8
D5037
- SIL 2 Switch/Proximity Detector Repeater Transistor Out
G.M. International ISM0270-3
D5037 series are isolated Intrinsically Safe Associated Apparatus installed into standard EN50022 T35 DIN-Rail located in Safe Area or Zone 2, Group IIC, Temperature T4,
Hazardous Area (according to EN/IEC60079-15) within the specified operating temperature limits Tamb –40 to +70 °C, and connected to equipment with a maximum limit for
AC power supply Um of 250 Vrms.
Not to be connected to control equipment that uses or generates more than 250 Vrms or Vdc with respect to earth ground.
D5037 series must be installed, operated and maintained only by qualified personnel, in accordance to the relevant national/international installation standards (e.g. IEC/EN60079-14
Electrical apparatus for explosive gas atmospheres - Part 14: Electrical installations in hazardous areas (other than mines)), following the established installation rules, particular care
shall be given to segregation and clear identification of I.S. conductors from non I.S. ones.
De-energize power source (turn off power supply voltage) before plug or unplug the terminal blocks when installed in Hazardous Area or unless area is known to be nonhazardous.
Warning: substitution of components may impair Intrinsic Safety and suitability for Zone 2.
Explosion Hazard: to prevent ignition of flammable or combustible atmospheres, disconnect power before servicing or unless area is known to be nonhazardous.
Failure to properly installation or use of the equipment may risk to damage the unit or severe personal injury.
The unit cannot be repaired by the end user and must be returned to the manufacturer or his authorized representative.
Any unauthorized modification must be avoided.
Warning
Operation
D5037 module is a unit suitable for applications requiring SIL 2 level (according to IEC 61508) in safety related systems for high risk industries.
The unit can be configured for switch or proximity detector (EN60947-5-6, NAMUR), NO or NC and for NO or NC optocoupled open collector transistor output.
Each channel enables a Safe Area load to be controlled by a switch, or a proximity detector, located in Hazardous Area.
Fault detection circuit (DIP switch configurable) is available for both proximity sensor and switch equipped with end of line resistors. In case of fault, when enabled it de-energizes
the corresponding output transistor and turns the fault LED on; when disabled the corresponding output transistor repeats the input line open or closed status as configured.
In case of fault output, transistor driving can be programmed as normally close or normally open.
Presence of supply power and status of output (energized or de-energized), as well as integrity or fault condition of sensor and connecting line are displayed by signaling LEDs
(green for power, yellow for status and red for fault condition).
Note:
use of voltage free electrical contacts with fault detection enabled (control equipment) requires, near the switch at the end of the line a R1=1 k
Ω
typical (470
Ω
to 2 k
Ω
range)
resistor in series and a R2=10 k
Ω
typical (5 k
Ω
to 15 k
Ω
range) resistor in parallel to the contacts in order to allow the fault detection circuit to distinguish between a condition of
contact close/open and a line open/short circuit fault.
Installation
D5037 series are Switch/Proximity Detector Interface housed in a plastic enclosure suitable for installation on T35 DIN-Rail according to EN50022, with or without Power Bus or
on customized Termination Board.
D5037 unit can be mounted with any orientation over the entire ambient temperature range.
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 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.
Identify the number of channels of the specific card (e.g. D5037S is a single channel model and D5037D is a dual channel model), the function and location of each connection terminal
using the wiring diagram on the corresponding section, as an example:
Connect 24 Vdc power supply positive at terminal “5” and negative at terminal “6”.
For Model D5037S connect positive output of channel 1 at terminal “1” and negative output at “2”.
For Model D5037D in addition to channel 1 connections above, connect positive output of channel 2 at terminal “3” and negative output at “4”.
For Model D5037S, in case of Proximity or Voltage free Contact, connect the wires at terminal “7” for positive and “8” for negative.
For Model D5037D in addition to channel 1 connections above, connect terminal “9” for positive and “10” for negative on channel 2.
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)), 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 at 35 Vdc (
≤
1.5 V voltage drop)).
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 D5037 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, D5037 series must be connected to SELV or SELV-E supplies.
Start-up
Before powering the unit check that all wires are properly connected, particularly supply conductors and their polarity, input and output wires, also check that Intrinsically Safe conductors
and cable trays are segregated (no direct contacts with other non I.S. conductors) and identified either by color coding, preferably blue, or by marking. Check conductors for exposed
wires that could touch each other causing dangerous unwanted shorts. Turn on power, the “power on” green led must be lit, status and fault led on each channel must be in accordance
with condition of the corresponding input line. If possible close and open input lines one at time checking the corresponding status and fault leds condition as well as output to be correct.
Testing procedure at T-proof
Steps
Action
1
Bypass the Safety-related PLC or take any other appropriate action in order to avoid a false trip.
2
Vary the state conditions of the input sensors/contacts coming from field and verify that the transistor outputs change from de-energized to energized and vice
versa; then, check that the de-energized state condition corresponds to the required Safety-related function.
3
If input line fault detection is enabled for each channel by means of a dip-switches specific set up, disconnect the input wiring coming from the field sensor/contact
and check that the correspondent transistor output is de-energized. Then, put in short circuit condition the input connections and verify that the same output
remains de-energized. In both cases, the related red alarm LEDs on the front panel will be turned on.
4
Restore the loop to full operation.
5
Remove the bypass from the safety-related PLC or restore normal operation.
This test will reveal approximately 99 % of possible Dangerous Undetected failures in the repeater.
The proof test shall be performed to reveal dangerous faults which are undetected by diagnostic. This means that it is necessary to specify how dangerous undetected fault,
which have been noted during the FMEDA, can be revealed during proof test.
Note for switch input: to detect a broken wire, or a short circuit condition, in the input connections it is necessary to mount, close to the switches, the end of line resistors:
R1=1 K
Ω
typical (470
Ω
to 2 K
Ω
range) resistor in series and R2=10 k
Ω
typical (5 K
Ω
to 15 K
Ω
range) resistor in parallel to the contacts.
The Proof test
consists of the following steps:
