GMI D5036S Instruction Manual

D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
SIL 2 Switch/Proximity Detector Repeater,
Relay Output DIN-Rail
Models D5036S, D5036D
D5036S - D5036D
INSTRUCTION & SAFETY MANUAL

2 D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
General Description: The single and dual channel Switch/Proximity Detector Repeater, D5036S and D5036D module is a unit suitable for applications requiring SIL 2 level (according to
IEC 61508:2010 Ed. 2) 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 NE or ND SPST (D5036D) or SPDT (D5036S) relay output contact. Each
channel enables a Safe Area load to be controlled by a switch, or a proximity detector, located in Hazardous Area.
A fault detection circuit (DIP switch enabled) 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 relay and turns the fault LED on; when disabled the corresponding output relay repeats the input line open or closed status as configured.
Mounting on standard DIN-Rail, with or without Power Bus, in Safe Area or in Zone 2.
Functional Safety Management Certification:
G.M. International is certified by TUV to conform to IEC61508:2010 part 1 clauses 5-6 for safety related systems up to and included SIL3.
Technical Data
Characteristics
Supply: 24 Vdc nom (18 to 30 Vdc) reverse polarity protected, ripple within voltage limits 5 Vpp, 2 A time lag fuse internally protected.
Current consumption @ 24 V: 35 mA for 2 channels D5036D, 18 mA for 1 channel D5036S with short circuit input and relay energized, typical.
Power dissipation: 0.85 W for 2 channels D5036D, 0.45 W for 1 channel D5036S with 24 V supply voltage, short circuit input and relay energized, typical.
Isolation (Test Voltage): I.S. In/Out 1.5 KV; I.S. In/Supply 1.5 KV; I.S. In/ I.S In 500 V; Out/Supply 1.5 KV; Out/Out 1.5 KV.
Input switching current levels: ON 2.1 mA (1.9 to 6.2 mA range), OFF 1.2 mA (0.4 to 1.3 mA range), switch current 1.65 mA ± 0.2 mA hysteresis.
Fault current levels: open fault 0.2 mA, short fault 6.8 mA.
Input equivalent source: 8 V 1 Ktypical (8 V no load, 8 mA short circuit).
Output: voltage free SPST (D5036D) or SPDT (D5036S) relay contact.
Contact material: Ag Alloy (Cd free), gold plated.
Contact rating: 4 A 250 Vac 1000 VA, 4 A 250 Vdc 120 W (resistive load). Min. switching current 1 mA.
DC Load breaking capacity:
Mechanical / Electrical life: 5 * 106/ 3 * 104operation, typical.
Operate / Release time: 8 / 4 ms typical.
Bounce time NO / NC contact: 3 / 8 ms typical.
Frequency response: 10 Hz maximum.
Compatibility:
CE mark compliant, conforms to Directive: 2014/34/EU ATEX, 2014/30/EU EMC, 2014/35/EU LVD, 2011/65/EU RoHS.
Environmental conditions:
Operating: temperature limits – 40 to + 70 °C, relative humidity 95 %, up to 55 °C.
Storage: temperature limits – 45 to + 80 °C.
Safety Description:
ATEX: II 3(1)G Ex nA nC [ia Ga] IIC T4 Gc, II (1)D [Ex ia Da] IIIC, I (M1) [Ex ia Ma] I
IECEx: Ex nA nC [ia Ga] IIC T4 Gc, [Ex ia Da] IIIC, [Ex ia Ma] I,
UL: NI / I / 2 / ABCD / T4, AIS / I, II, III / 1 / ABCDEFG, AEx nA nC [ia Ga] IIC T4 Gc
C-UL: NI / I / 2 / ABCD / T4, AIS / I, II, III / 1 / ABCDEFG, Ex nA nC [ia Ga] IIC T4 Gc
EAC-EX: 2Ex nA nC [ia Ga] IIC T4 Gc X, [Ex ia Da] IIIC X, [Ex ia Ma] I X
UKR TR n. 898: 2ExnAnCiaIICT4 X, ExiaI X
associated apparatus and non-sparking electrical equipment.
Uo/Voc = 10.5 V, Io/Isc = 22 mA, Po/Po = 56 mW at terminals 7-8, 9-10.
Um = 250 Vrms, -40 °C Ta 70 °C.
Approvals:
BVS 10 ATEX E 113 X conforms to EN60079-0, EN60079-11, EN60079-15,
IECEx BVS 10.0072X conforms to IEC60079-0, IEC60079-11, IEC60079-15,
UL & C-UL E222308 conforms to UL913, UL 60079-0, UL60079-11, UL60079-15, ANSI/ISA 12.12.01 for UL
and CSA-C22.2 No.157-92, CSA-E60079-0, CSA-E60079-11, CSA-C22.2 No. 213 and CSA-E60079-15 for C-UL.
C-IT.ME62.B.04182 conforms to GOST R IEC 60079-0,GOST R IEC 60079-11, GOST R IEC 60079-15.
C16.0036 X conforms to  7113,  22782.5-78,  I 60079-15.
TÜV Certificate No. C-IS-236198-04, SIL 2 conforms to IEC61508:2010 Ed. 2.
TÜV Certificate No. C-IS-236198-09, SIL 3 Functional Safety Certificate conforms to IEC61508:2010 Ed.2, for Management of Functional Safety.
Mounting:
T35 DIN-Rail according to EN50022, with or without Power Bus.
Weight: about 135 g D5036D, 120 g D5036S.
Connection: by polarized plug-in disconnect screw terminal blocks to accommodate terminations up to 2.5 mm2.
Location: installation in Safe Area or Zone 2, Group IIC T4.
Protection class: IP 20.
Dimensions: Width 12.5 mm, Depth 123 mm, Height 120 mm.
0.20.0
V (V)
I (A)
10
20
30
40
50
100
0.3 0.4 0.5 1 2 3
Resistive
Load
200
4
300
250
0.1
FSM
SIL 3

3
D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay OutputG.M. International ISM0269-3
Ordering Information
Front Panel and Features
SIL 2 according to IEC 61508:2010 Ed. 2
for Tproof = 4 / 20 years (10% / >10 % of total SIF) for D5036S and D5036D.
PFDavg (1 year) 2.25 E-04, SFF 70.87 % for D5036S.
PFDavg (1 year) 2.25 E-04, SFF 71.76 % for D5036D.
Systematic capability SIL 3.
Input from Zone 0 (Zone 20), installation in Zone 2.
NO/NC switch/proximity Detector Input, NE/ND relay actuation mode.
Field open and short circuit detection.
Three port isolation, Input/Output/Supply.
EMC Compatibility to EN61000-6-2, EN61000-6-4, EN61326-1, EN61326-3-1 for safety system.
In-field programmability by DIP Switch.
ATEX, IECEx, UL & C-UL, EAC-EX, UKR TR n. 898, TÜV Certifications.
TÜV Functional Safety Certification.
High Density, two channels per unit.
Simplified installation using standard DIN-Rail and plug-in terminal blocks, with or without Power Bus.
250 Vrms (Um) max. voltage allowed to the instruments associated with the barrier.
+ Input Ch 1 for Proximity or Voltage free Contact
Terminal block connections
HAZARDOUS AREA SAFE AREA
- Input Ch 1 for Proximity or Voltage free Contact
+ Input Ch 2 for Proximity or Voltage free Contact
- Input Ch 2 for Proximity or Voltage free Contact
7
8
9
10
Output Ch 1
1
Output Ch 1
2
Output Ch 2
3
Output Ch 2
4
+ Power Supply 24 Vdc
5
- Power Supply 24 Vdc
6
Model: D5036
1 channel S
2 channels D
Power Bus and DIN-Rail accessories:
Connector JDFT049 Cover and fix MCHP196
Terminal block male MOR017 Terminal block female MOR022
7 8
9 10
2 1
4 3
6 5

4 D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
Parameters Table
Must
be
Hazardous Area/
Hazardous Locations
Device Parameters
D5036 Associated
Apparatus Parameters
Must
be
Hazardous Area/
Hazardous Locations
Device + Cable Parameters
Uo / Voc = 10.5 V Ui / Vmax
In the system safety analysis, always check the Hazardous Area/Hazardous Locations devices to conform with the related system documentation, if the device is Intrinsically Safe check
its suitability for the Hazardous Area/Hazardous Locations and group encountered and that its maximum allowable voltage, current, power (Ui/Vmax, Ii/Imax, Pi/Pi) are not exceeded
by the safety parameters (Uo/Voc, Io/Isc, Po/Po) of the D5036 series Associated Apparatus connected to it. Also consider the maximum operating temperature of the field device,
check that added connecting cable and field device capacitance and inductance do not exceed the limits (Co/Ca, Lo/La, Lo/Ro) given in the Associated Apparatus parameters for the
effective group. See parameters indicated in the table below:
D5036 Terminals
Ch1
Ch2
7 - 8
9 - 10
Ch1
Ch2
7 - 8
9 - 10 Io / Isc = 22 mA
Ch1
Ch2
7 - 8
9 - 10 Po / Po = 56 mW

Ii/ Imax

Pi / Pi

D5036 Terminals D5036 Associated Apparatus
Parameters Cenelec (US)
Ci / Ci device + C cable
IIC (A, B)
Co / Ca = 2.41 µF
Co / Ca = 16.8 µF
Co / Ca = 75 µF
IIB (C)
IIA (D)
For installations in which both the Ci and Li of the Intrinsically Safe apparatus exceed 1 % of the Co and Lo parameters of the Associated Apparatus (excluding the cable),
then 50 % of Co and Lo parameters are applicable and shall not be exceeded (50 % of the Co and Lo become the limits which must include the cable such that
Ci device + C cable 50 % of Co and Li device + L cable 50 % of Lo).
If the cable parameters are unknown, the following value may be used: Capacitance 180pF per meter (60pF per foot), Inductance 0.60µH per meter (0.20µH per foot).
Co / Ca = 66 µF
Co / Ca = 16.8 µF
I
IIIC (E, F, G)
Ch1
Ch2
7 - 8
9 - 10
Li / Li device + L cable

IIC (A, B)
Lo / La = 78.3 mH
Lo / La = 313.4 mH
Lo / La = 626.9 mH
IIB (C)
IIA (D)
Lo / La = 1028.6 mH
Lo / La = 313.4 mH
I
IIIC (E, F, G)
Ch1
Ch2
7 - 8
9 - 10
Li / Ri device and
L cable / R cable

IIC (A, B)
Lo / Ro = 635 µH/
Lo / Ro = 2543 µH/
Lo / Ro = 5087 µH/
IIB (C)
IIA (D)
Lo / Ro = 8347 µH/
Lo / Ro = 2543 µH/
I
IIIC (E, F, G)
Ch1
Ch2
7 - 8
9 - 10

5
D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay OutputG.M. International ISM0269-3
Function Diagram
HAZARDOUS AREA ZONE 0 (ZONE 20)
GROUP IIC SAFE AREA, ZONE 2 GROUP IIC T4
Resistors R1 - R2 used with
voltage free contact required
for line fault detection.
Resistors R1 - R2 used with
voltage free contact required
for line fault detection.
MODEL D5036D
5 +
6 -
1
2Out 1 (SIL 2)
10
+
-
In 1
Proximity
voltage free
Contact
7
8
Power and
Fault Bus
+
-
F
Supply 24 Vdc
3
4Out 2 (SIL 2)
+
-
In 2
Proximity
voltage free
Contact
9
voltage free
Contact
voltage free
Contact
R1
R2
R1
R2
MODEL D5036S
5 +
6 -
1
2Out NO Contact (SIL 2)
7
8
Power and
Fault Bus
+
-
F
Supply 24 Vdc
3
4Out NC Contact
+
-
In
Proximity
voltage free
Contact
voltage free
Contact
R1
R2
Relay contact shown in de-energized position.
Terminals 1-2 and 3-4 open.
Relay contact shown in de-energized position.
Terminals 1-2 open, terminals 3-4 close.

6 D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
Functional Safety Manual and Application
Application for D5036D
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes 10% of total SIF dangerous failures:
Failure rates table according to IEC 61508:2010 Ed.2 :
Failure rate table:
Safety Function and Failure behavior:
D5036D is considered to be operating in Low Demand mode, as a Type A module, having Hardware Fault Tolerance (HFT) = 0.
The failure behavior is described from the following definitions :
Fail-Safe State: it is defined as the relay output being de-energized (so that the NO contact is open);
Fail Safe: failure mode that causes the module / (sub)system to go to the defined Fail-Safe state without a demand from the process;
Fail Dangerous: failure mode that does not respond to a demand from the process (i.e. being unable to go to the defined Fail-Safe state), so that the relay output remains
energized (the NO contact is blocked in closed position);
Fail “No Effect”: failure mode of a component that plays a part in implementing the Safety Function but that is neither a safe failure nor a dangerous failure.
When calculating the SFF, this failure mode is not taken into account;
Fail “Not part”: failure mode of a component that is not part of the Safety Function but that is part of the circuit diagram and is listed for completeness.
When calculating the SFF, this failure mode is not taken into account.
The 2 channels of D5036D module must not be used to increase the hardware fault tolerance, needed for a higher SIL of a certain Safety Function, as they are not completely
independent each other, containing common components.
Failure rate date: taken from Siemens Standard SN29500.
Input signal state
Pins 7-8 (In 1 - Ch.1) or 9-10 (In 2 - Ch.2)
Output relay contact state
Pins 1-2 (Out 1 - Ch.1) or 3-4 (Out 2 - Ch.2)
Proximity sensor is OFF or switch is open Open (De-energize relay)
Proximity sensor is ON or switch is closed Closed (Energized relay)
Independently from proximity sensor or switch state, the input line is break Open (De-energized relay as safe state condition)
Independently from proximity sensor or switch state, the input line is in short circuit Open (De-energized relay as safe state condition)
Channel status
yellow LED state
OFF
ON
OFF
OFF
Channel fault
red LED state
OFF
OFF
ON
ON
Description: For this application, enable input line fault (open or short) detection and direct input to output transfer function, by set the internal dip-switches in the following mode (see
page 9 for more information):
D5036D
(Ch.1 and Ch.2)
OFF operation ON operation
Field Input: proximity is OFF
or switch is open
Field Input: proximity is OFF
or switch is open
Out 1 relay is de-energized,
out contact is open
Out 2 relay is de-energized,
out contact is open
Channel 1
Channel 2
D5036D
(Ch.1 and Ch.2)
Field Input: proximity is ON
or switch is closed
Field Input: proximity is ON
or switch is closed
Out 1 relay is energized,
out contact is closed
Out 2 relay is energized,
out contact is closed
Channel 1
Channel 2
1
2 Out 1
Out 2
3
4
Out 2
3
4
Safety
PLC
Input
1
2 Out 1
Safety
PLC
Input
Safety
PLC
Input
Safety
PLC
Input
The module is powered by connecting 24 Vdc power supply to Pins 5 (+ positive) - 6 (- negative). The green LED is lit in presence of supply power.
Input signals from field are applied to Pins 7-8 (In 1 - Ch.1) and Pins 9-10 (In 2 - Ch.2).
Relay contact outputs Pins 1-2 (for Channel 1) and Pins 3-4 (for Channel 2) are both normally open (or relay de-energized as safe state condition) for OFF operation,
while they are both closed (or relay energized) for ON operation.
The following table describes for each channel the state (open or closed) of its output when its input signal is in OFF or ON state, and it gives information about turn-on or turn-off
of the related channel status LED and channel fault LED:
Dip-switch position 1 2 3 4
ON/OFF state ON OFF ON OFF
Supply
24 Vdc
5 + 6 -
7
8
In 1
9
10
In 2
Supply
24 Vdc
5 + 6 -
7
8
In 1
9
10
In 2
Systematic capability SIL 3.
Failure category Failure rates (FIT)
dd = Total Dangerous Detected failures 0.00
du = Total Dangerous Undetected failures 51.22
sd = Total Safe Detected failures 0.00
su = Total Safe Undetected failures 130.16
λtot safe = Total Failure Rate (Safety Function) = λdd + λdu + λsd + λsu 181.38
MTBF (safety function, one channel) = (1 / λtot safe) + MTTR (8 hours) 629 years
no effect = “No Effect” failures 138.62
not part = “Not Part” failures 200.20
λtot device = Total Failure Rate (Device) = λtot safe + λno effect + λnot part 520.20
MTBF (device, one channel) = (1 / λtot device) + MTTR (8 hours) 219 years
λsd λsu λdd λdu SFF
0.00 FIT 130.16 FIT 0.00 FIT 51.22 FIT 71.76%
T[Proof] = 20 years
PFDavg = 4.50 E-03 Valid for SIL 2
T[Proof] = 1 year T[Proof] = 4 years
PFDavg = 2.25 E-04 Valid for SIL 2 PFDavg = 8.99 E-04 Valid for SIL 2
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes >10% of total SIF dangerous failures:

7
D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay OutputG.M. International ISM0269-3
Failure category Failure rates (FIT)
dd = Total Dangerous Detected failures 0.00
du = Total Dangerous Undetected failures 51.22
sd = Total Safe Detected failures 0.00
su = Total Safe Undetected failures 124.62
λtot safe = Total Failure Rate (Safety Function) = λdd + λdu + λsd + λsu 175.84
MTBF (safety function, one channel) = (1 / λtot safe) + MTTR (8 hours) 649 years
no effect = “No Effect” failures 128.26
not part = “Not Part” failures 23.50
λtot device = Total Failure Rate (Device) = λtot safe + λno effect + λnot part 327.60
MTBF (device, one channel) = (1 / λtot device) + MTTR (8 hours) 348 years
λsd λsu λdd λdu SFF
0.00 FIT 124.62 FIT 0.00 FIT 51.22 FIT 70.87%
Functional Safety Manual and Application
Application for D5036S
Safety Function and Failure behavior:
D5036S is considered to be operating in Low Demand mode, as a Type A module, having Hardware Fault Tolerance (HFT) = 0.
The failure behavior is described from the following definitions :
Fail-Safe State: it is defined as the relay output being de-energized (so that the NO contact is open and the NC contact is closed);
Fail Safe: failure mode that causes the module / (sub)system to go to the defined Fail-Safe state without a demand from the process;
Fail Dangerous: failure mode that does not respond to a demand from the process (i.e. being unable to go to the defined Fail-Safe state), so that the relay output remains
energized (the NO contact is blocked in closed position and the NC contact is blocked in open position);
Fail “No Effect”: failure mode of a component that plays a part in implementing the Safety Function but that is neither a safe failure nor a dangerous failure.
When calculating the SFF, this failure mode is not taken into account;
Fail “Not part”: failure mode of a component that is not part of the Safety Function but that is part of the circuit diagram and is listed for completeness.
When calculating the SFF, this failure mode is not taken into account.
Failure rate date: taken from Siemens Standard SN29500.
Description:
For this application, enable input line fault (open or short) detection and direct input to output transfer function, by set the internal dip-switches in the following mode (see page 10
for more information):
D5036S
(Ch.1)
OFF operation ON operation
Field Input: proximity is OFF
or switch is open
Out relay is de-energized,
out contact is open
Channel 1
D5036S
(Ch.1)
Field Input: proximity is ON
or switch is closed
Out relay is energized,
out contact is closed
Channel 1
1
2
1
2 Out with
NO contact
Safety
PLC
Input
Safety
PLC
Input
The module is powered by connecting 24 Vdc power supply to Pins 5 (+ positive) - 6 (- negative). The green LED is lit in presence of supply power.
Input signal from field is applied to Pins 7-8 (In 1 - Ch.1).
Relay contact output Pins 1-2 is normally open or Pins 3-4 is normally closed (because relay is de-energized as safe state condition) for OFF operation, while Pins 1-2 is closed
or Pins 3-4 is open (because relay is energized) for ON operation. The following table describes for Channel 1 the state (open or closed) of its output contacts when its input
signal is in OFF or ON state, and it gives information about turn-on or turn-off of its channel status LED and channel fault LED:
Dip-switch position 1 2 3 4
ON/OFF state ON OFF Not used Not used
7
8
In 7
8
In
Supply
24 Vdc
5 + 6 -
Supply
24 Vdc
5 + 6 -
Out with
NC contact
3
4
Out relay is de-energized,
out contact is closed
Safety
PLC
Input
3
4
Input signal state
Pins 7-8
Out relay contact state
Pins 1-2 (with NO contact)
Channel status
yellow LED
state
Channel fault
red LED state
Proximity is OFF or switch is open Open (De-energize relay) OFF OFF
Proximity is ON or switch is closed Closed (Energized relay) ON OFF
If the input line is break Open (safe state condition) OFF ON
If the input line is in short circuit Open (safe state condition) OFF ON
Out relay contact state
Pins 3-4 (with NC contact)
Closed (De-energize relay)
Open (Energized relay)
Closed (safe state condition)
Closed (safe state condition)
Out with
NO contact
Out with
NC contact
Out relay is energized,
out contact is open
Safety
PLC
Input
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes 10% of total SIF dangerous failures:
Systematic capability SIL 3.
T[Proof] = 20 years
PFDavg = 4.50 E-03 Valid for SIL 2
T[Proof] = 1 year T[Proof] = 4 years
PFDavg = 2.25 E-04 Valid for SIL 2 PFDavg = 8.99 E-04 Valid for SIL 2
PFDavg vs T[Proof] table (assuming Proof Test coverage of 99%), with determination of SIL supposing module contributes >10% of total SIF dangerous failures:
Failure rates table according to IEC 61508:2010 Ed.2 :
Failure rate table:

8 D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
D5036 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.
D5036 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
D5036 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 NE or ND SPST (D5036D) or SPDT (D5036S) relay output contact.
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 sensors and switch equipped with end of line resistors. In case of fault, when enabled it de-energizes
the corresponding output relay and turns the fault LED on; when disabled the corresponding output relay repeats the input line open or closed status as configured.
In case of fault output, relay actuation can be programmed as normally energized or normally de-energized.
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typical (470 to 2 krange)
resistor in series and a R2=10 ktypical (5 kto 15 k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
D5036 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.
D5036 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. D5036S is a single channel model and D5036D 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 D5036S connect output of channel 1 at terminals “1” and “2”.
For Model D5036D in addition to channel 1 connections above, connect output of channel 2 at terminals “3” and “4”.
For Model D5036S, in case of Proximity or Voltage free Contact, connect the wires at terminal “7” for positive and “8” for negative.
For Model D5036D 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 SPDT (D5036S) or SPST (D5036D) relay contacts checking the load rating to be within the contact maximum rating (4 A 250
Vac 1000 VA, 4 A 250 Vdc 120 W resistive load. If necessary, to prevent relay contacts from damaging, an external protection (fuse or similar) should be connected.
A suitable protection must be chosen according to the relay breaking capacity diagram on data sheet.
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 D5036 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, D5036 series must be connected to SELV or SELV-E supplies. Relay output contact must be connected to load non exceeding category II overvoltage limits.
Warning: de-energize main power source (turn off power supply voltage) and disconnect plug-in terminal blocks before opening the enclosure to avoid electrical shock
when connected to live hazardous potential.
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 relay 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 relay 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typical (470 to 2 Krange) resistor in series and R2=10 ktypical (5 Kto 15 Krange) resistor in parallel to the contacts.
The Proof test consists of the following steps:

9
D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay OutputG.M. International ISM0269-3
ON
D5036D
A configuration DIP switch is located on component side of pcb. This switch allows the configuration of input/output relationship, fault detection functions and operating mode.
Configuration
Dip switch configuration
Input Input
OutputInputOutputInput
2
CH1
Setting
Line fault
detection
IN / OUT
Operation
NO-NE or
NC-ND
NO-ND or
NC-NE
ON
Disabled
(switch / proximity sensor)
Enabled
(proximity sensor or switch
with end of line resistors,
de-energizes relay in fault condition)
7
2
OFF
NO
8
OR NC 7
8
7
NO
8
OR NC 7
8
1
OFF
1
ON
NE 1
2
1
ND
2
Output
1
ND
2
Output
NE 1
2
Position in fault condition
1
2
Input Input
OutputInputOutputInput
CH2
Setting
Line fault
detection
IN / OUT
Operation
NO-NE or
NC-ND
NO-ND or
NC-NE
Disabled
(switch / proximity sensor)
Enabled
(proximity sensor or switch
with end of line resistors,
de-energizes relay in fault condition)
9
NO
10
OR NC 9
10
9
NO
10
OR NC 9
10
NE 3
4
3
ND
4
Output
3
ND
4
Output
NE 3
4
3
3
ON
OFF
4
4
ON
OFF
Position in fault condition
3
4
1234
ON
Dip switch factory settings. All Switches are OFF
1234
ON
CH1 CH2
For SIL Application
For SIL Application
For SIL Application
For SIL Application

10 D5036 - SIL 2 Switch/Proximity Detector Repeater, Relay Output G.M. International ISM0269-3
ON
Line fault detection SW1
Disabled
(switch/proximity sensor) OFF
Enabled, for SIL application
(proximity sensor or switch with end of line resistors,
detects field open circuit and short circuit,
de-energizes relay in fault condition)
ON
IN/OUT Operation SW2
NO-NE or NC-ND ON
NO-ND or NC-NE
(for SIL application) OFF
D5036S Configuration Summary Table
Channel 1 2
Line fault detection SW1 SW3
Disabled
(switch/proximity sensor) OFF OFF
Enabled, for SIL application
(proximity sensor or switch with end of line resistors,
detects field open circuit and short circuit,
de-energizes relay in fault condition)
ON ON
IN/OUT Operation SW2
NO-NE or NC-ND ON
NO-ND or NC-NE
(for SIL application) OFF
Channel 1 2
SW4
ON
OFF
D5036D Configuration Summary Table
D5036S
A configuration DIP switch is located on component side of pcb. This switch allows the configuration of input/output relationship, fault detection functions and operating mode.
Configuration
Dip switch configuration
CH1
Setting
Line fault
detection
IN / OUT
Operation
NO-NE or
NC-ND
NO-ND or
NC-NE
2ON
2
OFF
Disabled
(switch / proximity sensor)
Enabled
(proximity sensor or switch
with end of line resistors,
de-energizes relay in fault condition)
1
OFF
1
ON
Input Input
InputInput
7
NO
8
OR NC 7
8
7
NO
8
OR NC 7
8
Output
1-3
2
4
NE
Output
1-3
2
4
NE
Output
1-3
2
4
ND
Output
2
4
ND 1-3
Position in fault condition
1-3
2
4
SW1 SW2 SW3 SW4
OFF OFF OFF OFF
DIP Switch factory settings (valid for D5036S and D5036D)
Configuration
1234
ON
Dip switch factory settings. All Switches are OFF
1234
ON
CH1 3-4 not used
Note: SW3 and SW4 not used.
Note: SW3 and SW4 used only in D5036D.
For SIL Application
For SIL Application