PR electronics 9202 Series User manual

9202
Pulse isolator
No. 9202V105-UK
Product version: 9202-003

1641
PR electronics A/S tilbyder et bredt program af analoge og digitale
signalbehandlingsmoduler til industriel automation. Programmet
består af Isolatorer, Displays, Ex-barrierer, Temperaturtransmittere,
Universaltransmittere mfl. Vi har modulerne, du kan stole på i selv
barske miljøer med elektrisk støj, vibrationer og temperaturudsving,
og alle produkter opfylder de strengeste internationale standarder.
Vores motto »Signals the Best« er indbegrebet af denne filosofi – og
din garanti for kvalitet.
PR electronics A/S oers a wide range of analog and digital
signal conditioning devices for industrial automation. The product
range includes Isolators, Displays, I.S. Interfaces, Temperature
Transmitters, and Universal Devices. You can trust our products in
the most extreme environments with electrical noise, vibrations and
temperature fluctuations, and all products comply with the most
exacting international standards. »Signals the Best« is the epitome
of our philosophy – and your guarantee for quality.
PR electronics A/S ore une large gamme de produits pour le
traitement des signaux analogiques et numériques dans tous
les domaines industriels. La gamme de produits s’étend des
transmetteurs de température aux acheurs, des isolateurs aux
interfaces SI, jusqu’aux modules universels. Vous pouvez compter
sur nos produits même dans les conditions d’utilisation sévères,
p.ex. bruit électrique, vibrations et fluctuations de température.
Tous nos produits sont conformes aux normes internationales les
plus strictes. Notre devise »SIGNALS the BEST« c’est notre ligne
de conduite - et pour vous l’assurance de la meilleure qualité.
PR electronics A/S verfügt über ein breites Produktprogramm
an analogen und digitalen Signalverarbeitungsgeräte für die in-
dustrielle Automatisierung. Dieses Programm umfasst Displays,
Temperaturtransmitter, Ex- und galvanische Signaltrenner, und
Universalgeräte. Sie können unsere Geräte auch unter extremen
Einsatzbedingungen wie elektrisches Rauschen, Erschütterungen
und Temperaturschwingungen vertrauen, und alle Produkte von
PR electronics werden in Übereinstimmung mit den strengsten
internationalen Normen produziert. »Signals the Best« ist Ihre
Garantie für Qualität!
DK
UK
FR
DE

9202 - Product Version 9202-003 1
PULSE ISOLATOR
9202
CONTENTS
Warning....................................................................................................... 2
Symbol identification............................................................................ 2
Safety instructions................................................................................. 2
How to dismantle system 9000....................................................... 4
Advanced features................................................................................. 5
Application................................................................................................. 5
Technical characteristics...................................................................... 5
Applications............................................................................................... 6
PR 4501 Display / programming front........................................... 7
Mounting / demounting the PR 4501/4511............................... 8
Order: 9202B............................................................................................ 9
Accessories ............................................................................................... 9
Electrical specifications........................................................................ 9
Configuration of cable fault check .................................................. 11
Function description.............................................................................. 12
Connections .............................................................................................. 13
Block diagram........................................................................................... 14
Signal error and cable fault indications
without display front......................................................................... 15
Configuration / operating the function keys............................... 16
Scrolling help texts in display line 3............................................... 18
Routing diagram...................................................................................... 19
Routing diagram, Advanced settings (ADV.SET)........................ 20
Appendix.................................................................................................... 21
IECEx Installation Drawing.............................................................. 22
ATEX Installation Drawing............................................................... 24
FM Installation Drawing ................................................................... 26
INMETRO Installation Drawing ...................................................... 28
Safety Manual....................................................................................... 30

2 9202 - Product Version 9202-003
SYMBOL IDENTIFICATION
Triangle with an exclamation mark: Read the manual before installation
and commissioning of the module in order to avoid incidents that could
lead to personal injury or mechanical damage.
The CE mark proves the compliance of the module with the essential
requirements of the directives.
The double insulation symbol shows that the module is protected by
double or reinforced insulation.
Ex modules have been approved according to the ATEX directive for use in
connection with installations in explosive areas.
SAFETY INSTRUCTIONS
DEFINITIONS
Hazardous voltages have been defined as the ranges: 75...1500 Volt DC, and
50...1000 Volt AC.
Technicians are qualified persons educated or trained to mount, operate, and also
troubleshoot technically correct and in accordance with safety regulations.
Operators, being familiar with the contents of this manual, adjust and operate
the knobs or potentiometers during normal operation.
WARNING
The following operations should only be carried out on a discon-
nected module and under ESD-safe conditions:
General mounting, connection and disconnection of wires.
Troubleshooting the module.
Repair of the module and replacement of circuit breakers
must be done by PR electronics A/S only.
WARNING
Do not open the front plate of the module as this will cause
damage to the connector for the display / programming front PR
4501. This module contains no DIP-switches or jumpers.

9202 - Product Version 9202-003 3
RECEIPT AND UNPACKING
Unpack the module without damaging it. The packing should always follow the
module until this has been permanently mounted.
Check at the receipt of the module whether the type corresponds to the one
ordered.
ENVIRONMENT
Avoid direct sunlight, dust, high temperatures, mechanical vibrations and shock,
as well as rain and heavy moisture. If necessary, heating in excess of the stated
limits for ambient temperatures should be avoided by way of ventilation.
The module must be installed in pollution degree 2 or better.
The module is designed to be safe at least under an altitude up to 2 000 m.
MOUNTING
Only technicians who are familiar with the technical terms, warnings, and instruc-
tions in the manual and who are able to follow these should connect the module.
Should there be any doubt as to the correct handling of the module, please
contact your local distributor or, alternatively,
PR electronics A/S
www.prelectronics.com.
The use of stranded wires is not permitted for mains wiring except when wires
are fitted with cable ends.
Descriptions of input / output and supply connections are shown in the block
diagram and on the side label.
The module is provided with field wiring terminals and shall be supplied from a
Power Supply having double / reinforced insulation. A power switch should be
easily accessible and close to the module. The power switch should be marked
with a label telling that it will switch off the voltage to the module.
For installation on Power Rail 9400 the power is supplied by the Power Control
Unit 9410.
Year of manufacture can be taken from the first two digits in the serial number.
CALIBRATION AND ADJUSTMENT
During calibration and adjustment, the measuring and connection of external
voltages must be carried out according to the specifications of this manual. The
technician must use tools and instruments that are safe to use.

4 9202 - Product Version 9202-003
NORMAL OPERATION
Operators are only allowed to adjust and operate modules that are safely fixed in
panels, etc., thus avoiding the danger of personal injury and damage. This means
there is no electrical shock hazard, and the module is easily accessible.
CLEANING
When disconnected, the module may be cleaned with a cloth moistened with
distilled water.
LIABILITY
To the extent that the instructions in this manual are not strictly observed,
the customer cannot advance a demand against PR electronics A/S that would
otherwise exist according to the concluded sales agreement.
HOW TO DISMANTLE SYSTEM 9000
Picture 1:
By lifting the bottom lock, the module
is detached from the power rail.

9202 - Product Version 9202-003 5
PULSE ISOLATOR
9202
• Interface for NAMUR sensors and switches
• Extended self-diagnostics and detection of cable fault
• 1 or 2 channels
• Can be supplied separately or installed on power
rail, PR type 9400
• SIL 2-certified via Full Assessment
Advanced features
• Configurationandmonitoringbywayofdetachabledisplayfront(PR4501).
• SelectionofdirectorinvertedfunctionforeachchannelviaPR4501.
• Advancedmonitoringofinternalcommunicationandstoreddata.
• Optionalredundantsupplyviapowerrailand/orseparatesupply.
• SIL2functionalityisoptionalandmustbeactivatedinamenupoint.
Application
• Themodulecanbemountedinthesafeareaandinzone2/cl.1div.2andreceive
signals from zone 0, 1, 2 and zone 20, 21, 22 including M1 / Class I/II/III, Div. 1, Gr. A-G.
• PulseisolatorfortransmissionofsignalstothesafeareafromNAMURsensors
and mechanical switches installed in the hazardous area.
• Monitoringoferroreventsandcablebreakageviatheindividualstatusrelay
and/or a collective electronic signal via the power rail.
• The9202hasbeendesigned,developedandcertifiedforuseinSIL2
applications according to the requirements of IEC 61508.
Technical characteristics
• 1greenand2yellow/redfrontLEDsindicateoperationstatusandmalfunction.
• 2.6kVACgalvanicisolationbetweeninput,outputandsupply.

NAMUR
Opto +
14
13
12
11
Opto -
Opto -
Opto +
44
43
42
41
NAMUR
31
32
33
34
54
53
52
51
Rp
Rs
Rp
Rp
Rs
Rp
-
+
-
+
6 9202 - Product Version 9202-003
APPLICATIONS
Zone 0, 1, 2,
20, 21, 22, M1 &
Cl. I/II/III, div. 1
gr. A-G Zone 2 / Cl. 1, div. 2, gr. A-D or safe area
Input signals:
Mechanical
switch
Channel 1:
Output signals:
Channel 2:
Mechanical
switch
Relay
Relay
Relay
Channel 1:
N.O. or
N.C.
Relay
Channel 2:
N.O. or
N.C.
Power connection:
Rail, +24 VDC
Rail, Gnd.
Status relay signal
Module status
Module status
Gnd. -
Supply +19.2...31.2 VDC
Supply via
power rail
N.C.
Ch. 2:
Ch. 1:
Power rail

9202 - Product Version 9202-003 7
PR 4501 DISPLAY / PROGRAMMING FRONT
Functionality
The simple and easily understandable menu structure
and the explanatory help texts guide you effortlessly and
automatically through the configuration steps, thus making
the product very easy to use. Functions and configuration
options are described in the section ”Configuration /
operating the function keys”.
Application
• Communicationsinterfaceformodificationofoperationalparametersin9202.
• Whenmountedintheprocess,thedisplayshowsprocessvaluesandmodule
status.
Technical characteristics
• LCDdisplaywith4lines;Line1(H=5.57mm)showsstatusforeachchannel
(OKorerror).Line2(H=3.33mm)showsoutputforchannel1(ON/OFF),line3
(H=3.33mm)showsoutputforchannel2(ON/OFF),andline4showswhether
themoduleisSIL-locked.Staticdot=SIL-lockedandflashingdot=notSIL-
locked. Line 4 also indicates status for relay 1 and relay 2.
•Inordertoprotecttheconfigurationagainstunauthorisedchanges,accessto
the menus can be blocked by a password.

OK
4501


1
3

4
2
3
8 9202 - Product Version 9202-003
MOUNTING / DEMOUNTING THE PR 4501/4511
1: Insert the taps of 4501/4511 into the holes at the top of the device.
2: Swing 4501/4511 into place.
Demounting of 4501/4511
3: Push the release button on the bottom of 4501/4511 and swing 4501/4511
up.

9202 - Product Version 9202-003 9
Accessories
Electrical specifications
Environmental conditions
Specifications range............................................... -20...+60°C
Storage temperature .............................................. -20...+85°C
Calibration temperature ........................................ 20...28°C
Relative humidity..................................................... < 95% RH (non-cond.)
Protection degree.................................................... IP20
Installation in............................................................. Pollution degree 2 & measurement /
overvoltage category II
Mechanical specifications:
Dimensions (HxWxD).............................................. 109 x 23.5 x 104 mm
Dimensions (HxWxD) w/ 4501 / 4511........... 109 x 23.5 x 116 / 131 mm
Weight approx........................................................... 170 g
Weight incl. 4501 / 4511 (approx.).................. 185 g / 270 g
DIN rail type............................................................... DIN EN 60715 / 35 mm
Wire size...................................................................... 0.13...2.08 mm2AWG 26...14
stranded wire
Screw terminal torque........................................... 0.5 Nm
Vibration...................................................................... IEC 60068-2-6 : 2007
Vibration: 2...13.2 Hz.............................................. ±1 mm
Vibration: 13.2...100 Hz........................................ ±0.7 g
Order: 9202B
Type Switch Channels
9202B Opto........ : 1
Relay N.O. .. : 2
Relay N.C.... : 3
Single ....: A
Double ...: B
Type Description
4501
4511
9400
9404
9410
9420
Display / programming front
Communication enabler
Power rail
Module stop for rail
Power control unit
Power supply 24 V / 120 W - Ex nAC

10 9202 - Product Version 9202-003
Common specifications:
Supply voltage, DC.................................................. 19.2...31.2 VDC
Max. consumption.................................................... ≤3 W (2 channels)
Fuse............................................................................... 400 mA SB / 250 VAC
Isolation voltages, test / operation:
Inputs / outputs / supply............................ 2.6 kVAC / 300 VAC reinforced
Output 1 to output 2.................................... 1.5 kVAC / 150 VAC reinforced
Status relay to supply .................................. 1.5 kVAC / 150 VAC reinforced
Communications interface ................................... Communication enabler 4511 /
Programming front 4501
Response time for cable fault............................ < 200 ms
Calibration temperature ........................................ 20...28°C
Auxiliary supplies:
NAMUR supply.......................................................... 8 VDC / 8 mA
Inputs:
Sensor types:
NAMUR according to..................................... EN 60947-5-6
Mechanical switch with
series (Rs) and parallel (Rp) resistance:
Rs.......................................................................... Nom. 750 Ω
Rp.......................................................................... Nom. 15 kΩ
Frequency range...................................................... 0...5 kHz
Min. pulse length ..................................................... > 0.1 ms
Input resistance........................................................ Nom. 1 kΩ
Trig level, signal ....................................................... < 1.2 mA, > 2.1 mA
Trig level, cable fault.............................................. < 0.1 mA, > 6.5 mA
Outputs:
Relay outputs:
Status relay:
Max. voltage..................................................... 125 VAC / 110 VDC
Max. current...................................................... 0.5 A AC / 0.3 A DC
Max. power........................................................ 62.5 VA / 32 W
Relay outputs:
Max. switch frequency................................. 20 Hz
Max. voltage..................................................... 250 VAC / 30 VDC
Max. current...................................................... 2 A AC / 2 A DC
Max.power......................................................... 500 VA / 60 W
Opto, NPN outputs:
Max. switch frequency................................. 5 kHz
Min. pulse length............................................ > 0,1 ms
Max. load, current / voltage....................... 80 mA / 30 VDC
Voltage drop at 80 mA................................. < 2.5 VDC

9202 - Product Version 9202-003 11
Approvals:
EMC 2004/108/EC .................................................. EN 61326-1
LVD 2006/95/EC...................................................... EN 61010-1
UL, Standard for Safety......................................... UL 61010-1
EAC TR-CU 020/2011............................................ EN 61326-1
Marine:
Det Norske Veritas, Ships & Offshore ............. Stand. f. Certific. No. 2.4
I.S. / Ex:
ATEX 94/9/EC............................................................ KEMA 07ATEX0146 X
IECEx............................................................................. IECEx KEM 06.0039 X
c FM us......................................................................... 3034430-C
INMETRO ..................................................................... NCC 12.1307 X
CCOE.............................................................................. P337349/5
EAC Ex TR-CU 012/2011 ..................................... RU C-DK.GB08.V.00410
Functional Safety:
SIL2 Certified & Fully Assessed acc. to IEC 61508
Configuration of cable fault check
Diagnostics
Cable fault detection
Cable fault detection (CA.BR, CA.SH):
Input Event Readout Limit
All Cable break CA.BR < 0.1 mA
All Short-circuited cable CA.SH > 6.5 mA
Cable fault check, independent detection and visualisation for each channel:
Module: Configuration, common for both channels Cable fault detection:
9202 CA.BR=YesorCA.SH=Yes ON
Else: OFF

12 9202 - Product Version 9202-003
Hardware / Software error
FUNCTION DESCRIPTION
Examples of connections in connection drawing and block diagram (1)...(4)
(1) NAMUR sensor with cable error detection in case of cable disconnection or
short-circuit.
(2) Mechanical contact with cable error detection in case of cable disconnection or
short-circuit, when Rs and Rp are mounted on the contact.
(3) Mechanical contact with cable error detection in case of cable disconnection,
when Rp is mounted on the contact.
(4) Mechanical contact without cable error detection.
! All error indications in the display flash once per second. The help text explains the error.
In case of cable fault the backlight also flashes. This can be reset by pressing the 3key.
Errors affecting both channels are shown as error on channel 1 - and the line showing channel 2 is
blank.
Hardware error can be reset in two ways. Either step through the menus (if the other channel is to
stay in operation) or power cycle the module.
Readout at hardware error:
Error search Readout Cause
Communications test 4501 / 9202 NO.CO Connection error
EEprom error - check configuration FL.ER
Configuration error or crc
mismatch, recovery confi-
guration is loaded
Hardware error DE.ER Invalid recovery configura-
tion in device
Hardware error FC.ER Invalid code checksum
in 4501
EEprom error - check configuration CO.ER Invalid configuration
(CRC or data)
Hardware error CA.ER Factory calibration error
Hardware error HW.ER HW setup - configuration
mismatch
Hardware error OC.ER Main output controller
communication error
Hardware error MS.ER Main internal supply out
of bounds
Hardware error MI.ER Main initialisation
selftest failed
Hardware error MC.ER Main flash or ram
selftest failed

91 92 93 94 95 31 32 33 34
11 12 13 14
11 12 13 14
11 12 13 14
41 42 43 44
51 52 53 54
Rs
Rp
51 52 53 54
Rp =15kΩ
Rs =750 Ω
51 52 53 54 51 52 53 54
Rp
41 42 43 44
Rs
Rp
41 42 43 44 41 42 43 44
Rp
11 12 13 14
+24 V
N.C.
NCNC
+24 V
11 12 13 14
11 12 13 14
9202 - Product Version 9202-003 13
CONNECTIONS
NAMUR sensor,
cable fault (1)
Switch,
cable fault (2)
Switch,
no cable fault (4)
Switch, cable fault,
disconnection (3)
NAMUR sensor,
cable fault (1)
Switch,
no cable fault (4)
Switch, cable fault,
disconnection (3)
Switch,
cable fault (2)
Inputs:
Outputs:
Supply and
status relay
Relay, N.C. Opto, NPN
Power rail
connections
Relay, N.O.
Channel 1Channel 2Channel 1
Relay, N.C. Opto, NPNRelay, N.O.
Channel 2
NC=noconnection
Gnd.
Gnd.
Error
(1)...(4)=Seefunction
description on page 12

44 43 42 41 54 53 52 51 9202
+24 V
FLASH
CPU 31
14 12 11
32 34 33
13
VNAMUR VNAMUR
9202B1 9202B2...B3 9202B1 9202B2...B3
NC*NC*
Rp =15kΩ Rs =750Ω
Rs
Rp
Rs
Rp
Rp Rp
(3) (4) (1)(2) (3) (4) (1)(2)
1
   O F F  
14 9202 - Product Version 9202-003
BLOCK DIAGRAM
Status relay N.C. Status relay N.C.
Device status, Green
Switch,
cable error
Gnd. -
Power rail connections
Supply +24 VDC
Gnd.
Ch. 1 status, Yellow/Red Ch. 2 status, Yellow/Red
NAMUR
sensor
Switch,
cable error NAMUR
sensor
Channel 1 Channel 2
Opto + or relay N.O. or relay N.C. Opto - or relay N.O. or relay N.C. Opto + or relay N.O. or relay N.C. Opto - or relay N.O. or relay N.C.
Channel 1
Channel 2
*NC=noconnection
(1)...(4)=Seefunction
description on page 12

9202 - Product Version 9202-003 15
Signal error and cable fault indications without display front
List of LED and error signal indications
State Green LED Ch. 1:
Yellow / red
Ch. 2:
Yellow / red
Status relay,
N.C.
Power rail
signal status
Module OK Flashing Energised OFF No supply OFF OFF OFF De-energised ON Module defective OFF Red Red De-energised ON Channel 1, relay energised Flashing Yellow Energised OFF Channel 1, relay de-energised at cable fault Flashing Red flashing De-energised ON (if activated)
Channel 1, relay de-energised Flashing OFF Energised OFF
Channel 2, relay energised Flashing Yellow Energised OFF Channel 2, relay de-energised at cable fault Flashing Red flashing De-energised ON (if activated)
Channel 2, relay de-energised Flashing OFF Energised OFF

16 9202 - Product Version 9202-003
CONFIGURATION /
OPERATING THE FUNCTION KEYS
Documentation for routing diagram.
In general
When configuring the 9202, you will be guided through all parameters and you
can choose the settings which fit the application. For each menu there is a
scrolling help text which is automatically shown in line 3 on the display.
Configuration is carried out by use of the 3 function keys:
1 will increase the numerical value or choose the next parameter
2will decrease the numerical value or choose the previous parameter
3will save the chosen value and proceed to the next menu
When configuration is completed, the display will return to the default state 1.0.
Pressing and holding 3will return to the previous menu or return to the default
state (1.0) without saving the changed values or parameters.
If no key is activated for 1 minute, the display will return to the default state
(1.0) without saving the changed values or parameters.
Further explanations
Password protection: Programming access can be blocked by assigning a
password. The password is saved in the module in order to ensure a high
degree of protection against unauthorised modifications to the configuration.
Default password 2008 allows access to all configuration menus.
Cable fault information via display front 4501
Cable fault (see limits in the table) is displayed as CA.BR (cable break) or CA.SH
(cable short-circuited). Cable fault is shown independently for each channel
but the configuration is common for both channels. In case of cable fault the
backlight flashes. This can be reset by pressing the 3key. When the cable
fault has been remedied, the module will return to normal operation.

9202 - Product Version 9202-003 17
Advanced functions
The unit gives access to a number of advanced functions which can be reached
by answering “Yes” to the point “adv.set”.
Display setup: Here you can adjust the brightness contrast and the backlight.
Setup of tag numbers with 5 alphanumerics. Selection of functional readout in
line 2 and 3 of the display - choose between readout of digital output or tag no.
When selecting ”ALT” the readout toggles between digital output and tag no.
Password: Here you can choose a password between 0000 and 9999 in order to
protect the unit against unauthorised modifications to the configuration. The
unit is delivered default without password.
Language: In the menu ”LANG” you can choose between 7 different language
versions of help texts that will appear in the menu. You can choose between
UK, DE, FR, IT, ES, SE and DK.
Power rail: In the menu ”RAIL” you can choose if errors in the module are
transmitted to the central surveillance in the PR 9410 power control unit.
Safety integrity level: See Safety Manual for details

18 9202 - Product Version 9202-003
[01]
[02]
[03]
[04]
[05]
[06]
[6/1]
[6/2]
[6/3]
[6/4]
[07]
[09]
[10]
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19
Set correct password [ PASS ]
Enter advanced setup [ ADV.SET ]
Enable cable short circuit error indication [ CA.SH ]
Enable cable breakage error indication? [ CA.BR ]
Enable rail status signal output? [ RAIL.ER ]
Enter language setup [ SETUP ]
Enter password setup [ SETUP ]
Enter display setup [ SETUP ]
Enter rail setup [ SETUP ]
Enter SIL setup [ SETUP ]
Select Direct channel function [ CH1.FUN ] [CH2.FUN ]
Select Inverted channel function [ CH1.FUN ] [ CH2.FUN ]
Adjust LCD contrast [ CONTRA ]
Adjust LCD backlight [ LIGHT ]
Write a 5-character channel TAG [ ’TAGON ] [ ”TAGON ]
Show Output load in display [ DISP ]
Show Output state in display
Show TAG in display
Alternate information shown in display
Configuration SIL status (Open / Locked) [ CONFIG ]
Enable SIL configuration lock [ EN.SIL ]
Enable Password protection [ EN.PASS ]
Set New password [ NEW.PAS ]
Select Language [ LANGUA ]
Cable short circuit [ ICA.SH ] [ IIOFF ]
Cable breakage [ ION ] [ IICA.BR ]
SCROLLING HELP TEXTS IN DISPLAY LINE 3