GMI D6032S User manual

D6032 - SIL 3 Switch/Proximity Detector Repeater Relay Output G.M. International ISM0405-0
SIL 3 Switch/Proximity Detector Repeater
Relay Output, Termination Board
Models D6032S, D6032D
D6032S - D6032D
INSTRUCTION MANUAL

2 D6032 - SIL 3 Switch/Proximity Detector Repeater Relay Output G.M. International ISM0405-0
General Description: The single and dual channel Switch/Proximity Detector Repeater, D6032S and D6032D module is a unit suitable for applications requiring SIL 3 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 relay output contact.
Each channel enables a load to be controlled by a switch, or a proximity detector.
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 relay and turns the fault LED on; when disabled the corresponding output relay repeats the input line
open or closed status as configured.
D6032D is programmable via dip switches as single input and two independent outputs. Out 2 can be programmed for output duplicating Out 1 or Fault detection Out.
In case of duplication, relay actuation can be independently configured for each output.
In case of fault output, relay actuation can be programmed as normally energized or normally de-energized.
Mounting on customized Termination Boards.
Functional Safety Management Certification:
G.M. International is certified by TÜV 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 D6032D, 18 mA for 1 channel D6032S with short circuit input and relay energized, typical.
Power dissipation: 0.85 W for 2 channels D6032D, 0.45 W for 1 channel D6032S with 24 V supply voltage, short circuit input and relay energized, typical.
Isolation (Test Voltage): In/Out 2.5 KV; In/Supply 2.5 KV; In/In 500 V; Out/Supply 500 V; Out/Out 500 V.
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 (when enabled both faults de-energize channel relay with single channel unit D6032S or
de-energize channel relay with D6032D used as dual channel unit or actuate the fault relay out with D6032D used as fault signaling unit).
Input equivalent source: 8 V 1 Ktypical (8 V no load, 8 mA short circuit).
Output: voltage free SPST 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.
Mechanical / Electrical life: 5 * 106/ 1 * 106operation, 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: 2014/30/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.
Approvals:
TÜV Certificate No. C-IS-722134640-01, SIL 2 / SIL 3 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:
on customized Termination Board.
Weight: about 125 g D6032D, 115 g D6032S.
Connection: by polarized plug-in disconnect screw terminal blocks to accommodate terminations up to 2.5 mm2.
Protection class: IP 20.
Dimensions: Width 12.5 mm, Depth 123 mm, Height 120 mm.
FSM
SIL 3

3
D6032 - SIL 3 Switch/Proximity Detector Repeater Relay OutputG.M. International ISM0405-0
Ordering Information
Front Panel and Features
SIL 3 according to IEC 61508:2010 Ed. 2 for Tproof = 2 / 10 years (10% / >10 % of total SIF),
considering 100 mA max contact current.
SIL 2 according to IEC 61508:2010 Ed. 2 for Tproof = 20 years (10% of total SIF),
considering 100 mA max contact current.
PFDavg (1 year) 4.92 E-05, SFF 90.06 %, with independent channel configuration.
PFDavg (1 year) 4.96 E-05, SFF 93.16 %, with D6032D used as duplicator (both channels) or
as fault indicator (only 1st ch.).
PFDavg (1 year) 4.66 E-05, SFF 93.53 %, with D6032D used as fault indicator (only 2nd ch.).
Systematic capability SIL 3
2 fully independent channels.
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.
TÜV Certification.
TÜV Functional Safety Certification.
High Density, two channels per unit.
Simplified installation using customized Termination Boards.
+ Input Ch 1 for Proximity or Voltage free Contact
Terminal block connections
- 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
Model: D6032
1 channel S
2 channels D
7 8
9 10

4 D6032 - SIL 3 Switch/Proximity Detector Repeater Relay Output G.M. International ISM0405-0
Function Diagram
Internal Dip switches programmable
Relay contacts shown in
de-energized position
Relay contact shown in
de-energized position
Relay contacts shown in
de-energized position
MODEL D5032D
=
=
=
=
7
8
Termination
board
connector
Supply 24 Vdc
Out 1 (SIL3)
Out 2 (SIL 3)
+
-
F
=
=
=
=
9
10
+
-
In 1
Proximity
voltage free
Contact
+
-
In 2
Proximity
voltage free
Contact
voltage free
Contact
voltage free
Contact
R1
R2
R1
R2
Resistors R1 - R2 used with
voltage free contact required
for line fault detection.
MODEL D5032D Duplicator or Fault Out
=
=
=
=
7
8
Termination
board
connector
Supply 24 Vdc
Out 1 (SIL3)
Out 2 Duplicator or Fault
+
-
F
9
10
+
-
In
Proximity
voltage free
Contact
voltage free
Contact
R1
R2
Resistors R1 - R2 used with
voltage free contact required
for line fault detection.
Terminals 9-10 must be
shorted to set module as
Duplicator or Fault Out
MODEL D5032S
=
=
=
=
7
8
Termination
board
connector
F
Supply 24 Vdc
Out NO Contact (SIL 3)
+
-
+
-
In
Proximity
voltage free
Contact
voltage free
Contact
R1
R2
Resistors R1 - R2 used with
voltage free contact required
for line fault detection.
(SIL 3)
MODEL D6032D
MODEL D6032D Duplicator or Fault Out
MODEL D6032S

5
D6032 - SIL 3 Switch/Proximity Detector Repeater Relay OutputG.M. International ISM0405-0
D6032 series must be installed, operated and maintained only by qualified personnel, in accordance to the relevant national/international installation standards.
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
D6032 module is a unit suitable for applications requiring SIL 3 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 relay output contact.
Each channel enables a load to be controlled by a switch, or a proximity detector.
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 relay and turns the fault LED on; when disabled the corresponding output relay repeats the input line open or closed status as configured.
D6032D is programmable via dip switches as single input and two independent outputs. Out 2 can be programmed for output duplicating Out 1 or Fault detection Out.
In case of duplication, relay actuation can be independently configured for each output.
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
D6032 series are Switch/Proximity Detector Interface housed in a plastic enclosure suitable for installation on customized Termination Board.
D6032 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.
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. D6032S is a single channel model and D6032D is a dual channel model), the function and location of each connection terminal
using the wiring diagram on the corresponding section, as an example:
For Model D6032S, in case of Proximity or Voltage free Contact, connect the wires at terminal “7” for positive and “8” for negative.
For Model D6032D in addition to channel 1 connections above, connect terminal “9” for positive and “10” for negative on channel 2.
Connection for power supply and output are provided by Termination Board connector.
Connect SPST relay contacts checking the load rating to be within the contact maximum rating (100 mA 50 Vac 5 VA, 100 mA 50 Vdc 5 W (resistive load)).
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.
Any penetration of cleaning liquid must be avoided to prevent damage to the unit. Any unauthorized card modification must be avoided.
According to EN61010, D6032 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. 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.

6 D6032 - SIL 3 Switch/Proximity Detector Repeater Relay Output G.M. International ISM0405-0
ON
D6032D used as double channel
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.
WARNING: dip-switch 6-7-8 must be set to “OFF” position.
Configuration
Dip switch configuration
1234
CH1
5678
CH2
ON
Must be set to
"OFF" position
Input Input
OutputInputOutputInput
CH1
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)
7
NO
8
OR NC 7
8
7
NO
8
OR NC 7
8
1
OFF
5
OFF
1
ON
5
ON
NE ND
Output
ND
Output
NE
Position in fault condition
2
ON
2
OFF
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 ND
Output
ND
Output
NE
3
3
ON
OFF Position in fault condition
4
4
ON
OFF
12345678
ON
Dip switch factory settings. All Switches are OFF
For SIL Application
For SIL Application
For SIL Application
For SIL Application

7
D6032 - SIL 3 Switch/Proximity Detector Repeater Relay OutputG.M. International ISM0405-0
ON
Configuration
Dip switch configuration
12345678
ON
Must be set to
"OFF" position
D6032D used as duplicator or fault output
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.
WARNING: Terminals 9-10 must be shorted to set module as Duplicator or Fault Out.
Dip-switch 3 must be set to “OFF” position.
Fault condition
1
1
8
7
6
8
7
4
4
CH
Setting
Line fault
detection
IN / OUT
Operation
Output 1
NO-NE or
NC-ND
NO-ND or
NC-NE
Duplicator Parallel
Mode
Reverse
Mode
Fault
Output OFF
ON
OFF
ND
Mode
NE
Mode
ON
OFF
OFF
ON
Disabled
(switch / proximity sensor)
Enabled
(proximity sensor or switch
with end of line resistors,
de-energizes relay in fault condition)
No Fault
No Fault
1
OFF
5
OFF
5
ON
Output 2
Operation
Input Input
Output 1InputOutput 1Input
7
NO
8
OR NC 7
8
7
NO
8
OR NC 7
8
NE ND
Output 1
ND
Output 1
NE
NE
ND
Set SW4
equal to
SW2
Set SW4
opposite to
SW2
6
6
ON
De-energized in
fault condition if
line fault detection
enabled (SW1 ON)
OFF
Not specified fault condition
Position in fault
condition
ON
Output 1,
De-energized in
fault condition
OFF
Output 1, not specified fault condition
Position in fault
condition
Fault condition
2
ON
2
OFF
12345678
ON
Dip switch factory settings. All Switches are OFF
For SIL Application
For SIL Application
For SIL Application
For SIL Application
For SIL Application
For SIL Application
For SIL Application
For SIL Application

8 D6032 - SIL 3 Switch/Proximity Detector Repeater Relay Output G.M. International ISM0405-0
ON
D6032S
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.
WARNING: Dip-switch 7-8 must be set to “OFF” position.
Configuration
Dip switch configuration
1234
7-8 must be set to "OFF" position
3-4-6 Not used
5678
ON
CH
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)
1
OFF
5
OFF
1
ON
5
ON
Input Input
InputInput
7
NO
8
OR NC 7
8
7
NO
8
OR NC 7
8
Output
NE
Output
NE
Output
ND
Output
ND
Position in fault condition
2
ON
2
OFF
12345678
ON
Dip switch factory settings. All Switches are OFF
For SIL Application
For SIL Application

9
D6032 - SIL 3 Switch/Proximity Detector Repeater Relay OutputG.M. International ISM0405-0
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
SW5
OFF
ON
IN/OUT Operation SW2
NO-NE or NC-ND ON
NO-ND or NC-NE
(for SIL application) OFF
D6032S Configuration Summary Table
WARNING: Dip-switch 7-8 must be set to “OFF” position.
D6032D (used as duplicator or fault output) Configuration Summary Table
WARNING: Terminals 9-10 must be shorted to set module as Duplicator or Fault Out. Dip-switch 3 must be set to “OFF” position.
Channel 2
Line fault detection SW1 SW5 SW3
Disabled
(switch/proximity sensor) OFF 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 ON
1
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
D6032D (used as double channel) Configuration Summary Table
WARNING: dip-switch 6-7-8 must be set to “OFF” position.
Output 2 Operation SW6 SW7 SW8 Mode SW4
Duplicator
De-energized in
fault condition
(for SIL application)
if line fault
detection enabled
(SW1 ON)
ON
OFF ON
Parallel
(for SIL
applica-
tion)
Set equal
to SW2
Not specified
Fault condition OFF Reverse
Set opposite
to SW2
OFF
(for SIL application) ON OFF
ND ON
NE
(for SIL
applica-
tion)
OFF
Fault Output
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
OFF OFF OFF OFF OFF OFF OFF OFF
DIP Switch factory settings (valid for D6032S and D6032D)
Configuration
IN/OUT Operation Output 1 SW2
NO-NE or NC-ND ON
NO-ND or NC-NE
(for SIL application) OFF
Line fault detection SW1 SW5
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)
Output 1,
(for SIL application)
De-energized in Fault condition
ON
Output 1,
Not specified Fault condition OFF
ON