D1049
- SIL 3 Digital Output Driver NE Loads Bus Powered
G.M. International ISM0097-9
7
Testing procedure at T-proof
The proof test must be performed to reveal dangerous faults which cannot be otherwise detected. This means that it is necessary to specify how dangerous undetected faults, which
have been noted during the FMEDA analysis, can be revealed during the proof test.
The
Proof Test
consists of the following steps
Testing procedure at T-proof
Steps
Action
1
Bypass the Safety-related PLC or take any other appropriate action to avoid a false trip.
2
Set the following configuration:
□
SW1 DIP-switch: SW1-1 = OFF (to disable the field line and load fault detection), SW1-2 = SW1-3 = SW1-4 = ON or OFF (because they are not used);
□
SW2 DIP-switch: SW2-1 = ON (direct IN/OUT transfer function), SW2-2 = ON , SW2-3 = OFF , SW2-4 = OFF (to enable fault output and disable override input function-
ality).
The series connection of a 1 k
Ω
load resistor and an ammeter must be connected, in parallel with a voltmeter, to one of the module outputs (starting with Out A, then going
on with Out B and finally proceeding with Out C). Supply the D1049S module at 24 Vdc. Then, apply the control signal to the module input channel, which can
have the following two states:
□
OFF = 0 Vdc, implying that the load current is 0 mA and the load voltage is 0 V because the 1 k
Ω
load resistor must be de-energized in accordance with the control input
signal OFF state;
□
ON = 24 Vdc, so that the 1 k
Ω
load resistor must be energized, with the following current and voltage values: 17.5 ÷ 18.5 mA and 17.5 ÷ 18.5 V (for Out A); 16.5 ÷ 17.5
mA and 16.5 ÷ 17.5 V (for Out B); 16 ÷ 17 mA and 16 ÷ 17 V (for Out C).
In addition, disconnect the 1 k
Ω
load resistor from the output channel in order to generate an open / short output circuit, when the line and load fault detection is disabled
and the control signal is ON:
□
open circuit: connect only the voltmeter in parallel to the output, so that the output voltage is within the 21 ÷ 21.5 V range;
□
short circuit: connect only the ammeter in parallel to the output, so that the output current is within the 53 ÷ 57 mA range.
3
Consider the configuration setup defined in the previous proof test step (
2
) and change the SW1-1 DIP-switch from the OFF to the ON position, in order to enable the field
line and load fault detection. Supply the D1049S module at 24 Vdc, apply a 24 Vdc = ON control signal to the module input channel, then connect an ohmmeter to the fault
output and another one to the Fault Bus output.
In the presence of the 1 k
Ω
load resistor connected to the output channel, the fault red LED is turned off, the fault output is closed (that is, there is presence of ohmic continui-
ty) and the Fault Bus output is open (that is, there is absence of ohmic continuity) because no line or load fault is detected.
Now, disconnect the 1 k
Ω
load resistor from the output channel in order to generate a line or load fault (open / short circuit fault), so that fault red LED is turned on, the fault
output is open (that is, there is absence of ohmic continuity) and the Fault Bus output is closed (that is, there is presence of ohmic continuity).
Then, generate an open or short output circuit fault performing the following setup changes:
□
open circuit: connect only the voltmeter in parallel to the module output, so that the load voltage is within the 4 ÷ 4.5 V range (open circuit voltage of the diagnostic
circuit);
□
short circuit: connect only the ammeter in parallel to the module output, so that the load current is < 1 mA (short circuit current of the diagnostic circuit).
These results are also valid when the control signal state is OFF and the channel is turned off, because the fault diagnostic circuit (if enabled) is always active independently
from the channel state.
4
Consider the configuration setup defined in the previous proof test step (
2
) and change SW1-1 DIP-switch from the OFF to the ON position, in order to enable the field line
and load fault detection. Replace the series connection of a 1 k
Ω
load resistor and an ammeter with a current calibrator (set to 45 mA). This current generator and a voltmeter
are connected in parallel to one of the module outputs (starting with Out A, then going on with Out B and finally proceeding with Out C). Supply the D5049S or D1049S mod-
ule at 24 Vdc and apply a 24 Vdc = ON control signal to the module input channel, verifying the following load voltage values: 13 ÷ 13.5 V (for Out A), 10.2 ÷ 10.7 V (for Out
B) and 8.5 ÷ 9 V (for Out C).
5
Restore the loop to full operation.
6
Remove the bypass from the Safety-related PLC or restore normal operation.
This test reveals almost 99 % of all possible Dangerous Undetected failures in the digital output module.
Installation
D1049 is a digital output isolator housed in a plastic enclosure suitable for installation on T35 DIN Rail according to EN50022.
D1049 unit can be mounted with any orientation over the entire ambient temperature range, see section “Installation in Cabinet” and "Installation of Electronic Equipments in Cabinet"
Instruction Manual D1000 series for detailed instructions.
Electrical connection of conductors up to 2.5 mm² are accommodated by polarized plug-in removable screw terminal blocks which can be plugged in/out into a powered unit
without suffering or causing any damage
(for Zone 2 or Division 2 installations check the area to be nonhazardous before servicing).
The wiring cables have to be proportionate in base to the current and the length of the cable.
On the section “Function Diagram” and enclosure side a block diagram identifies all connections and configuration DIP switches.
Identify the function and location of each connection terminal using the wiring diagram on the corresponding section, as an example:
Connect 24 Vdc power supply at terminal “3” positive and at terminal “4” negative.
Connect control input signal positive at terminal “5” and negative at terminal “6”.
Connect fault open collector transistor output positive at terminal “1” and negative at terminal “2”.
Connect override input at terminal “7” positive and at terminal “8” negative.
Connect positive output at terminal “13” and negative output at “16” using “Out A” diagram or positive output at terminal “14” and negative at terminal “16” using “Out B” diagram or
positive output at terminal “15” and negative at “16” using “Out C” diagram.
NOTE: use only one output at a time, Out A or Out B or Out C not contemporary.
Intrinsically Safe conductors must be identified and segregated from non I.S. and wired in accordance to the relevant national/international installation standards
(e.g. EN/IEC60079-14 Electrical apparatus for explosive gas atmospheres - Part 14: Electrical installations in hazardous areas (other than mines), BS 5345 Pt4, VDE 165,
ANSI/ISA RP12.06.01 Installation of Intrinsically Safe System for Hazardous (Classified) Locations, National Electrical Code NEC ANSI/NFPA 70 Section 504 and 505,
Canadian Electrical Code CEC), make sure that conductors are well isolated from each other and do not produce any unintentional connection.
Connect SPST output transistors checking the load rating to be within the maximum rating (100 mA, 35 Vdc resistive load).
The enclosure provides, according to EN60529, an IP20 minimum degree of mechanical protection (or similar to NEMA Standard 250 type 1) for indoor installation, outdoor installation
requires an additional enclosure with higher degree of protection (i.e. IP54 to IP65 or NEMA type 12-13) consistent with the effective operating environment of the specific installation.
Units must be protected against dirt, dust, extreme mechanical (e.g. vibration, impact and shock) and thermal stress, and casual contacts.
If enclosure needs to be cleaned use only a cloth lightly moistened by a mixture of detergent in water.
Electrostatic Hazard: to avoid electrostatic hazard, the enclosure of D1049 must be cleaned only with a damp or antistatic cloth.
Any penetration of cleaning liquid must be avoided to prevent damage to the unit. Any unauthorized card modification must be avoided.
According to EN61010, D1049 must be connected to SELV or SELV-E supplies.
