2904665

PSR-PC50 SIL 3 coupling relay for safety-related switch on Data sheet 105818_en_02 1 © PHOENIX CONTACT 2015-05-18 Description The PSR-PC50 SIL coupling relay can be used for power adaptation and electrical isolation in Safe-State-ON applications up to SIL 3 according to IEC 61508 as well as IEC 61511. The category 3 device is designed for installation in zone 2 potentially explosive areas. By filtering the controller test pulses, premature failure of the safety relays is prevented. The contact side is fully monitored for open circuit and short circuit as well as load and diagnostics supply voltage. If an error occurs, the internal device input impedance is affected. As such, the test pulses sent from the controller are disrupted and the error is reported to the corresponding digital output without additional wiring effort. Features – – – – – – – – – – – – SIL 3 coupling relays for safety-related switch on Applications: Energized-to-Safe / Class I Div II Complete monitoring of the load side for: - Open circuit - Short circuit - Presence of supply voltage for diagnostics and loads Error message output through interrupting test pulses of the higher-level controller Easy proof test Integrated DCS test pulse filter Low inrush current One undelayed enabling channel Option of screw or spring-cage terminal blocks for plugin Special design for avoiding spurious trips Housing width 17.5 mm Compatible with EMERSON DeltaV SIS SLS1508 and CSLS (further controller cards on request) WARNING: Risk of electric shock Observe the safety instructions in the corresponding section! Make sure you always use the latest documentation. It can be downloaded from the product at phoenixcontact.net/products. This data sheet is valid for all products listed on the following pages. PSR-PC50 2 Table of contents 1 Description .............................................................................................................................. 1 2 Table of contents ..................................................................................................................... 2 3 Ordering data .......................................................................................................................... 3 4 Technical data ......................................................................................................................... 3 5 Safety notes............................................................................................................................. 6 5.1 Installation in the Ex area (zone 2)............................................................................................ 7 5.2 Installation in areas with a danger of dust explosions .................................................................... 7 6 Basic circuit diagram ............................................................................................................... 8 7 Derating................................................................................................................................... 8 7.1 Vertical mounting position ...................................................................................................... 8 7.2 Horizontal mounting position .................................................................................................. 8 8 Load curve............................................................................................................................... 8 9 Operating and indication elements .......................................................................................... 9 9.1 Connection versions ............................................................................................................. 9 9.2 Connection assignment ......................................................................................................... 9 10 Mounting and connection ...................................................................................................... 10 11 Startup................................................................................................................................... 10 12 Proof test ............................................................................................................................... 11 12.1 Testing of relay channels ..................................................................................................... 11 12.2 Testing diagnostics ............................................................................................................ 11 13 Calculating the power dissipation .......................................................................................... 11 14 Application examples ............................................................................................................ 12 14.1 Application example 1 - SIL 3................................................................................................ 13 15 Revision history ..................................................................................................................... 14 105818_en_02 PHOENIX CONTACT 2 PSR-PC50 3 Ordering data Description Type Order No. Pcs./Pkt. Coupling relay for SIL 3 low demand applications, couples digital output signals to the periphery, 1 enabling current path, module for F&G applications, test pulse filter, plug-in screw connection, 17.5 mm width PSR-PC50-1NO-1DO-24DC-SC 2904664 1 Coupling relay for SIL 3 low-demand applications, couples digital output signals to the I/O, 1 enabling current path, module for F&G applications, test pulse filter, plug-in spring-cage terminal block, width: 17.5 mm PSR-PC50-1NO-1DO-24DC-SP 2904665 1 4 Technical data Hardware/firmware version HW/FW ≥ 00/-- (The technical data and safety characteristics are valid as of the specified HW/FW version.) Input data Nominal input voltage UN 24 V DC -15 %; +10 % (A1/A2 and 24V/A2) Input voltage range (factor) 0.85 ... 1.1 Typical input current 65 mA (A1/A2) 15 mA (24V/A2; depending on load M1 +100 mA) Typical inrush current ≤ 200 mA (A1/A2) 2.5 A (24V/A2; for 10 s) 200 mA (Inputs TP1, TP2 and TP3) Current consumption typ. 20 mA (Input TP1) typ. 18 mA (Input TP2) typ. 35 mA (Input TP3) Max. permissible overall conductor resistance (Input and reset circuit at UN) < 10 Ω (LO/LO' and NI/NI' and load resistance in the event of a short circuit) Typical pick-up time 30 ms (when controlled via A1) Typical release time 30 ms (when controlled via A1) Recovery time 1s Maximum switching frequency 0.5 Hz Operating voltage display Yellow LED Status display Green LED Indication Red LED Protective circuit Overload protection Suppressor diode Output data Contact type 1 enabling current path Contact material AgNi, gold-flashed Minimum switching voltage 15 V AC/DC (without diagnostics) 20 V AC/DC (with diagnostics) Maximum switching voltage 250 V AC 125 V DC Limiting continuous current 5 A (N/O contact) Diagnostic threshold 20 Ω / 18 kΩ (lower/upper) Maximum inrush current 5A Inrush current, minimum 100 mA Switching capacity min. 1.5 W Mechanical service life Approx. 5 x 107 cycles 105818_en_02 PHOENIX CONTACT 3 PSR-PC50 Alarm outputs Number of outputs 1 (digital) Voltage 23 V DC Current max. 100 mA Short-circuit protection no General data Relay type Electromechanically forcibly guided, dust-proof relay. Nominal operating mode 100% operating factor Degree of protection IP20 Min. degree of protection of inst. location IP54 Mounting position vertical or horizontal Mounting type DIN rail mounting Air clearances and creepage distances between the power circuits DIN EN 50178 Rated insulation voltage 250 V AC Rated surge voltage/insulation 6 kV/safe isolation (through protective impedance) Pollution degree 2 Surge voltage category III Dimensions Screw connection Spring-cage connection WxHxD 17.5 x 112.2 x 114.5 mm 17.5 x 117.4 x 114.5 mm Connection data Screw connection Spring-cage connection Conductor cross section, solid 0.2 mm² ... 2.5 mm² 0.2 mm² ... 1.5 mm² Conductor cross section, stranded 0.2 mm² ... 2.5 mm² 0.2 mm² ... 1.5 mm² Conductor cross section AWG/kcmil 24 ... 12 24 ... 16 Stripping length 7 mm 8 mm Ambient conditions Ambient temperature (operation) -20 °C ... 55 °C Ambient temperature (storage/transport) -40 °C ... 65 °C Max. permissible relative humidity (operation) 75 % (on average, 85% infrequently, non-condensing) Max. permissible humidity (storage/transport) 75 % (on average, 85% infrequently, non-condensing) Maximum altitude ≤ 2000 m (Above sea level) Shock 15g Vibration (operation) 2g Conformance / approvals Conformance CE-compliant Approvals  IECEx ( IECEx ULD 14.0003X ) Ex nA nC IIC T4 Gc ATEX ( DEMKO 14 ATEX 1284X )  II 3 G Ex nA nC IIC T4 Gc UL, USA / Canada ( E140324 ) cULus UL, USA / Canada ( E360692 ) Class I, Zone 2, AEx nA nC IIC T4 / Ex nA nC IIC Gc T4 X Shipbuilding ( 11253-14 HH ) C, EMC2 Functional Safety in accordance with IEC 61508 to SIL 3 105818_en_02 PHOENIX CONTACT 4 PSR-PC50 Safety parameters for IEC 61508 - Low demand SIL 3 (15 % of total SIL) PFDavg 1,49 x 10-4 Proof test interval 120 Months Duration of use 240 Months Alternative illustration of the device as 1001 structure for process customers Calculation basis Application example 1 - SIL 3 Equipment type Type A HFT 0 SIL 3 (15 % of total SIL) Safe Failure Fraction (SFF) 99.6 % SD 4.27 FIT SU 849 FIT DD 4.21 FIT DU 3.40 FIT Total 860.88 FIT MTBF 110.5 Years PFDavg 1,49 x 10-5 (For T1 = 1 year) 105818_en_02 PHOENIX CONTACT 5 PSR-PC50 5 Safety notes NOTE: Risk of damage to equipment due to noise emissions WARNING: Risk of electric shock During operation, parts of electrical switching devices carry hazardous voltages. Before working on the switching device, disconnect the power. Please observe the safety regulations of electrical engineering and industrial safety and liability associations! Disregarding these safety regulations may result in death, serious personal injury or damage to equipment. Startup, mounting, modifications, and upgrades should only be carried out by a skilled electrical engineer! WARNING: Danger due to faulty devices! When operating relay modules the operator must meet the requirements for noise emission for electrical and electronic equipment (EN/ IEC 61000-6-4) on the contact side and, if required, take appropriate measures. NOTE: Risk of damage to equipment due to noise emissions This is a Class A product. In a domestic environment it may cause radion inteference, in which case the user may be required to take adequate measures. Only use power supply units with safe isolation and SELV / PELV in accordance with EN 50178/VDE 0160 (SELV / PELV). The devices may be damaged following an error and correct operation can no longer be ensured. In the event of an error, replace the device immediately. Repairs to the device, especially if the housing must be opened, may only be carried out by the manufacturer or authorized persons. Otherwise the warranty is invalidated. WARNING: risk of electric shock! The safety relay may only be connected to devices which meet the requirements of EN 60950. Suitable devices are available online at phoenixcontact.net/products. WARNING: Loss of safety function When an error is detected by the higher-level controller, it is assumed that the safety function can no longer be performed. The error must be removed within 72 hours or within the process safety time if required by the application. WARNING: Risk due to incorrect installation For reliable operation, the safety relay must be installed in housing protected from dust and humidity (IP54). Carry out wiring according to the application. Refer to the “Application examples” section for this. 105818_en_02 PHOENIX CONTACT 6 PSR-PC50 5.1 Installation in the Ex area (zone 2) Ambient temperature in hazardous areas (zone 2) Observe the derating curves. WARNING: Explosion hazard The category 3 device is suitable for installation in the zone 2 potentially explosive area. It fulfills the requirements of EN 600790:2012+A11:2013 (IEC 600790:2011 6th ED.) and EN 60079-15:2010 (IEC 60079-15:2010 4th ED.). WARNING: Explosion hazard The device should be installed in a housing (control or distributor box) that fulfills the requirements of EN 60079-15:2010 (IEC 60079-15:2010 4th ED.) and at least IP54 (EN/ IEC 60529) degree of protection. WARNING: Explosion hazard Observe the special temperature conditions according to the rating plate. Relay Output 250 V AC / 24 V DC, 5 A Resistive B300, R300 250 V AC / 24 V DC, 0.5 A Ambient Temperature -20 °C to 40 °C -20 °C to 60 °C 5.2 Installation in areas with a danger of dust explosions WARNING: Explosion hazard The device is not designed for use in atmospheres with a danger of dust explosions. The device must be used in no more than a pollution degree 2 environment as defined by EN/ IEC 60664-1. WARNING: Explosion hazard When installing and connecting the supply and signal circuits observe the requirements of EN/ IEC 60079-14. Only devices suitable for operation in Ex zone 2 and the conditions at the application site may be connected to the circuits in zone 2. In potentially explosive areas, only connect and disconnect cables when the power is disconnected. WARNING: Explosion hazard The device must be stopped and immediately removed from the Ex area if it is damaged or was subject to an impermissible load or stored incorrectly or if it malfunctions. Only use category 3G devices (ATEX 94/9/ EC). 105818_en_02 PHOENIX CONTACT 7 PSR-PC50 7.2 Basic circuit diagram A1 A1' M1 24V L L' Horizontal mounting position I [A] 6 5 4 3 Power Error TP1 TP2 TP3 2 LO LO' NI NI' Diagnostics Diag Logic 1A 1 0 -30 N A2 A2' Figure 1 Explanation Safety relay input voltage Safety relay input voltage for optionally redundant wiring Digital alarm output Supply voltage for connectable load monitoring Test point for proof test On-load voltage input 0 V Load input Load output Contact current [A] 8 TP1/TP2/TP3 L/L' N/N' LO/LO' NI/NI' Contacts A1', A2', L', N', LO', NI' are not suitable for further wiring. These contacts may only be used for optional redundant wiring. 7.1 Vertical mounting position I [A] Derating 10 20 30 40 50 60 70 Horizontal installation derating curve Load curve 10 5 1 0,1 10 100 1000 Contact voltage [V] Figure 4 7 0 T [°C] Figure 3 Key: M1 24 V -10 N' Block diagram Designation A1/A2 A1'/A2' -20 Relay load curve Key: No. 1 2 3 4 Explanation AC inductive load cos  = 0.4 AC resistive load DC resistive load DC inductive load L/R = 7 ms 5 4 3 2 1 500 mA 0 -30 -20 -10 0 10 20 30 40 50 60 70 T [°C] Figure 2 105818_en_02 Vertical installation derating curve PHOENIX CONTACT 8 PSR-PC50 9 Operating and indication elements 9.1 Connection versions         2 1 1.2 1.1 1.3 1.1 2.3 2.2 2.1 1.2 1.3 2.1 2.2   2.3 3.3 3.2 3.1 3.1 3.2 3.3     3     PSR-...-SP PSR-...-SC 7 mm Figure 5 9.2 0,5-0,6 Nm 5-7 lb In 8 mm   1 2 3 COMBICON plug-in screw terminal block COMBICON plug-in spring-cage terminal block Metal lock for fixing to DIN rail Connection versions Connection assignment Figure   TP1 TP2 TP3 A1´ 24V A2´ A1 M1 A2 Power Error Explanation Test point for proof test Safety relay input voltage Safety relay input voltage for optionally redundant wiring Supply voltage for connectable load monitoring Digital alarm output Power Error Diag LED status indicator, yellow - contacts on the load side are closed LED status indicator, red - error LED status indicator, green - diagnostics are active L/L' N/N' LO/LO' NI/NI' On-load voltage input 0 V Load input Load output PSR-PC50 Diag Designation TP1/TP2/TP3 A1/A2 A1'/A2' 24 V M1 L LO L´ NI LO´ N´ N NI´ Contacts A1', A2', L', N', LO', NI' are not suitable for further wiring. These contacts may only be used for optional redundant wiring. 105818_en_02 PHOENIX CONTACT 9 PSR-PC50 10 Mounting and connection Mount the module on a 35 mm DIN rail according to EN 60715. 11 Startup Once the nominal input voltage of 24 V DC has been enabled at terminals A1 and A2 (as well as A1' and A2' for optionally redundant wiring), the Power LED lights up. The contacts L, L', LO, LO' as well as NI, NI' and N, N' close. The 24 V connection should only be activated if the diagnostic function is to be used, and should be set to A2. The minimum diagnostic threshold value is 20 Ω, the maximum value is 18 kΩ. Figure 6 Diagnostics is performed for open circuit and short circuit of the load as well as for a loss of on-load voltage, load supply voltage and supply voltage for diagnostics. Mounting and removing Connect the cables to the connection terminal blocks using a screwdriver. AWG 24-14 2 0,2-2,5 mm PSR-...-SC A If the diagnostics respond, the minimum current consumption is pushed and a bad channel is generated via A1 (depending on the controller). Additionally the Error LED illuminates and the semiconductor alarm output M1 is active. 7 mm B Figure 7 The activation of diagnostic functions is indicated by the Diag LED. The load is not monitored when the contacts are closed on the output side. 0,5-0,6 Nm 5-7 lb In Connecting the cables for PSR-...-SC (screw terminal block) The diagnostic function is not suitable for semiconductor loads. • Perform a full function and diagnostic test during startup. Load resistance + Diagnostics: interrupt AWG 24-16 2 0,2-1,5 mm PSR-...-SP A B 22k 18k 8 mm A Figure 8 Discrepancy area to Interrupt Diagnostics: OK Connecting the cables for PSR-...-SC (spring-cage terminal block) 20 10 For compliance with UL approval, use copper wire that is approved up to 60°C/75°C. Discrepancy area to Short circuit Diagnostics: short circuit 0 Figure 9 105818_en_02 Diagnostic thresholds PHOENIX CONTACT 10 PSR-PC50 12 Proof test 13 Calculating the power dissipation The Proof test checks the individual relay channels and device diagnostics to ensure proper functioning. The total power dissipation of the safety relay is based on the input power dissipation and the contact power dissipation for the same and for different load currents. CAUTION: The enabling contacts are closed during the Proof test! Input power dissipation 12.1 1. 2. 3. 4. 5. Testing of relay channels Disconnection of A1/A1' Apply 24 V DC to TP1 (set to A2/A2'. Check whether the load is activated/whether the contacts L to LO to N to NI have continuity. Then disconnect TP1 again. Repeat step 2 for TP2 and TP3 Restore the original configuration so that the reference configuration and the physical configuration are the same again. Check switchability by the controller! CAUTION: If during step 2 or 3 the load is not activated or no continuity can be measured, the device is faulty. Replace the device! PInput = UB² / (US/IS) Contact power dissipation With the same load currents: PContact = n  IL²  50 mΩ With different load currents: PContact = (IL1² + IL2² + ... + ILn²)  50 mΩ Total power dissipation PTotal =PInput + PContact therefore PTotal = UB² / (US/IS) + n  IL²  50 mΩ or PTotal = UB² / (US/IS) + (IL1² + IL2² + ... + ILn²)  50 mΩ 12.2 1. 2. 3. Testing diagnostics Interrupt the load path then close it again. Interrupt the load path briefly then restore this to the operating state. Interrupt the supply voltage of the load before connection L or after connection N. Then restore the supply voltage. CAUTION: If during this diagnostics test no error (ERROR) is displayed. the device is faulty. Replace the device! 105818_en_02 Key: Designation P UB US IS n IL Explanation Power dissipation in mW Applied operating voltage Rated control supply voltage Rated control supply current Number of enabling current paths used Contact load current PHOENIX CONTACT 11 PSR-PC50 14 Application examples Key: SIS DC DI DO = Safety Instrumented System (safe control) = Diagnostic Coverage according to IEC 61508 (line/load diagnostics at DO) = Digital input = Digital output Connection options: SIS with line/load diagnostics 24V DC DO Load supply voltage Supply voltage for line/load diagnostics DI L+(L1) Option for redundant connection Option for redundant connection Signal output A1 A1' M1 24V L N L´ N´ PSR-PC50 A2 A2' 0V Option for redundant connection LO LO´ TP1 TP2 TP3 Test points for the proof test NI NI´ Option for redundant connection K1 Typically ... ... ... M(N) Figure 10 105818_en_02 Connection options PHOENIX CONTACT 12 PSR-PC50 14.1 Application example 1 - SIL 3 Assumptions, information, and marginal conditions – – – – The DC of the digital output is 90%. Diagnostics of PSR-PC50 are active. The test pulses of the controller are activated and evaluated. A potential error is indicated accordingly. A fault e.g., open circuit or short circuit of the load is reported by detuning the test pulse of the safe controller. 24V DC L+(L1) SIS DC 90% 24V DC DO DI A1 A1' M1 24V L N L´ N´ PSR-PC50 A2 A2' 0V Figure 11 105818_en_02 TP1 TP2 TP3 NI NI´ LO LO´ K1 M(N) Application example 1 - SIL 3 PHOENIX CONTACT 13 PSR-PC50 15 Revision history Version 00 01 Date 2014-05-23 2014-08-14 02 2014-04-08 105818_en_02 Contents First publication Data added regarding the compatible controllers; technical data updated; notes on contacts A1', A2', L', N', LO', NI' added; figure on diagnostic thresholds added; general conditions for application example extended HW/FW status added; safety notes revised; section added: mounting and connection, calculation of power dissipation, revision history; data added according to Ex approval PHOENIX CONTACT GmbH & Co. KG • 32823 Blomberg • Germany phoenixcontact.com 14