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? phoenix contact - 07/2009 103120_en_01 interface pi-ex-sd-24-48 data sheet 1description 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 insta lled 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. the pi-ex-sd-24-48 solenoid dr iver does not require its own power supply; instead, it is simply looped into the circuit. 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 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 di rectives (including national safety directives), accident prevention regulations, as well as ge neral technical regulations, must be observed. warning: explosion hazard observe the safety regulations an d 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 pr oducts listed on the following page: ex-i solenoid driver for group iic gases, loop-powered, pluggable
pi-ex-sd-24-48 103120_en_01 phoenix contact 2 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 2ordering 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 fo r intrinsically safe signals with knife disconnection and test connections pi-ex-tb 2835901 10 intrinsically safe basic terminal bloc k, 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 continuous plug-in bridge, 500 mm long, insulated, can be cut to length, for potential distribution, i max = 32 a, color of the insulating material: red blue gray fbst-500-plc-rd fbst-500-plc-bu fbst-500-plc-gy 2966786 2966692 2966838 20 20 20 for additional accessories, please refer to the phoenix contact "interface" catalog.
pi-ex-sd-24-48 103120_en_01 phoenix contact 3 3 technical data output characteristic curve figure 1 output characteristic curve for pi-ex-sd-24-48 input input signal 20 v dc ? 30 v dc output output characteristic curve (see figure 1 on page 3) u v = 24 v (guaranteed voltage) r i = 246 (internal resistance) output voltage, intrinsically safe 11.8 v at 48 ma current limit at 48 ma 0 10 20 0 102030405060 24 v 11.8 v output voltage u v output current i v 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 po lyamide 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) -20c ... +5 5c (perpendicular mounting of din rail) -20c ... +60c (horizontal mounting of din rail) average temperature according to iec 61508 40c ambient temperature (storage/transport) -40c ? +80c permissible humidity (operation) 10% ... 95% (relative humi dity, 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
pi-ex-sd-24-48 103120_en_01 phoenix contact 4 safety data according to atex for intrinsically safe circuits maximum output voltage u o 27.7 v maximum output current i o 101 ma maximum output power p o 697 mw gas group maximum external inductance l o maximum external capacitance c o maximum ratio l o /r o iia 20 mh 0.44 f iib 2 mh 0.29 f iic 0.5 mh 0.067 f 51.1 h/ 1 true r.m.s. value of maximum ac voltage u m maximum dc voltage u m 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, tv 06 atex 553193 x ii 3 g ex na ii t4 x ul/cul ul applied for
pi-ex-sd-24-48 103120_en_01 phoenix contact 5 4 safety regulations and installation notes 4.1 installation and operation follow the installation instructions. when installing and operatin g the device, the applicable safety directives (including national safety directives), accident prevention regula tions, as well as general technical regulations, must be observed. do not repair the device yourself, replace it with an equivalent device. repairs may only be carried out by the manufacturer. in order to provide protecti on 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 for the safety data, please refer to the operating instructions and certificates (ec-type ex amination certificate, other approvals, if necessary). installation in zone 2 observe the specified conditio ns for use in potentially explosive areas. note: installation, operatio n, and maintenance may only be carried out by qualified specialist personnel. note: the circuits inside the device must not be accessed. 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. 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 non- intrinsically safe circuits, it must not be used again in intrinsically safe circuits. the module must be clearly labeled as non- intrinsically safe. warning: explosion hazard the device is an associated item of equipment with "intrinsically safe" explosion protection and is designed for installation in zone 2. 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 non- intrinsically safe circuits. warning: explosion hazard only use category 3g pi ex modules (atex 94/9/ec).
pi-ex-sd-24-48 103120_en_01 phoenix contact 6 installation in areas with a danger of dust explosions connection to the intrinsicall y 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-2 4-48 in safety-related applications, observe the instru ctions in section 9, as the requirements differ for safety-related functions. warning: explosion hazard the device is not designed for use in areas with a danger of dust explosions.
pi-ex-sd-24-48 103120_en_01 phoenix contact 7 5 structure figure 2 structure 1 output "+" 2 output "?" 3 input signal "+" 4 input signal "?" 1 - 4 terminal block screw with integrated test socket 56 not used 7 isolating connectors 8 test sockets 9 locking clips 0 keying pin ! status indicators dimensions figure 3 dimensions (in mm) 6 installation 6.1 base elements the device is designed for inst allation in the control cabinet and must be plugged into a ba se 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 elec tronic module, gently press the locking clip towards the housing; it can then be removed. + - ub+ ub- ub+ ub- ub+ ub- 9 10 - + + - 1 2 8 7 4 6 5 3 20...30 v dc + - in out pi-ex-sd-2x-xx stat err 11 10 pi-ex-sd-24-48 pi-ex-tb basic terminal block the pi-ex-sd-24-48 can be inst alled in safe areas or in zone 2. pi-ex-sd-24-48 basic terminal block note: electrostatic discharge 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. 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 . cables of non-intrinsically safe circuits must only be connected and disconnected when the power is disconnected . warning: explosion hazard if the device has been used in non- intrinsically safe circuits, it must not be used again in intrinsically safe circuits. the module must be clearly labeled as non- intrinsically safe. connection cross-section (solid/stranded): 0.2 mm 2 ... 2.5 mm 2 tightening torque: 0.5 nm ... 0.6 nm
pi-ex-sd-24-48 103120_en_01 phoenix contact 8 6.2 automatic keying of electronic modules 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 acci dentally inserted in the wrong place, any plastic parts remain ing in the base element can be removed using a screwdriver. 7 comparison of safety data safety data for: for the values for u o , i o , p o , l o , and c o , please refer to "safety data according to atex for intrinsically safe circuits" on page 4. capacitance and inductan ce of base elements ex-i requirements: 8 calculating a valve circuit figure 4 equivalent circuit in order to connect a solenoid valve to the device, it is necessary to compare the safe ty data and calculate the measurements. r sv and u sv are determined by the copper resistance, which depends on the ambient temperature. the values for r sv and i sv must be obtained from the valve manufacturer. the values for r i and u v can be found in the technical data under "output" on page 3. the permissible cable resistance can be determined according to the following formula: in the event of a negative re sistance, it is no longer guaranteed that the connection will function. requirements for operation: i v i sv and r c > 0 . 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 pi-ex-sd-24-48 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. field devices: u i , i i , p i , l i , c i solenoid driver: u o , i o , p o , l o , c o base elements: l ib , c ib, pi-ex-tb pi-ex-tb/t tt-pi-ex-tb tt-pi-ex-tb/t motherboards electronics base l ib 1 h 1 h0 h c ib 1 nf 3 nf 0 nf u i u o i i i o p i p o for iib and iia: l i + l c + l ib l o and (l c and c c or l o and r o are dependent on the cables/lines used.) c i + c c + c ib c o for iic: l i , c i = 0 and l c /r c l o /r o r i : internal resistance of the solenoid driver. u v : guaranteed voltage of th e solenoid driver without load. i v : maximum current that can be supplied by the solenoid driver. r c : maximum permissible cable resistance when connecting the solenoid driver and valve. r sv : effective coil resistance of the solenoid valve (the copper resistance of the coil depends on the temperature). i sv : the current required by the solenoid coil so that the valve can close tightly. u sv : the voltage which is present at the coil with i sv . recommendation: for r c , an actual cable resistance of +25 should be calculated. a list of suitable valves can be found in the download center at www.phoenixcontact.net/download . sv i i r sv u c r sv r v u valve solenoid driver u v r c = ??? ? r i ? r sv i sv
pi-ex-sd-24-48 103120_en_01 9 phoenix contact gmbh & co. kg ? 32823 blombe rg ? 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 safety-related applications (sil 3) 9.1 installation 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 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 operating mode according to iec 61508: "low demand mode". 9.4 failure behavior and required response 1. the safe state is entered in the event of an input voltage failure. 2. 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 pfd avg values since the pfd avg value is 0, it is not necessary to perform regular proof tests. this is , however, still recommended (see section 9.6). failure limit 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%. figure 5 safety loop conditions ? 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 (= replacem ent) 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 +40c. this is base d on standard industrial conditions. 9.6 proof test even where the pfd avg 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 sy stem from be ing 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. 10 appendix exida assessment summary (3 pages) safe dangerous sff 1 1 sff = safe failure fraction dc s 2 2 dc = diagnostic coverage (safe or dangerous) dc d 2 284 fit 3 3 fit = failure in time (1 fit = 1 failure/10 9 h) 0 fit 100% 0% 0% t[proof] = 1 year 5 years 10 years pfd avg 1 = 1 pfd = probability of failure on demand 0 0 0 sensor and switching amplifier 35% processing 15% actuator control ? 10% actuator 40%
the document was prepared using best effort. the a uthors make no warranty of any kind and shall not b e liable in any event for incidental or consequential damages i n connection with the application of the document. ? all rights on the format of this technical report reserved. 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
? exida.com gmbh phoenix contact 06-06-05 r004 v2r0.doc, january 18, 2008 philipp neumeier page 2 of 3 management summary this report summarizes the results of the hardware assessment carried out on the solenoid drivers type pi-ex-sd-**-** with a corresponding mo therboard 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: output values: pi-ex-sd-21-25 macx mcr-ex-sl-sd-21-25-lp / macx mcr-ex-sl-sd-21-25-lp-sp 21 v / 25 ma pi-ex-sd-21-40 macx mcr-ex-sl-sd-21-40-lp / macx mcr-ex-sl-sd-21-40-lp-sp 21 v / 40 ma pi-ex-sd-21-45 macx mcr-ex-sl-sd-21-45-lp / macx mcr-ex-sl-sd-21-45-lp-sp 21 v / 45 ma pi-ex-sd-24-48 macx mcr-ex-sl-sd-24-48-lp / macx mcr-ex-sl-sd-24-48-lp-sp 24 v / 48 ma pi-ex-sd-21-60 macx mcr-ex-sl-sd-21-60-lp / macx mcr-ex-sl-sd-21-60-lp-sp 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 achie ve 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 d evice. for full assessment purposes all requirements of iec 61508 must be considered. the failure rates used in this analysis are the bas ic 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 3 10 -4 to < 10 -3 for sil 3 safety functions. however, as the module s 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 cor responding 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 a 1 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 tole rance of 0. the solenoid drivers pi-ex-sd-**-** and macx mcr-ex -sl-sd-**-**-lp and macx mcr-ex- sl-sd-**-**-lp-sp are operated in passive mode, and can therefore be regarded as loop powered modules. because loop powered modules are d irectly driven from the digital output of a safety plc there is no additional power supply wh ich 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: non-complex component (all failu re modes are well defined); for details see 7.4.3.1 .2 of iec 61508-2.
? exida.com gmbh phoenix contact 06-06-05 r004 v2r0.doc, january 18, 2008 philipp neumeier page 3 of 3 results for solenoid drivers pi-ex-sd-**-** with mo therboard: the following table shows how the above stated requ irements are fulfilled. table 2: summary for pi-ex-sd-**-** with motherboard C iec 61508 fai lure rates 2 l ll l safe l ll l dangerous sff pfd avg 284 fit 0 fit 3 100% 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 requ irements are fulfilled. table 3: summary for macx mcr-ex-sl-sd-**-**-lp / macx mcr-ex-sl-sd- **-**-lp-sp C iec 61508 failure rates 2 l ll l safe l ll l dangerous sff pfd avg 282fit 0 fit 3 100% 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-**-**-l p-sp - both when loop powered - can be used for all safety applications. the calculations are based on the assumption that t he devices are mounted in an environment that is ip 54 compliant (e.g. housing, control cabi net 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-**-**-l p-sp (see appendix 1). 2 it is assumed that practical fault insertion tests can demonstrate the correctness of the failure eff ects assumed during the fmedas. 3 in order to deal with the excluded faults in the q uantitative analysis it might be reasonable to cons ider a dangerous failure rate of 0.1 fit, leading to a sff of 99,97% and a pfd avg of 4,38e-06 for a proof time of 10 years.

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