maximum output current Io
188 mA
Maximum output power Po
1,180 mW
Gas group
IIA
5.2 mH
0.51 μF
Max. external inductance Lo
Max. external capacitance Co’
True r.m.s. value of maximum AC voltage Um
Maximum DC voltage Um
IIB
2.7 mH
0.28 μF
250 V AC
125 V DC
Certificates
ATEX
X II (1) GD [EEx ia] IIB/IIA, TÜV 06 ATEX 553193
X II 3 G Ex nA II T4 X
UL/CUL
UL applied for
103245_00_en
PHOENIX CONTACT
3
PI-EX-SD-21-60
4
Safety Regulations and Installation Notes
4.1
Installation and Operation
Follow the installation instructions.
Installation, operation, and maintenance may
only be carried out by qualified specialist
personnel.
The safety data may be derived from the operating
instructions and the certificates (EC type examination
certificate; additional certificates if necessary).
Installation in Zone 2
WARNING: Risk of explosion
The device is associated equipment of the
"intrinsic safety" protection type, and is suitable
for installation in Zone 2 if the
symbol is
printed on the block.
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.
Access to the circuits within the device is
prohibited.
Observe the specified conditions for use in potentially
explosive areas.
Do not repair the device yourself, but replace it with an
equivalent device. Repairs may only be carried out by the
manufacturer.
WARNING: Risk of explosion
Install the device in a suitable housing with a
minimum of IP54 degree of protection.
Within this context, observe the requirements
of IEC 60079-14/EN 60079-14, e.g., steel
housing with a wall thickness of 3 mm.
The device is suitable for IP20 degree of
protection if:
– It is installed outside the potentially
explosive area.
– The area around the device is clean and
dry.
WARNING: Risk of explosion
Disconnect the block before you:
– Snap it on or remove it.
– Connect or dismantle cables for
non-intrinsically safe circuits.
Install the device in a suitable housing with a suitable
degree of protection in accordance with IEC 60529 in order
to protect it from mechanical and electrical damage.
4.2
WARNING: Risk of explosion
Only use Category 3G PI-EX modules
(ATEX 94/9/EC).
Safety Regulations for Installation in the
Potentially Explosive Area
Regulations for Intrinsically Safe Circuits
WARNING: Risk of explosion
When taking measurements on the
intrinsically safe side, it is imperative that you
observe the relevant regulations regarding the
connection of intrinsically safe equipment.
Only use equipment approved for
intrinsically safe circuits.
WARNING: Risk of explosion
If the device has been used in
non-intrinsically safe circuits, it must not be
used again in intrinsically safe circuits.
Installation in Areas With a Danger of Dust Explosions
WARNING: Risk of explosion
The device is not designed for use in areas
where there is a danger of dust explosions.
Connection to intrinsically safe circuits in areas with a
danger of dust explosions (Zones 20, 21, or 22) is only
permitted if the equipment connected to this circuit is
approved for these zones (e.g., Category 1D, 2D, or 3D).
4.3
Use in Safety-Related Applications (SIL 3)
When using the PI-EX-SD-21-60 in safety-related
applications, observe the instructions in Section 9, as the
requirements differ for safety-related functions.
Clearly label the module as being
non-intrinsically safe.
103245_00_en
PHOENIX CONTACT
4
PI-EX-SD-21-60
5
Structure
6
Installation
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-
STAT
3
5
4
6
Connecting and disconnecting cables for
non-intrinsically safe circuits is only permitted
if they are not live.
ERR
11
8
WARNING: Risk of explosion
When being used as equipment in Zone 2, the
electronic module must not be disconnected
from the base element while it is still live.
UB+
UB-
UB+
1
20...30 V DC
PI-EX-SD-2x-xx
2
7
PI-EX-SD-21-60
The PI-EX-SD-21-60 can be installed in the safe area or
in Zone 2.
Figure 2
1
2
3
4
5
7
8
9
0
!
Structure
Output "+"
Output "–"
Input signal "+"
Input signal "–"
1 – 4 Terminal screw with integrated test socket
6 Not used
Isolating connectors
Test sockets
Locking clips
Keying pin
Status indicators
Dimensions
PI-EX-SD-21-60
6.1
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 in order to prevent accidental
removal. To remove the electronic module, gently press the
locking clip towards the housing; it can then be removed.
WARNING: Risk of explosion
If the device has been used in
non-intrinsically safe circuits, it must not be
used again in intrinsically safe circuits.
Clearly label the module as being
non-intrinsically safe.
Connection cross section
(solid and stranded):
Tightening torque:
0.2 mm2 - 2.5 mm2
0.5 Nm - 0.6 Nm
Basic
terminal
block
Figure 3
103245_00_en
Dimensions (in mm)
PHOENIX CONTACT
5
PI-EX-SD-21-60
Automatic Keying of the Electronic Modules
8
Calculation of a Valve Circuit
The base element is not keyed upon delivery. The
user-friendly keying is located in the electronic module and
consists of four plastic parts, which are joined together. The
first time the electronic module is removed, the bottom part
of the keying pins (0 in Figure 2 on page 5) 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.
Automatic keying
Electronic module
Base element
View from below
(locking clip to the
right)
View from above
(isolating connector to the
left)
Input
Output
Input
Output
Comparison of Safety Data
Compare the safety data before connecting a
device in the Ex-i area to the PI-EX-SD-21-60.
Please also observe the internal capacitance
and inductance of the base elements.
Safety data of the
Field devices:
Solenoid driver:
Base elements:
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 3.
Capacitances and Inductances of Base Elements
LiB
CiB
PI-EX-TB
PI-EX-TB/T
TT-PI-EX-TB
TT-PI-EX-TB/T
1 μH
1 nF
1 μH
3 nF
Motherboards
Electronics
bases
0 μH
0 nF
Ex i Prerequisites:
Ui ≥ Uo
Ii ≥ Io
Pi ≥ Po
Li + Lc + LiB ≤ Lo
Ci + Cc+ CiB ≤ Co
103245_00_en
ISV
UV
RC
USV
Solenoid driver
Figure 4
Valve
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:
PI-EX-SD-21-60
7
RI
R SV
6.2
Internal resistance of solenoid driver
Guaranteed voltage of the solenoid driver without
load
Maximum current that can be supplied by the
IV:
solenoid driver
RC: Maximum permissible conductor 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 applied across the coil with ISV
RSV and USV are dependent on the ambient temperature
due to the copper resistance.
The values of RSV and ISV must be found out from the valve
manufacturer. The values for Ri and UV can be found in the
technical data under "Output" on page 2.
On the basis of this, the permissible conductor resistance
can be calculated according to the formula below:
Recommendation:
RC =
UV – R – R
–––
i
SV
ISV
For RC, the actual conductor
resistance +25 Ω is to be
calculated.
Where negative resistance occurs, it is no longer possible
to guarantee that the connection will function.
Function prerequisites: IV ≥ ISV and RC > 0 Ω.
(Lc and Cc are dependent on the
cables/lines used.)
You can obtain a list of suitable valves from the
Download Center at
www.download.phoenixcontact.com.
PHOENIX CONTACT
6
PI-EX-SD-21-60
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 or
– 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 overall safety
loop is less than 10%.
Sensor and
switching
amplifier
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
Figure 5
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 Integrity Requirements
Error Rates
–
–
Type A device (according to IEC 61508-2)
Safety Integrity Level (SIL) 3
λSAFE
284 FIT3
λDANGEROUS
0 FIT
SFF1
100%
1
SFF = Safe Failure Fraction
2
DC = Diagnostic coverage (safe or dangerous)
3
FIT = Failure in Time (1 FIT = 1 failure/109 h)
DCS2
0%
9.6
DCD2
0%
PFDAVG Values
T[PROOF] =
PFDAVG1 =
1
1 year
0
5 years
0
Actuator
control
Actuator
« 10%
40%
Safety loop
Conditions
–
2.
15%
35%
Operating mode according to IEC 61508: "Low demand
mode"
1.
Processing
10 years
0
PFD = Probability of Failure on Demand
Since the PFDAVG value is 0, it is not necessary to perform
regular Proof Tests; however, this is still recommended
(see Section 9.6).
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 take 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.
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 of > 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.
10
Appendix
Exida Assessment Summary (3 pages)
103245_00_en
PHOENIX CONTACT GmbH & Co. KG • 32823 Blomberg • Germany
Phone: +49 - 52 35 - 30 0 • Fax: +49 - 52 35 - 34 12 00
www.phoenixcontact.com
7
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
