GMI D6038D Series User manual

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0431-2
SIL3 Line-Fault Transp. Switch/Prox. Repeater,
DIN-Rail and Termination Board
Models D6038S*, D6038D*, D6038X*
D6038S*, D6038D*, D6038X*
INSTRUCTION MANUAL

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0431-2
2
General Description:
The Switch/Proximity Detector Repeater D6038 is a module suitable for applications requiring SIL 3 level in safety related systems for high risk industries. The unit can be configured
for switches or proximity detectors (EN60947-5-6, NAMUR) and repeats the input state to the output. The output port can assume two different impedance values (RL or RH) or it can
open completely. The module output repeats the input state according to the following correspondence: low input state -> RL, high input state -> RH. Alternatively, the output can be
configured to invert the input state. In both cases, the output opens if any fault (open or short circuit) occurs at the corresponding input.
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.
Current consumption: 30 mA (D6038D), 25 mA (D6038X), 15 mA (D6038S), @ 24 Vdc, typical.
Power dissipation: 1.0 W (D6038D), 1.0 W (D6038X), 0.4 W (D6038S), @ 24 Vdc, typical.
Isolation (test voltage):
In/Out 1.5 kV; In/Supply 1.5 kV; In/In 500 V; Out/Supply 500 V; Out/Out 500 V.
Input:
Input switching current levels: ON 2.1 mA, OFF 1.2 mA.
Open fault: current 0.05 mA.
Short fault: resistance 100 .
No fault: current 0.35 mA and resistance 360 .
Input equivalent source: 8 V 1 ktypical (8 V no load, 8 mA short).
Output:
Voltage free SPST solid-state relays, with series (RL) and parallel (RH-RL) resistances, ±5% tolerance.
Fault impedance: > 1 M.
Max voltage: 30 Vdc.
Max current: 15 mA.
Response time: 500 s.
Frequency response: 1 kHz maximum.
Compatibility:
CE mark compliant, conforms to Directives: 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:
TUV Certificate No. C-IS-272994-01 SIL 3 conforms to IEC61508:2010 Ed. 2.
SIL 3 Functional Safety TÜV Certificate conforms to IEC61508:2010 Ed.2, for Management of Functional Safety.
Mounting:
EN/IEC60715 TH 35 DIN-Rail, with or without Power Bus or on customized Termination Board.
Weight: about 135 g (D6038D and D6038X), 120 g (D6038S).
Connection: by polarized plug-in disconnect screw terminal blocks to accommodate terminations up to 2.5 mm² (13 AWG).
Protection class: IP 20.
Dimensions: Width 12.5 mm, Depth 123 mm, Height 120 mm.
Ordering Information
Model: D6038
1 channel S
2 channels D
Power Bus and DIN-Rail accessories:
Bus connector JDFT049 Bus mounting kit OPT5096
duplicator X
RL = 2.2k, RH = 14.3kA
RL = 476, RH = 1.38kB
C
D
RL = 5k, RH = 15k
RL = 0, RH = 33.2k

D6038 - SIL3 Line-Fault Transp. Switch/Prox. RepeaterG.M. International ISM0431-2 3
Front Panel and Features
SIL 3 (low demand mode of operation) according to IEC 61508:2010 Ed.2 with Tproof = 2 / 5 yrs (10 / >10 % of total SIF).
SC 3: Systematic Capability SIL 3
Field open and short circuit detection
Field fault universal mirroring to PLC DI
Line monitoring transparency
In-field programmability by DIP Switch
Three port isolation, Input/Output/Supply
High Density, two channels per unit
+ 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
11
12
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
8
10
12
56
D6038
7 8
1 2
5 6
SIL 3
PWR
3 4
9 10
STS 1
FLT 1
STS 2
FLT 2
34
87
109

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0431-2
4
Function Diagram
MODEL D5038S
5 +
6 -
1
2Out 1 (SIL 3)
+
-
In 1
Proximity
voltage free
Contact
7
8
Power and
Fault Bus
+
-
F
Supply 24 Vdc
voltage free
Contact
R1
R2 RH-RL
RL
Termination
board
connector
MODEL D5038D
5 +
6 -
1
2Out 1 (SIL 3)
10
+
-
In 1
Proximity
voltage free
Contact
7
8
Power and
Fault Bus
+
-
F
Supply 24 Vdc
3
4Out 2 (SIL 3)
+
-
In 2
Proximity
voltage free
Contact
9
voltage free
Contact
voltage free
Contact
R1
R2
R1
R2
RL
RH-RL
RH-RL
RL
Termination
board
connector
MODEL D5038X
5 +
6 -
1
2Out 1 (SIL 3)
+
-
In 1
Proximity
voltage free
Contact
7
8
Power and
Fault Bus
+
-
F
Supply 24 Vdc
3
4Out 2 (SIL 3)
voltage free
Contact
R1
R2
RH-RL
RH-RL
RL
RL
Termination
board
connector
MODEL D6038S
MODEL D6038D
MODEL D6038X

D6038 - SIL3 Line-Fault Transp. Switch/Prox. RepeaterG.M. International ISM0431-2 5
D6038 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
D6038 series can accept on input connections switches or proximity detectors (EN60947-5-6, NAMUR). The output port can assume two different impedance values (RL or RH) or it can
open completely. The module output repeats the input state according to the following correspondence: low input state -> RL, high input state -> RH. Alternatively, the output can be
configured to invert the input state. In both cases, the output opens and the fault LED turns on if any fault (open or short circuit) occurs at the corresponding input.
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
D6038 series is switch/proximity repeater housed in a plastic enclosure suitable for installation on EN/IEC60715 TH 35 DIN-Rail, with or without Power Bus or on customized Termination
Board. D6038 series can be mounted with any orientation over the entire ambient temperature range.
Electrical connections 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. Connect only one individual conductor per each clamping point, use conductors up to 2.5 mm² (13 AWG) and a torque value of 0.5-0.6 Nm. Use only cables that are suitable for
a temperature of at least 85°C.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.
The enclosure provides, according to EN60529, an IP20 minimum degree of protection (or similar to NEMA Standard 250 type 1). The equipment shall only be used in an area of at least
pollution degree 2, as defined in IEC 60664-1. The end user is responsible to ensure that the operating temperature of the module is not exceeded in the end use application.
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 modification must be avoided.
D6038 series must be connected to SELV or PELV supplies.
All circuits connected to D6038 series must comply with the overvoltage category II (or better) according to EN/IEC60664-1.
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.

D6038 - SIL3 Line-Fault Transp. Switch/Prox. Repeater G.M. International ISM0431-2
6
Configuration
ON
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 of channel 2 is relevant only for D6038D*.
Line fault
detection
Dip switch factory settings.
Switches 1 and 3 are ON, switches 2 and 4 are OFF
1234
ON
ON OFF ON OFF
CH1 CH2
OFF
1
CH1
Enabled
(proximity sensor or switch with end of
line resistors, output opens in fault condition)
OFF
3
CH2
1
CH1
ON
3
CH2
ON
IN / OUT
operation Direct
function
OutputInput Output Input
open
or
closed RL RH
Reverse
function
OutputInputOutputInput
open
or
closed
RL RH
2
CH1
ON
4
CH2
ON
OFF
2
CH1
OFF
4
CH2
Disabled
(switch / proximity sensor)
For SIL application
For SIL application
For SIL application