Phoenix Contact PSR-PS40 User manual

1Description
SIL coupling relay
PSR-PS40
© PHOENIX CONTACT
Data sheet
Intended Use
The SIL coupling relay is used to adjust the power and for electrical
isolation in high- and low-demand applications. The coupling relay
safely interrupts circuits. The device performs a self test the
moment it is switched on and prevents the enable contacts from
being closed in the event of an error. The category 3 device is
designed for installation in zone 2 potentially explosive areas.
Possible signal generators
– Failsafe controllers
Contact type
– 1 undelayed enabling current path
– 1 digital signal output
–1Startcircuit
The enabling current path drops out without delay according
to stop category0 (EN60204-1).
Control
–Single-Channel
– Automatic start
Achievable safety integrity
– Suitable for high and low-demand applications up to
SIL3 according to IEC61508, IEC61511, and
IEC50156
Additional features
– Easy proof test:
-Self-monitoring, with device-internal locking
-Visually on the device
– Additional diagnostics and status information
-Error indication via M1
– Readback of field devices possible
– Integrated test pulse filter.
– Corrosion protection through lacquering the printed-
circuit board
– Fixed screw connection
–6.8mm housing width
Approvals
   
WARNING: Risk of electric shock
Observe the safety regulations and installation notes in the corresponding section.
Make sure you always use the latest documentation.
It can be downloaded from the product at phoenixcontact.net/products.
This document is valid for the products listed in the “Ordering data”.
This document meets the same requirements as the original operating instructions with respect to the
contents.
106254_en_03 2018-10-19
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2Tableofcontents
1 Description .............................................................................................................................. 1
2 Table of contents ..................................................................................................................... 2
3 Ordering data .......................................................................................................................... 3
4 Technical data ......................................................................................................................... 3
5 Notes regarding documentation .............................................................................................. 7
6 Safety regulations and installation notes.................................................................................. 8
7 Specific terms and conditions of use for ATEX/IECEx ........................................................... 10
8 UL notes ................................................................................................................................ 10
9 Function description .............................................................................................................. 11
10 Function and time diagrams .................................................................................................. 11
11 Basic circuit diagram ............................................................................................................. 12
12 Derating................................................................................................................................. 13
13 Load curve............................................................................................................................. 14
14 Operating and indication elements ........................................................................................ 15
15 Mounting and removing .........................................................................................................16
16 Wiring .................................................................................................................................... 16
17 Startup................................................................................................................................... 17
18 Calculating the power dissipation .......................................................................................... 17
19 Proof test ............................................................................................................................... 18
20 Diagnostics............................................................................................................................ 18
21 Application examples ............................................................................................................ 19
22 Attachment ............................................................................................................................ 21
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Description Ty p e Order No. Pcs./Pkt.
Coupling relay for SIL3 high- and low-demand
applications, couples digital output signals to the I/O, 1
enabling current path, 1 digital signal output, safe state off
applications, test pulse filter, fixed screw terminal block
PSR-PS40-1NO-1DO-24DC-
SC
2700398 1
3Orderingdata
4 Technical data
Hardware/firmware version
HW/FW ≥02/--
The technical data and safety characteristics are valid as of the specified HW/FW version.
Supply
Rated control circuit supply voltage US24 V DC -15 % / +10 % (A1/A2)
Rated control supply current IStyp. 50 mA (depending on load M1 +100mA)
Power consumption at UStyp. 1.2 W
Input voltage range "0" signal 0 V DC ... 5 V DC (for safe Off)
Input current range "0" signal 0 mA ... 2 mA (for safe Off)
Inrush current typ. 400 mA (Δt<10µs at Us)
Filter time max. 2 ms (at A1-A2; test pulse width)
≥100 ms (at A1-A2; test pulse rate)
Protective circuit Serial protection against polarity reversal 33 V suppressor
diode
Digital inputs: Start circuit
Number of inputs 2 (Non-safety-related start inputs: Y1/Y2)
Inrush current < 10 mA
Current consumption < 5 mA
Voltage at input/start and feedback circuit 24 V DC -15 % / +10 %
Max. permissible overall conductor resistance
(Input and reset circuit at US)
150 Ω
Relay outputs: Enabling current path
Number of outputs 1 (safety-related N/O contacts: 13/14)
Output description 2 N/O contacts in series, without delay, floating
Contact material AgSnO2
Switching voltage min. 12 V AC/DC
max. 250 V AC/DC (Observe the load curve)
Limiting continuous current 6 A (High demand)
4 A (Low demand)
Inrush current min. 3 mA
max. 6 A
Sq. Total current
ITH2 = I12+ I22 + ... + IN236 A2(observe derating)
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Switching capacity min. 60 mW
Switching frequency max. 0.5 Hz
Mechanical service life 10x 106cycles
Switching capacity according to IEC 60947-5-1 4 A (24 V (DC13))
5 A (250 V (AC15))
Output fuse 6 A gL/gG
4 A gL/gG (for low-demand applications)
Relay outputs: Enabling current path
Alarm outputs
Designation M1
Number of outputs 1 (non-safety-related)
Output description PNP
Voltage approx. 22 V DC (Us-2V)
Current max. 100 mA
Maximum inrush current 500 mA (Δt=1ms at Us)
Short-circuit protection no
Output fuse 150 mA fast blow
Times
Typical starting time with Us< 200 ms (when controlled via A1, automatic start)
Typical release time with Us< 35 ms (when controlled via A1)
Recovery time 500 ms
General data
Relay type Electromechanical relay with forcibly guided contacts in
accordance with IEC/EN61810-3 (EN50205)
Nominal operating mode 100% operating factor
Degree of protection IP20
Min. degree of protection of inst. location IP54
Mounting type DIN rail mounting
Mounting position vertical, horizontal, with front of module upward
Assembly instructions See derating curve
Dimensions (W/H/D) 6.8 x 93.1 x 102.5 mm
Type of housing PBT yellow
Operating voltage display 1 x yellow LED
Status display 2 x green LEDs
Indication 1 x red LED
Air clearances and creepage distances between the
power circuits
according to
DINEN50178, EN60079-15
Rated insulation voltage 250 V AC
Rated surge voltage/insulation
See “Insulation coordination”
Safe isolation, reinforced insulation 6kV from control circuit,
start circuit, signal output to the enabling current path; 4 kV /
basic insulation between all current paths and housing
Degree of pollution 2
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Overvoltage category III
Maximum power dissipation for nominal condition 3.25 W (IL²=36A²)
Note on power dissipation See “Calculating the power dissipation”
General data
Connection data
Connection method Screw connection
Conductor cross section, solid 0.2 mm² ... 2.5 mm²
Conductor cross section, flexible 0.2 mm² ... 2.5 mm²
Conductor cross section AWG/kcmil 26 ... 12
Stripping length 12 mm
Screw thread M3
Torque 0.5 Nm ... 0.6 Nm
Ambient conditions
Ambient temperature (operation) -40 °C ... 70 °C (observe derating)
Ambient temperature (storage/transport) -40 °C ... 85 °C
Max. permissible relative humidity (operation) 75 % (on average, 85% infrequently, non-condensing)
Max. permissible humidity (storage/transport) 75 % (on average, 85% infrequently, non-condensing)
Maximum altitude ≤2000 m (Above sea level)
Information on operating height See the “Using PSR devices at altitudes greater than
2000mabovesea level” section
Shock 15g
Vibration (operation) 10 Hz ...150 Hz, 2g
Conformance/Approvals
Conformance CE-compliant
The full EC Declaration of Conformity can be downloaded for the product at phoenixcontact.net/products.
Approvals    
IECEx ( IECEx ULD 14.0003X ) Ex nA nC IIC T4 Gc
ATEX ( DEMKO 14 ATEX 1284X ) II 3 G Ex nA nC IIC T4 Gc
UL, USA/Canada ( E140324 ) cULus
UL, USA/Canada ( E360692 ) Class I, Zone 2, AEx nA nC IIC T4 / Ex nA nC IIC Gc T4 X
Class I, Div. 2, Groups A, B, C, D, T4
Shipbuilding ( 11253-14 HH ) C, EMC2
Environmental simulation test ISA-S71.04 (G3)
Functional Safety in accordance with IEC 61508 to SIL 3
Safety data
Stop category according to IEC 60204 0
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Safety parameters for IEC 61508 - High demand
Equipment type Type A
HFT 1
SIL 3
PFHD1.04x10-9 (4ADC13; 5AAC15; 8760switching cycles/year)
Demand rate < 12 Months
Proof test interval 240 Months
Duration of use 240 Months
Alternative illustration as 1oo1 structure
Equipment type Type A
HFT 0
SIL 3
Safe Failure Fraction (SFF) 99.99 %
SD 989.32 FIT
SU 460.91 FIT
DD 51.90 FIT
DU 0.10 FIT
Total 1502.24 FIT
MTBF 64.01 Years
PFHD1.04x10-9
Safety parameters for IEC 61508 - Low demand
Equipment type Type A
HFT 1
SIL 3
PFDavg 1.23 x 10-4
Proof test interval 72 Months
Duration of use 240 Months
Alternative illustration as 1oo1 structure
Equipment type Type A
HFT 0
SIL 3
Safe Failure Fraction (SFF) 99.72 %
SD 0 FIT
SU 1891 FIT
DD 0 FIT
DU 5.236 FIT
Total 1896 FIT
MTBF 52 Years
PFDavg 2.29 x 10-5 (For T1 = 1 year)
Safety parameters forEN50156
SIL 3
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5 Notes regarding documentation
5.1 Explanation of symbols used and signal words
5.2 Validity
This data sheet is valid for the described product(s) from the
hardware/firmware version specified in the technical data.
5.3 Target group
This data sheet is therefore aimed at:
– Qualified personnel who plan and design safety
equipment for machines and systems and are familiar
with regulations governing occupational safety and
accident prevention.
– Qualified personnel who install and operate safety
equipment in machines and systems.
Qualified personnel:
Qualified personnel are people who, because of their
education, experience, and instruction and their knowledge
of relevant standards, regulations, accident prevention, and
service conditions, have been authorized by those
responsible for the safety of the system to carry out any
required operations and who are able to recognize and
avoid any possible dangers.
Requirements:
Knowledge of the following topics is required:
– Handling safety components
– Valid EMC regulations
– Valid regulations governing occupational safety and
accident prevention
This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety
measures that follow this symbol to avoid possible injury or death.
There are three different categories of personal injury that are indicated with a signal word.
DANGER This indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING This indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.
This symbol together with the signal word NOTE and the accompanying text alert the reader to a situation which
may cause damage or malfunction to the device, hardware/software, or surrounding property.
This symbol and the accompanying text provide the reader with additional information or refer to detailed
sources of information.
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6 Safety regulations and installation notes
General
•Observe the safety regulations of electrical engineering
and industrial safety and liability associations.
Disregarding these safety regulations may result in death,
serious personal injury or damage to equipment.
•When handling the device, observe the necessary
safety precautions against electrostatic discharge
(ESD) according to EN 61340-5-1 and IEC 61340-5-1.
Direct/indirect contact
•Protection against direct and indirect contact according
to VDE0100Part410 must be ensured for all
components connected to the system.
In the event of an error, parasitic voltages must not occur
(single-fault tolerance).
Power supply units for 24 V supply
•Only use power supply units with safe isolation
andSELV/PELVaccording to EN 50178/VDE0160.
•Protect the 24V area with a suitable external fuse.
•Make sure that the power supply unit is able to supply
four times the nominal current of the external fuse, to
ensure that it trips in the event of an error.
•Make sure that the output voltage of the voltage supply
does not exceed 32V even in the event of error.
Startup, mounting, and modifications
Startup, mounting, modifications, and upgrades may only be
carried out by an electrically skilled person.
•Before working on the device, disconnect the power.
•Carry out wiring according to the application. Refer to
the “Application examples” section for this.
Reliable operation is only ensured if the device is installed in
housing protected from dust and humidity.
•Install the device in housing protected from dust and
humidity (min.IP54).
In operation
During operation, parts of electrical switching devices carry
hazardous voltages.
•Protective covers must not be removed when operating
electrical switching devices.
For emergency stop applications, automatic startup of the
machine can pose serious risks for the user.
•The machine must be prevented from restarting
automatically by a higher-level controller.
Inductive loads can lead to welded relay contacts.
•Connect a suitable and effective protective circuit to
inductive loads.
•Implement the protective circuit parallel to the load and
not parallel to the switch contact.
Magnetic fields can influence the device. The magnetic field
strength of the environment must not exceed 30A/m.
•Do not use the device in the vicinity of strong magnetic
fields (e.g.,caused by transformers or magnetic iron).
Noise emission may occur when operating relay modules.
Wireless reception may be disrupted in residential areas.
The device is a Class A product.
•Observe the requirements for noise emission for
electrical and electronic equipment (EN61000-6-4).
•Implement appropriate precautions against noise
emission.
WARNING: Death, serious personal injury or damage to equipment
Depending on the application, incorrect handling of the device may pose serious risks for the user or cause
damage to equipment.
•Observe all the safety notes and warning instructions provided in this chapter and elsewhere in this
document.
The device contains components that can be
damaged or destroyed by electrostatic
discharge.
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Faulty devices
The devices may be damaged following an error. Correct
operation can no longer be ensured.
•In the event of an error, replace the device.
Only the manufacturer or their authorized representative
may perform the following activities. Otherwise the warranty
is invalidated.
– Repairs to the device
– Opening the housing
Taking out of service and disposal
•Dispose of the device in accordance with environmental
regulations.
•Make sure that the device can never be reused.
6.1 Safety of machines or systems
Draw up and implement a safety concept
The machine or system manufacturer and the operator are
responsible for the safety of the machine or system and the
application in which the machine or system is used. In order
to use the device described in this document, you must have
drawn up an appropriate safety concept for your machine or
system. This includes a risk assessment in accordance with
the directives and standards specified in the EC Declaration
of Conformity,as well as other standards.
Risk assessment, validation and function test
•Before using the device, perform a risk assessment on
the machine or system.
•Validate your entire safety system.
•Carry out a new validation every time you make a
safety-related modification.
•Perform a function test on a regular basis.
Achievable safety integrity
Functional safety is guaranteed for the device as a single
component. However, this does not guarantee functional
safety for the entire machine or system. In order to achieve
the desired safety level for the entire machine or system,
define the safety requirements for the machine or system as
well as how to implement them from both a technological
and organizational perspective.
The EC Declaration of Conformity can be
downloaded for the product at
phoenixcontact.net/products.
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6.2 Installation in potentially explosive area
– The category 3 device is designed for installation in
zone2 potentially explosive areas. It satisfies the
requirements of the following standards.
Comprehensive details are to be found in the EU
Declaration of Conformity which is enclosed and also
available on our website in the latest version:
EN60079-0 and EN60079-15
– When installing and connecting the supply and signal
circuits observe the requirements of EN/IEC60079-14.
– Only devices that are suitable for operation in
Exzone2/Div.2 and for the conditions prevalent at the
installation location may be connected to the circuits in
Zone2/Div.2.
– Do not connect any cables/lines within the potentially
explosive area and do not disconnect any connections
if they are live.
– The device must be stopped and immediately removed
from the Ex area if it is damaged, was subject to an
impermissible load, stored incorrectly or if it
malfunctions.
6.3 Ambient temperature in potentially explosive
area
•Observe the derating curves.
•Observe the special temperature conditions according
to the rating plate.
Figure 1 Rating plate (laser printing)
6.4 Installation in areas with a danger of dust
explosions
7 Specific terms and conditions of
use for ATEX/IECEx
– The device shall be connected to supply circuits where
the rated voltage cannot be exceeded by 140% caused
by transient disturbances.
– The device is to be installed in a housing (control or
distributor box) that satisfies the requirements of
EN/IEC60079-15 and has at least IP54 degree of
protection (EN/IEC60529).
– The device is to be used in an environment that does
not exceed pollution degree2 in accordance with
EN/IEC60664-1.
8ULnotes
8.1 UL Ordinary Location
– Only use copper connecting cables providing the
permitted temperature range (60°C/75°C).
– Tighten the screws on the screw terminal blocks with
5...7lb in (0.5...0.6Nm).
8.2 UL Hazardous Location
– This device must be installed in an area that is no longer
classified as pollution degree2 in accordance with
IEC60664-1.
– WARNING - Do not disconnect the terminal blocks
when energized!
– The device must be installed in a housing that is
certified for use in ClassI, Zone2, GroupIIC and IP54
in accordance with IEC60529 if it is used in the
environments of ClassI, Zone2.
– A surge protection device must be provided outside of
the device that is set to a level that does not exceed
140% of the nominal voltage at the power supply
connections of the device.
WARNING: Explosion hazard when used
in potentially explosive areas
Please make sure that the following notes and
instructions are observed.
WARNING: Explosion hazard
The device is not designed for use in
atmospheres with a danger of dust
explosions.
Output 250 , 24 6AV AC V DC
Resistive
B300, R300
24 100mAV DC
Surrounding Air
Temperature - °C to °C40 54
250 , 24 2.4AV AC V DC
Resistive
B300, R300
- °C to °C40 60
Input 24 V DC, mAA1/A2 50
13/14
NO-contact
M1
DO-contact
Resistive
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9 Function description
9.1 Single-channel control
The external enable signal of the failsafe controller is
switched at A1.
9.2 Automatic start
If the start circuit is closed, the device starts automatically
once it has received the external enable signal of the failsafe
controller.
The start circuit is monitored and can be used for readback
of field devices.
9.3 Safe shutdown
After deactivating the external enable signal of the failsafe
controller, the enabling current path opens and the contacts
enter the safe state.
When the enabling current path is open, the device is in the
safe state.
9.4 Diagnostics and status information
The device provides the following non-safety-relevant
diagnostic capabilities and status information.
9.4.1 Error indication via M1
Signal output M1 is active in the event of an error.
Error indication via signal output M1 is non-safety-related.
9.5 Proof-Test
The repeat testing required by standards can be carried out
on the device visually using the diagnostics LEDs.
The device performs a self test the moment it is switched on
and prevents the enable contacts from being closed in the
event of an error.
9.6 Test pulse filter
By filtering the control controller test pulses, premature
failure of the forcibly guided safety relay is prevented.
10 Function and time diagrams
10.1 Time diagram for automatic start
Figure 2 Time diagram for automatic start
Key:
See section "Start and feedback circuit
connection versions".
You can find information on executing and
evaluating the proof test under the special
sections “Proof test” and “Diagnostics”.
A1/A2 Control
Y1/Y2 Start circuit
13/14 Enabling current path, undelayed
M1 Digital alarm output
tM1 Approx. 3 s
K1
K2
Y1
(+) Y2
( )
PSR-PS40
A1
Y1/Y2
13/14
M1
1
Y1
(+) Y2 ( )
PSR-PS40
2A1
Y1/Y2
13/14
M1
Y1
(+) Y2 ( )
PSR-PS40
3A1
Y1/Y2
13/14
M1
tM1
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11 Basic circuit diagram
Figure 3 Block diagram
Key:
11.1 Insulation coordination
Key:
A1 24VDC control
A2 0 V (GND)
M1 Signal output (PNP)
Y1 +24V start circuit output
Y2 +24V start circuit input
13/14 Enabling current path, undelayed
K1/K2 Channel 1/Channel 2
M1
Y1
Y2
13
14
A1
A2
PWR
24V DC
PSR-PS40ERR
DGN
K1/2
K1
K2
A1/A2,
Y1/Y2, M1
13/14 Housing
A1/A2,
Y1/Y2, M1
-6kV ST 4kV BI
13/14 --4kV BI
Housing ---
BI Basic insulation
ST Safe isolation
Basic insulation
(rated surge voltage of 4kV)
A mixture of SELV and PELV is strictly
prohibited. Only switch 250VAC at one of the
enable contacts if the adjacent contact/
enabling current path carries the same
potential.
Safe isolation/reinforced insulation
(rated surge voltage of 6kV)
Reinforced insulation (e.g.,thanks to greater
air clearances and creepage distances
between conductive paths) is designed for
one overvoltage category higher than basic
insulation. This means that SELV circuits of
U25VAC or U60VDC and circuits with
higher voltages can be mixed.
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12 Derating
12.1 Vertical mounting position
The derating curve applies for the following conditions:
– Mounting on a vertical DIN rail
– Devices mounted next to each other without spacing
– For enabling current path 13/14
Figure 4 Derating curve - vertical mounting position,
without spacing
Expanded ambient temperature range (with no distance):
up to +70°C
Conditions:
12.2 Horizontal mounting position
The derating curve applies for the following conditions:
– Mounting on a horizontal DIN rail
– Devices mounted next to each other without spacing
– For enabling current path 13/14
Figure 5 Derating curve - horizontal mounting position,
without spacing
Expanded ambient temperature range (with no distance):
up to +70°C
Conditions:
The temperature is measured at a 5cm
clearance below or to the side of the device.
Note section "Mounting positions".
Max. rated control circuit supply voltage 24VDC
Max. total current of the enabling current path 1A2
10 20 30 40 50 60 70
20
30
40
0
T [°C]
A
I[A]
TH
²
2
36
12
4
55 65
25
10
Max. rated control circuit supply voltage 24VDC
Max. total current of the enabling current path 250mA2
10 20 30 40 50 60 70
10
20
30
40
0
T [°C]
A
I[A]
TH
²²
1
36
16
6
55 65
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12.3 Mounting position with device front facing
upwards
The derating curve applies for the following conditions:
– Mounting on a lying DIN rail with the device front facing
upwards
– Devices mounted next to each other without spacing
– For enabling current path 13/14
Figure 6 Derating curve - mounting position with module
front at the top and aligned modules
Expanded ambient temperature range (with no distance):
up to +70°C
Conditions:
13 Load curve
13.1 Ohmic and inductive load
Figure 7 Relay load curve - ohmic and inductive load
Key:
Max. rated control circuit supply voltage 24VDC
Max. total current of the enabling current path 250mA2
1020 30 4050 60 70
20
30
40
0
2
36
12
2
55 65
25
10
T[°C]
A
I[A]
TH
²
2
Ohmic load L/R=0ms
Inductive load L/R=40ms
I [A]
DC
U[V]
DC
10
0,1
20
50
100
200
500
1000
0,2 0,5 1 2 5 10


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PSR-PS40
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14 Operating and indication elements
14.1 Connection versions
Figure 8 Connection versions





1Fixed screw connection
2Snap-on foot for DIN rail mounting











14.2 Connection assignment

14
2
APPROVALS
HW/FW: 00/--
Serial No. xxxxxxxxxx
Warning - Do not seperate
when energized!
PWR
1
0,5-0,6 Nm
5-7 lb In
12 mm
AWG 26-12
0,2-2,5 mm
2
The year the device was constructed can be
found underneath the CE designation on the
housing.
Y1 +24V start circuit output
Y2 +24V start circuit input
A2 0 V (GND)
A1 24VDC control





PWR Power LED (yellow)

K1/2 Status indicator safety circuit; LED (green)
ERR Error LED (red)
DGN Diagnostics LED (green)




13/14 Enabling current path, undelayed
M1 Signal output (PNP)
Y
Y
A
A
1
2
2
1
1
1
M
3
4
1
PS40
PWR
K
ERR
DGN
12
/
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PSR-PS40
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15 Mounting and removing
•Mount the device on a 35 mm DIN rail according to
EN60715.
•To remove the device, use a screwdriver to release the
snap-on foot.
Figure 9 Mounting and removing
15.1 Mounting positions
The following mounting positions are permissible:
Figure 10 Permissible mounting positions
1Vertical mounting position
2Horizontal mounting position
3Mounting position with device front facing upwards
16 Wiring
•Connect the cables to the connection terminal blocks
using a screwdriver.
Figure 11 Connection of the cables
16.1 Signal generator connection versions
•Connect suitable signal generators to A1/A2.
Figure 12 Signal generator connection versions
1Single-channel control via failsafe controller
Note the derating curves for various mounting
positions.
See section "Derating".
123
It is recommended that ferrules are used to
connect stranded cables.
For compliance with UL approval, use copper
wire that is approvedupto 60°C/75°C.
A
B
0,5-0,6Nm
5-7lb In
12mm
AWG 26-12
0,2-2,5mm2
A1
A2
1
24V
GND DIDO
SIS / FS-PLC
0V
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PSR-PS40
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16.2 Start circuit connection versions
•Bridge contacts Y1/Y2.
•Integrate the relevant N/C contacts into the Y1/Y2 start
circuit to monitor external contactors or extension
devices with force-guided contacts.
Figure 13 Start circuit connection versions
1Start circuit without monitored contact extension
2Start circuit with monitored contact extension
17 Startup
•Provide the external enable signal of the failsafe
controller (24VDC) at terminal blocks A1/A2.
•Close the Y1/Y2 start circuit.
PWR LED lights up.
K1/2 LED lights up.
DGN LED lights up.
Enabling current path 13/14 closes.
Signal output M1 is not active.
18 Calculating the power dissipation
Input power dissipation
PInput=UB²/(US/IS)
Contact power dissipation
With the same load currents:
PContact=nIL²50mΩ
With different load currents:
PContact=(IL1²+IL2²+...+ILn²)50mΩ
Total power dissipation
PTotal=PInput+PContact
therefore
PTotal=UB²/(US/IS)+nIL²50mΩ
or
PTotal=UB²/(US/IS)+(IL1²+IL2²+...+ILn²)50mΩ
Key:
12
Y2
( )
Y1
( )
+
K1
K2
Y2
( )
Y1
( )
+
The total power dissipation of the safety relay
is based on the input power dissipation and
the contact power dissipation for the same
and for different load currents.
PPower dissipation in mW
UBApplied operating voltage
USRated control circuit supply voltage
ISRated control supply current
nNumber of enabling current paths used
ILContact load current
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PSR-PS40
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19 Proof test
To verify the device function, proceed as follows.
19.1 Visually on the device via the diagnostics LEDs
1. Deactivate A1.
2. Ensure that the Y1/Y2 start circuit is closed.
3. Activate A1/A2.
Expectation (proof test passed):
– The yellow PWR LED, the green K1/2 LED, and the
green DGN LED light up.
– The enabling current path is closed.
Potential errors:
– The yellow PWR LED and the red ERR LED light up.
– The module-internal locking prevents the enable
contacts from being closed.
20 Diagnostics
20.1 Diagnostics via LEDs
*) The signaling output M1 is not safety-relevant and therefore not suitable for the proof test.
WARNING: Loss of functional safety due
to malfunction.
If the proof test contains errors, the device no
longer functions correctly.
•Replace the device.
Observe a potential error response time of 4s
for the diagnostics LEDs.
Overview of display options: See “Diagnostics
via LEDs” section.
PWR-
LED
K1/K2-
LED
ERR-
LED
DGN-
LED
M1 *) State Proof test
OFFOFFOFFOFF0V A1isnot activated. Diagnostics are not supported in a
de-activated state.
Yellow
on
Green
on
OFF Green
on
0 V A1 is activated. The Y1/Y2 start circuit
is closed.
Proof test passed.
Yellow
on
OFF Red on OFF 24 V A1 is activated. The Y1/Y2 start circuit
is closed.
Proof test not passed.
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PSR-PS40
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21 Application examples
21.1 High-demand application with failsafe controller
Application description:
The application example illustrates the safe disconnection
of a load in high-demand mode. The safe coupling relay is
controlled via a single channel using a failsafe controller.
The start circuit of the device is used for monitoring external,
force-guided contactors.
If the start circuit is closed, the device starts automatically
once it has received the external enable signal of the failsafe
controller.
Assumptions, information, and marginal conditions:
– It is assumed that errors in the cable installation have
been eliminated
– Error message about the diagnostic LEDs
– Monitoring of the N/C contacts K1, K2 in the start circuit
– The digital output (DO) of the failsafe controller meets
SIL3 requirements according to IEC61508.
Achievable safety integrity:
– Suitable for high-demand mode applications up to SIL3
in accordance with IEC61508, and IEC50156
Figure 14 High-demand application with failsafe
controller
Key:
Cross-circuits in the cable installation can be
excluded if the failsafe PLC, safety relay, and
external contactors K1 and K2 are located in
the same electrical installation space.
K2
K1
M
N
K2
K1
24 V DC
0 V
SIS / FS-PLC
L
DO
24V
GND DIDO0V
Logic
I/O
K1
K2
13A1
A2
PSR-PS40
14 M1
( )
Y2
( )
Y1
( )
+
SIS /
FS-PLC
Safety Instrumented System /
failsafe controller
DC Diagnostic Coverage according to IEC61508
(line/load diagnostics at DO)
DI Digital input
DO Digital output
Device data in the application example as
1oo1 structure
Error message about the diagnostic LEDs
Device type Type A
HFT 0
SIL 3
SFF 99,99%
SD 989.32 FIT
SU 460.91 FIT
DD 51.90 FIT
DU 0.10 FIT
Total 1502.24 FIT
MTBF 64.01 years
PFHD1.04x10-9
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PSR-PS40
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21.2 Low-demand application with failsafe controller
Application description:
The application example illustrates the safe disconnection
of a load in low demand mode. The safe coupling relay is
controlled via a single channel using a failsafe controller.
The start circuit of the device is used for monitoring external,
force-guided contactors.
If the start circuit is closed, the device starts automatically
once it has received the external enable signal of the failsafe
controller.
Assumptions, information, and marginal conditions:
– It is assumed that errors in the cable installation have
been eliminated
– Error message about the diagnostic LEDs
– The digital output (DO) of the failsafe controller meets
SIL3 requirements according to IEC61508.
Achievable safety integrity:
– Suitable for low-demand applications up to SIL3
according to IEC61508, IEC61511, and EN50156
Figure 15 Low-demand application with failsafe
controller
Key:
Cross-circuits in the cable installation can be
excluded if the failsafe PLC, safety relay, and
external contactors K1 and K2 are located in
the same electrical installation space.
K2
K1
M
N
K2
K1
24 V DC
0 V
SIS / FS-PLC
L
DO
24V
GND DIDO0V
Logic
I/O
K1
K2
13A1
A2
PSR-PS40
14 M1
( )
Y2
( )
Y1
( )
+
SIS /
FS-PLC
Safety Instrumented System /
failsafe controller
DC Diagnostic Coverage according to IEC61508
(line/load diagnostics at DO)
DI Digital input
DO Digital output
Device data in the application example as
1oo1 structure
Error message about the diagnostic LEDs
Device type Type A
HFT 0
SIL 3
SFF 99.72%
SD 0 FIT
SU 1891 FIT
DD 0 FIT
DU 5.236 FIT
Total 1896 FIT
MTBF 52 years
PFDavg 2.29x10-05 (for T1=1year)
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