GMI D5000 Series User manual

D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays ISM0121-1
D5000 - D5200 Series
INSTRUCTION MANUAL
INSTRUCTION MANUAL
D5D5000000 - -D5200 SERIESD5200 SERIES
DINDIN- -RAIL, POWER BUS,RAIL, POWER BUS,
TERMINATIONBOARDMOUNTINGTERMINATIONBOARDMOUNTING
INTRINSICALLY SAFE ISOLATORSINTRINSICALLY SAFE ISOLATORS
ANDAND SAFETY RELAYSSAFETY RELAYS

Technology for safety
2 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
D5000 - D5200 Intrinsically Safe Isolators and Safety Relays
Mechanical features .........................................................................................................................................................................3
Mounting and removing modules from DIN-Rail ..............................................................................................................................4
Power Bus connector.......................................................................................................................................................................6
Mounting modules on Power Bus connector....................................................................................................................................8
Ordering information ........................................................................................................................................................................8
Removing and mounting Main Case Top Cover ..............................................................................................................................9
Transparent Cover .........................................................................................................................................................................10
Terminal Blocks Connection Data..................................................................................................................................................11
Installation and removing modules from Termination Board..........................................................................................................12
Mounting Termination Board..........................................................................................................................................................14
Mounting and removing Termination Board onto DIN-Rail ............................................................................................................14
Termination Boards Characteristic.................................................................................................................................................15
Approvals and Certifications ..........................................................................................................................................................16
Storage...........................................................................................................................................................................................16
Disposal .........................................................................................................................................................................................16
Maintenance and Repair................................................................................................................................................................16
Installation of electronic equipments in cabinet..............................................................................................................................17
Heat dissipation in cabinets ...........................................................................................................................................................18
Calculation of radiant surfaces in closed cabinets .........................................................................................................................19
Placement of Isolators in cabinet ...................................................................................................................................................20
Index

Technology for safety 3
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Mounting Dimensions (D5000) Dimensions (D5200)
T35 DIN-Rail according to EN50022
with or without Power Bus connector
or on Termination Board
Width 12.5 mm
Depth 123.0 mm
Height 120.0 mm
Width 22.5 mm
Depth 123.0 mm
Height 120.0 mm
Case material Blister packing size (D5000) Blister packing size (D5200)
PA66 - Polyamide (Nylon) 66
Width 24.0 mm
Depth 132.0 mm
Height 138.0 mm
Width 34.0 mm
Depth 132.0 mm
Height 138.0 mm
123 mm
Laser engraving on entire enclosure
to provide Intrinsic Safety parameters,
schematic diagrams, connections
and instructions
Terminal Blocks
tagging zone
Side D5000 - D5200
Enclosure Characteristics
High channel density results from
innovative circuit design using
advanced surface mount components.
Plug-in screw terminal blocks to secure
terminations up to 2.5 mm2.
Configuration components are easily
accessed by removing side cover.
High packing density
35 mm (Top Hat) DIN-Rail.
Ultra slim 2 channels 12 mm wide DIN-Rail
and Termination Board mounting modules.
Power and fault on bus connectors.
6 mm per channel means
50% space reduction.
Mechanical features
Front D5000
120 mm
12.5 mm
Hazardous Area/
Field Side
Terminal Blocks
indicator
LEDs for power,
status and fault
indication
Front D5200
120 mm
22.5 mm
LEDs for power,
status and fault
indication
Hazardous Area/
Field Side
Terminal Blocks
indicator

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4 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Mounting and removing modules from DIN-Rail
Mounting
Removing
To remove a barrier from the mounting rail, insert a blade screwdriver in the mounting foot and lever against the side of the barrier casing
(see Fig.3 and Fig.4).
To mount Series D5000-D5200 on 35 mm DIN-Rail,
hook one side of the mounting foot over the rail’s lip and press
the barrier down firmly until fixed (see Fig.1 and Fig.2).
Fig. 3
Screwdriver
T35 DIN-Rail
Fig. 1
Push
to
engage T35 DIN-Rail
Fig. 2
T35 DIN-Rail

Technology for safety 5
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Fig. 6 T35 DIN-Rail Dimensions (millimeters)
Fig. 4
T35 DIN-Rail
Pull the module upwards
and remove from DIN-Rail
Fig. 5 T35 DIN-Rail

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6 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Power Bus connector
Power Supply Voltage 24 Vdc can be applied to the module, by connecting directly the voltage to the plug-in Terminal Block of each module,
or via the Power Bus System. The system consists of standard DIN-Rail modules mounted on optional DIN-Rail Power Bus connectors.
The maximum allowed powering capacity is 8 A. It is always possible to remove modules, without disconnecting the bus connector
which remains attached to the DIN-Rail.
Cumulative Fault Alarm indication is provided on the Power Bus connection.
Power Bus system need the accessories shown below, in order to be operative:
Push
To
engage
T35 DIN-Rail T35 DIN-Rail
JDFT049: D5000 Power Bus Connector (12mm)
JDFT050: D5200 Power Bus Connector (22mm)
Push
To
engage
T35 DIN-Rail T35 DIN-Rail
Power Supply
and Fault
F Modbus RS485
for diagnostic
only
Power Supply
and Fault
F Modbus RS485
for diagnostic
only

Technology for safety 7
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Push
To
engage
DIN-Rail Stopper (MCHP196)
T35 DIN-Rail T35 DIN-Rail T35 DIN-Rail T35 DIN-Rail
Secure the stopper to the rail
by completely rotating both
screws clockwise.
Plug-in terminal block male,
horizontal out, for Power Bus
(MOR022)
Power
Supply
Mounting a plug-in terminal block male onto a
connector Power Bus
Plug-in terminal block female,
horizontal out, for Power Bus
(MOR017)
Power
Supply
Mounting a plug-in terminal block female into a
connector Power Bus
MCHP196: DIN-Rail Stopper
MOR022, MOR017: Plug-in terminal blocks

Technology for safety
8 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Push
to
engage
Power
Supply
Module
enclosure with
Power Bus
Connector
Push
to
engage
Image Code Description
MCHP196 DIN-Rail Stopper
MOR017 Plug-in terminal block female, horizontal out, for Power Bus
MOR022 Plug-in terminal block male, horizontal out, for Power Bus
JDFT049 Connector 5 pin Power Bus 12mm DIN-Rail
JDFT050 Connector 5 pin Power Bus 22mm DIN-Rail
D5000 Series
Mounting a module onto 12 mm Power Bus connector and T35 DIN-Rail
(JDFT049)
D5200 Series
Mounting a module onto 22 mm Power Bus connector and T35 DIN-Rail
(JDFT050)
Ordering information
Mounting modules on Power Bus connector
Module
enclosure with
Power Bus
Connector
Power
Supply

Technology for safety 9
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Removing and mounting Main Case Top Cover
1. Main case top cover can be
plugged out by applying a pressure
as shown in the picture using a screwdriver
Removing
Mounting
1. Main case top cover will slide on the
enclosure dedicated guides.
2. Completely slide main case top cover
to the enclosure guides.
3. Press firmly main case top cover
as shown by arrows in the picture.
2. Pull firmly main case top cover
as shown in the picture.

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10 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Transparent Cover
4. Push the transparent cover to
module for the complete closure.
Operating parameters connector,
LEDs for power, status and fault
indication are visible through the
transparent cover.
3. Close the transparent cover
as shown in the picture.
1. Open the transparent cover using a screwdriver
as shown by arrows in the picture.
2. Open the transparent cover up to 90 degrees.
For fully programmable modules, a dedicated connector
is accessible and operating parameters are
programmable by the GM Configurator PPC5092 via
SWC5090 Configurator software.

Technology for safety 11
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Stripping
lenght
7 mm
Screwdriver for
Terminal Blocks
2.5 x 0.4 mm
Terminal blocks connection data
Conductor cross section solid From 0.2 mm² to 2.5 mm²
Conductor cross section stranded From 0.2 mm² to 2.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve From 0.25 mm² to 2.5 mm²
Conductor cross section stranded, with ferrule with plastic sleeve From 0.25 mm² to 2.5 mm²
Conductor cross section AWG From 24 to 12 AWG
Main enclosure terminal block connection data
Conductor cross section solid From 0.14 mm² to 1.5 mm²
Conductor cross section stranded From 0.14 mm² to 1.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve From 0.25 mm² to 1.5 mm²
Conductor cross section stranded, with ferrule with plastic sleeve From 0.25 mm² to 0.5 mm²
Conductor cross section AWG From 28 to 16 AWG
Power Bus terminal block connection data
Stripping
lenght
7 mm
Screwdriver for
Terminal Blocks
3.5 x 0.6 mm
Blue terminal blocks
on Hazardous Area
Grey terminal blocks
on Safe Area

Technology for safety
12 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Installation and removing modules from Termination Board
Safe Area
connectors
Latching
mechanism
Mounting a module onto a Termination Board
3. Press bottom up
the Hazardous Area latch
2. Press bottom up
the Safe Area latch
Latches position before pressure Latches position after pressure
1. Push over the module
to Termination Board.
Aligning the module to the
latching mechanism.

Technology for safety 13
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Removing a module from Termination Board
1. Unclip the
Safe Area latch
2. Unclip the
Hazardous Area latch
3. Pull up the module from
Termination Board

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14 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Mounting and removing Termination Board onto DIN-Rail
Mounting Termination Board
Nut M4 or M5
Screw
M4 or M5
Washer
Spacer 10 mm
Washer
Plate
Plate
To mount Termination Board on 35 mm DIN-Rail,
hook one side of the mounting foot over the rail’s lip and press
the Termination Board down firmly until fixed (see Fig.1 and Fig.2).
Mounting
Push
to
engage
Fig. 1
T35 DIN-Rail
Fig. 2
T35 DIN-Rail

Technology for safety 15
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Fig. 4
T35 DIN-Rail
Pull the Termination Board upwards
and remove from DIN-Rail
Termination Boards characteristic
 Suitable to accept up to 8/16 D5000 or D5200 modules 12mm/22mm wide.
 24 Vdc Power supply terminal blocks can be disconnected from the board without disconnecting the power to other boards connected in series.
 Boards are available with custom connectors for any system / PLC / DCS.
Supply line 1
Supply line 2
Output connector
Hart Multiplexer connectors
Up to 8/16 D5000/D5200 modules
Spare fuse
Common fault output signal
Supply paralleling diodes
Power ON LEDs 1 - 2
Removing
To remove a Termination Board from the mounting rail, insert a blade screwdriver in the mounting foot and lever as shown in Fig.3.
Fig. 3
T35 DIN-Rail
Screwdriver

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16 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Approvals and Certifications
Intrinsically Safe products
G.M. International has obtained IS certificates from the most credited Notified Bodies in the world for its D5000 Series.
SIL Certifications according IEC 61508 and IEC 61511
G.M. International offers a wide range of products that have been proved
to comply with the most severe quality and safety requirements.
IEC 61508 and IEC 61511 standards represent a milestone in the progress
of industry in the achievement of supreme levels of safety through the entire
instrumented system lifecycle.
Maritime Type Approval
G.M. International offers Type Approval Certificates for its line of
Intrinsically Safe Isolators D5000 Series and Power Supplies for use in
Maritime and Offshore applications.
Certificates have been released both by Korean Register of Shipping and
Det Norske Veritas.
Company Quality System
G.M. International’s Production Quality System is certified by Det Norske
Veritas (Norway) to be compliant with ATEX 94/9/EC Directive and
ISO 9001/2008.
This means our production facilities are periodically re-assessed throughout
the whole manufacturing process, to ensure that the highest quality
standards are met.
Storage
If after an incoming inspection the unit is not installed directly on a system (parts for spare or expansion with long storage periods) it must be
conveniently stocked. Stocking area characteristics must comply with the following parameters: Temperature: –40 to +60 / 70 °C,
the –45 to +80 °C in the data sheet is meant for limited periods, mainly to arrange for air transport, -10 to +30 °C are preferred.
Humidity: 0 to 95 %, long period high humidity affects the package integrity, 0 to 60 % humidity is preferred.
Vibration: no prolonged vibration should be perceivable in the stocking area to avoid loosening of parts or fatigue ruptures of components terminals.
Pollution: presence of pollutant or corrosive gases or vapors must be avoided to prevent corrosion of conductors and degradation of insulating
surfaces.
Disposal
The product should not be disposed with other wastes at the end of its working life. It may content hazardous substances for the health and the
environment, to prevent possible harm from uncontrolled waste disposal, please separate this equipment from other types of wastes and recycle it
responsibly to promote the sustainable reuse of material resources. This product should not be mixed with other commercial wastes for disposal.
Maintenance and Repair
Series D5000 and D5200 modules do not require particular maintenance under normal operating conditions. They are designed to operate trouble
free and with high stability for long time. If a unit is found not meeting specifications or in a failure condition then it requires recalibration or servicing.
Any repair made by unauthorized personnel may completely invalidate the safety characteristics of the card. Repair not made by G.M. International
is prohibited. If a barrier failure condition is actually found, replace the defective card with a good one and send it for repair to the nearest authorized
representative of G.M. International.

Technology for safety 17
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
All electronic equipment operate using electrical power and dissipate part of it into heat, which is generally removed by the surrounding ambient air
and determines an increase in the operating temperature. High operating temperatures reduce their life and increase the probability of failures
according to the Arrhenius criteria, for example an operating temperature increase from 25 to 50 °C can cause a failure rate ten times higher.
In a cabinet, air circulates and removes heat by convection (natural convection cooling) or, more effectively, by forced ventilation (fans) or
even more effectively, by refrigerated forced ventilation (air conditioning). Installation of electronics in cabinets restricts free air movement and
rises their internal temperature. These effects can be reduced in two concurring lines of action:
by limiting the power dissipation and the heat produced inside the cabinet
by encouraging air circulation (and exchange of heat) inside the cabinet
A simple way to improve air circulation is to provide space between the isolators, also installing isolators in horizontally oriented DIN-Rail rows
with the enclosure main surfaces oriented vertically allows better air circulation inside the enclosure and significantly improves heat exchange.
What ultimately determines the operating temperature rise inside a cabinet is the total power dissipation and the provisions available for removing
the heat with cool air (natural convection or forced cooling). The maximum power consumption of each type of isolator is specified,
so by summing the power of each unit in the cabinet the total power Pmax can be easily found.
In normal operating conditions however, the power dissipated by the installed equipments is not likely to be the maximum value specified for
all of them and at the same time, the value of the effective power Peff can therefore be considered smaller (typical 70 %) than the value Pmax:
Peff ≤ΣPmax * 70 %
1) Closed Cabinets with Natural Convection
Closed cabinets are preferred in dusty or harsh environments where they offer a better equipment protection, but their heat / power dissipation
capability is modest. Heat is removed by air flowing internally and exchanged with the walls, the calculation of the maximum allowed
power dissipation in this type is:
Pmax = Δt * S * K and Δt = ———
where: Pmax [W] maximum allowed power dissipation
Δt [°C] maximum allowed temperature rise
S [m²] free heat emitting surface of the cabinet
K [W/m² * °C] thermal conductivity coefficient (K=5.5 for painted steel sheets)
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 250 W.
2) Open Cabinets with Natural Convection
Open cabinets must operate in clean environments, their heat / power dissipation capability is medium.
Heat is removed by air flowing through the equipment, circulating from bottom to top of cabinet (convection). Depending on the type of engineering
(freedom of cool air to enter at the bottom, to circulate vertically around the equipment extracting heat and to exit at the top), the power dissipation
improvement can be 50% better than case 1.
The cabinet must be equipped with inlet and outlet louvers in the lower and upper ends, vertical air flow inside and outside the cabinet must be
kept free from obstacles to enhance the “chimney effect” air circulation.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 350 W.
3) Open Cabinets with Forced Ventilation
Open cabinets must operate in clean environments, their heat / power dissipation capability is high with forced ventilation.
Air is forced into the louvers on the bottom, flows through the equipments, and finally exits at the top, where generally is forced by one or more fans.
The calculation of the required airflow is:
Q = 3.1 * Peff / Δt
where: Q [m³/h] is the required air flow
Peff [W] is the dissipated power (typical 70 % of the maximum power dissipation)
Δt [°C] is the maximum allowed temperature rise in the cabinet
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 500 W.
4) Closed Cabinets with Forced Ventilation and Heat Exchanger
Closed cabinets with forced ventilation are preferred in high dissipated power and harsh environment where natural convention cannot be used.
Hot air is extracted from the cabinet by a fan, cooled by a heat exchanger (using a cooling fan with ambient air) and forced back into the cabinet;
depending on the type of engineering the improvement can reach a 5 times higher power dissipation than in case 1.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 1000 W.
5) Air Conditioned Cabinets
Air conditioned cabinets are preferred in hot climates and / or harsh environments. Cabinet temperature can become equal or even lower than the
ambient temperature. A specific refrigerating system or the existing air conditioning system can be used for cabinet conditioning.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 1000 W.
Installation of Electronic Equipments in cabinet
Pmax
S * K

Technology for safety
18 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Heat dissipation in cabinets
Example 1
Natural convection
~ 250 - 300 W
Forced convection by
Internal fan (increasing
In natural convention)
~ 250 - 300 W
Example 5
Heat dissipation via air
conditioner (cooling by
temperature lower than
the ambient temperature
~ 1000 W
Example 4
Forced air circulation
via heat exchanger
(air circulation by two
separate flows internal
and external)
~ 1000 W
Example 2
Air flow
(Natural convection)
~ 350 - 450 W
Example 3
Air flow
(filtered fans)
~ 500 - 750 W
CLOSED VERSION
OPEN VERSION
Power value dissipated per ΔT = 10°C (single cabinet)
For installation in a row of cabinets, power dissipated in the first two examples is decreased of about 15%
Power value dissipated per ΔT = 10°C (single cabinet)
For installation in a row of cabinets, power dissipated in the above two examples is decreased of about 5-10%

Technology for safety 19
D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Calculation of radiant surfaces in closed cabinets
Single cabinet
(all surfaces free of
contact)
Row of cabinets
Single cabinet
(one side on the wall)
Row of cabinets
(one side of each
on the wall)
A1A2
A3
A1A2
A3
A1
A3
A1
A3
A1
A3
A1
A3
A1
A3
A1
A3
A1A2
A3
A1A2
A3
ATOT = 2 x A1 +2 x A2+ A3
Formula for cabinet with no surfaces in contact with the wall
ATOT = 2 x N x A1+ 2 x A2+ N x A3
(N = Number of cabinets placed side by side)
Formula for row of cabinets with no surface in contact with the wall
ATOT = 1 x A1 +2 x A2+ A3
Formula for cabinet with one side on the wall
Row of cabinet (one side by the wall)
ATOT = N x A1+ 2 x A2+ N x A3
(N = Number of cabinets placed side by side)
Formula for row of cabinets with one side on the wall

Technology for safety
20 D5000 - D5200 Series - Intrinsically Safe Isolators and Safety Relays
Fig. 1 Horizontal orientation in the cabinet
Placement of isolators in cabinet
The placement of the barriers in the cabinet has an important impact on the ambient temperature. The following points should be considered:
1. The sum of the individual dissipated power of the installed barriers plus other devices need to be below the calculated or given maximum
dissipation power of the cabinet.
2. The D5000 and D5200 series could be installed in horizontal or vertical mounting position. The installation in horizontal position offers an
improved heat transport.
3. Place the units with higher dissipation power in the upper part of the cabinet.
4. If you apply ventilation please consider the following:
a) When applying temperature control you have to install the temperature sensor in the upper part of the cabinet.
b) It is more effective to install a fan into the roof of the cabinet rather than in the lower part of the cabinet.
5. Take care about reasonable distance between D5000 and D5200 series and cable channels. We recommend a distance of 5 cm.
(see figure 1 and 2). If the place in the cabinet does not allow to keep the distance we strongly recommend to place the DIN-Rail
away from the back side of the cabinet by means of distance bolts.
C
B
A
Minimum 5 cm distance
between isolators and
cable duct.
B
C
Non I.S. cable duct
A
D5000 - D5200 Series
I.S. cable duct
Fig. 2 Vertical orientation in the cabinet
Minimum 5 cm distance
between isolators and
cable duct.
B
C
Non I.S. cable duct
D5000 - D5200 Series
I.S. cable duct
A B C
A
B
B