D1000 Series

INSTRUCTION MANUAL
D1000 SERIES
DIN-RAIL MOUNTING
INTRINSICALLY SAFE ISOLATORS

D1000 Series - Intrinsically Safe Isolators ISM0102-0

 Index

D1000 Intrinsically Safe Isolators

Mechanical features......................................................................................................................................................................... 3
D1000 Power Bus Enclosure ........................................................................................................................................................... 4
Front Panel and PCB Removal........................................................................................................................................................ 6
Terminal Blocks Connection Data ................................................................................................................................................... 7
Mounting and Removing units from DIN-Rail .................................................................................................................................. 8
D1000 Series Configuration........................................................................................................................................................... 10
Installation of electronic equipments in cabinet ............................................................................................................................. 12
Placement of Isolators in cabinet ................................................................................................................................................... 13
Heat dissipation in cabinets ........................................................................................................................................................... 14
Calculation of radiant surfaces in closed cabinets ......................................................................................................................... 15
Approvals and Certifications .......................................................................................................................................................... 16
Storage .......................................................................................................................................................................................... 16
Disposal ......................................................................................................................................................................................... 16
Maintenance and Repair................................................................................................................................................................ 16

2 D1000 series - Intrinsically Safe Isolators Technology for safety

 Mechanical features

Mounting Dimensions
Width 22.5 mm
T35 DIN Rail according to EN50022 Depth 99.0 mm
Height 114.5 mm
Case material Blister packing size
Width 30.0 mm
PA66 - Polyamide (Nylon) 66 Depth 120.0 mm
Height 120.0 mm

Front Panel and Laser engraving on entire enclosure

Terminal Blocks tagging zone to provide Intrinsic Safety parameters,
schematic diagrams, connections,
instructions

LEDs for power,

status and fault
indication

Aeration
Slots

Terminals
Identification

Enclosure Characteristics
High channel density result from innovative circuit design using advanced surface mount components.
Single, dual or quad channel models.
Plug-in screw terminal blocks to secure termination up to 2.5 mm2.
Plug-in PCB can be removed for service or maintenance operations (see section “Front Panel and PCB Removing”).
High packing density
35 mm (Top Hat) DIN-Rail.
Ultra slim 4 channels 22.5 mm wide DIN-rail mounting modules.
6 mm per channel.
Up to 176 I/O channels per meter of DIN-rail.
Power Bus enclosure allows a significant reduction in cables, costs and space.

Technology for safety D1000 series - Intrinsically Safe Isolators 3

 D1000 Power Bus Enclosure

Power Supply Voltage 12-24 Vdc can be applied to the module,

by connecting directly the voltage to the plug-in Terminal Block of
each module, or via the Power Bus System. The system consists
of a standard DIN-Rail and modules with Bus Connectors (female
on one side and male on the other). The maximum allowed powering
capacity is 8 Amp. It is always possible to remove modules, without
disconnecting the bus connection. When the Power Bus is used,
Supply Contacts on Terminal Blocks are omitted to avoid accidental
short circuits on the Power Bus. Cumulative Fault Alarm indication is
provided on the Bus connection. This signal is in common with the
supply and drives a remote indication, typically through a D1091S
module.

DIN-Rail Anchor for terminal block

Side of the Power Bus DIN-Rail Stopper

Module Enclosure with

Power Bus Connector female Side

B+ A - FLT - +

Modbus Fault Power

Supply

Module Enclosure with

Power Bus Connector male Side

+ - FLT A- B+

Power Fault Modbus

Supply

4 D1000 series - Intrinsically Safe Isolators Technology for safety

 Module Enclosure with
Power Bus Male Termination Block

B+ A - FLT - +

Modbus Fault Power

Supply

Plug - in terminal block male, Plug - in terminal block male, Plug - in terminal block female,
vertical out, for Power Bus horizontal out, for Power Bus horizontal out, for Power Bus

Ordering Information:

Image Code Description

MCHP065 DIN-Rail Anchor for terminal block side of the Power Bus

MCHP139 5 mm spacer for modules on DIN-Rail

MOR016 DIN-Rail Stopper

MOR015 Plug-in terminal block male, vertical out, for Power Bus

MOR017 Plug-in terminal block male, horizontal out, for Power Bus

MOR022 Plug-in terminal block female, horizontal out, for Power Bus

Kit for Bus Mounting: 2 x MOR016, 1 x MOR017,

OPT1096
1 x MOR022, 2 x MCHP065

/B Power Bus Enclosure

Technology for safety D1000 series - Intrinsically Safe Isolators 5

 Front Panel and PCB Removal

Front panel and PCB can be

plugged out by applying a slight
pressure on both sides using a tool.

Slowly pull out Front Panel and PCB.

The PCB will slide on the enclosure
dedicated guides.

6 D1000 series - Intrinsically Safe Isolators Technology for safety

 Terminal blocks connection data

Grey terminal blocks

on Safe Area

Blue terminal blocks

On Hazardous Area

Screwdriver
for Trimmers
4 x 1 mm

7 mm
Stripping
lenght

Connection data
Conductor cross section solid From 0.2 mm² to 2.5 mm²
Conductor cross section stranded From 0.2 mm² to 2.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve From 0.25 mm² to 2.5 mm²
Conductor cross section stranded, with ferrule with plastic sleeve From 0.25 mm² to 2.5 mm²
Conductor cross section AWG From 24 to 12 AWG

Technology for safety D1000 series - Intrinsically Safe Isolators 7

 Mounting and Removing units from DIN-Rail

Mounting

Fig. 1 Fig. 2

Push
To
engage

T35 DIN Rail T35 DIN Rail

To mount Series D1000 on 35 mm DIN Rail, hook one side of the mounting foot over the lip of the rail and press down firmly on the barrier
(see Fig.1) to snap the other side of the mounting foot over the opposite rail lip (see Fig.2).

Removing

Fig. 3

Spring

Metallic
Part

Screwdriver

T35 DIN Rail

To remove a barrier from the mounting rail, insert the blade screwdriver in the metallic part of the mounting foot and lever the spring catch open
against the side of the barrier casing (see Fig.3).

8 D1000 series - Intrinsically Safe Isolators Technology for safety

Fig. 5

Pull and
removing
from Din-Rail

T35 DIN Rail

Fig. 7 T35 DIN Rail Dimensions (millimeters)

Fig. 6 T35 DIN Rail

Technology for safety D1000 series - Intrinsically Safe Isolators 9

 D1000 Series Configuration
The Pocket Portable Configurator type PPC1090 or PPC1092 is suitable to configure the “smart” barrier of D1000 series.
The PPC1090/PPC1092 unit is not ATEX, UL or FM approved and is only to be used in Safe Area/Non Hazardous Locations and prior to installation
of the isolator and prior to connection of any I.S. wiring. Do not use PPC1090/PPC1092 configurator in Hazardous Area/Hazardous Locations.
The PPC1090 configurator is powered by the unit (no battery power) when the telephone jack is plugged into the barrier (RJ12 6 poles connector
type with 1:1 connection). It has a 5 digit display, 4 leds and four push buttons with a menu driven configuration software and can be used in
Safe Area/Non Hazardous Locations without any certification because it plugs into the non intrinsically safe portion of circuit. The PPC1092 adapter
permits the configuration of the unit via a PC software program and acts as an interface for RS232 serial line and D1000 unit; it can be used in
Safe Area/Non Hazardous Locations without any certification because it plugs into the non intrinsically safe portion of circuit.
The main features of the converter can be easily configured, these are: type of input circuit, type of sensor, burnout operation, measuring range,
type of output and range, refer to the next section of Instruction Manual for a detailed description of configuration and menu options.

PPC 1090 Pocket Portable Configurator

The PPC1090 is a small and handy Pocket Portable Configurator suitable to program configuration parameters of D1000 series modules like:
type of input Sensors, input and output Ranges, Burnout conditions, High/Low Alarm mode, Relay NE/ND, Alarm Trip Point, Hysteresis value and
ON/OFF Alarm delays. The Configurator is powered by the unit and can be plugged in without disconnecting the module.
Refer to specific module Instruction Manual for details on using the PPC1090

PPC 1092 Serial Adapter

The PPC1092 adapter is needed to interface the PC with D1000 Series modules for a complete configuration of Input, Output and Alarm
parameters. The package includes necessary cables and a USB to RS-232 Adapter; a CD-Rom with the SWC1090 Software is also provided.
The SWC1090 can also be downloaded from our website.

10 D1000 series - Intrinsically Safe Isolators Technology for safety

 D1000 Series Configuration

SWC1090 Software
The SWC1090 software is designed to provide a PC user interface to configure programmable D1000 modules.

It easily allows the user to:

Read and write configuration parameters to the units (via COM port);
Store and restore data to and from local hard drive for backup or archive;
Load factory default configurations;
Monitor Input values via USB/COM port;
Print a report sheet containing configuration parameters and additional information
(see example on the right).

The SWC1090 is freely distributed at our website:

http://www.gmintsrl.com

Example Configuration Report Sheet

Technology for safety D1000 series - Intrinsically Safe Isolators 11

 Installation of Electronic Equipments in cabinet

All electronic equipment operate using electrical power and dissipate part of it into heat which is generally removed by the surrounding ambient air
and determines an increase in the operating temperature. High operating temperatures reduce their life and increase the probability of failures
according to the Arrhenius criteria, for example an operating temperature increase from 25 to 50 °C can cause a failure rate ten times higher.
In a cabinet air circulates and removes heat by convection (natural convection cooling) or, more effectively, by forced ventilation (fans) or even
more effectively by refrigerated forced ventilation (air conditioning). Installation of electronics in cabinets restricts free air movement and rises their
internal temperature. These effects can be reduced in two concurring lines of action:
by limiting the power dissipation and the heat produced inside the cabinet
by encouraging air circulation (and exchange of heat) inside the cabinet
A simple way to improve air circulation is to provide space between the isolators, also installing isolators in horizontally oriented DIN rail rows with
the enclosure main surfaces oriented vertically allows better air circulation inside the enclosure and significantly improves heat exchange.
What ultimately determines the operating temperature rise inside a cabinet is the total power dissipation and the provisions available for removing
the heat with cool air (natural convection or forced cooling). The maximum power consumption of each type of isolator is specified in the
corresponding data sheet so by summing the power of each unit in the cabinet the total power Pmax can be easily found. In normal operating
conditions however the power dissipated by the installed equipments is not likely to be the maximum value specified for all of them and at the
same time, the value of the effective power Peff can therefore be considered smaller (typical 70 %) than the value Pmax:
Peff ≤ Σ Pmax * 70 %

1) Closed Cabinets with Natural Convection

Closed cabinets are preferred in dusty or harsh environments where they offer a better equipment protection but their heat / power dissipation
capability is modest. Heat is removed by air flowing internally and exchanged with the walls of the cabinet, the calculation of the maximum allowed
power dissipation in this type of cabinet is:
P
Pmax = Δt * S * K and Δt = ———
S*K

where: Pmax [W] maximum allowed power dissipation

Δt [°C] maximum allowed temperature rise
S [m²] free heat emitting surface of the cabinet
K [W/m² * °C] thermal conductivity coefficient (K=5.5 for painted steel sheets)

As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 250 W.

2) Open Cabinets with Natural Convection

Open cabinets must operate in clean environments, their heat / power dissipation capability is medium.
Heat is removed by air flowing through the equipment, circulating from bottom to top of cabinet (convection). Depending on the type of engineering
(freedom of cool air to enter at the bottom of the cabinet, to circulate vertically around the equipment extracting heat and to exit at the top of the
cabinet), the power dissipation improvement can be two times better than case 1.
The cabinet must be equipped with inlet and outlet louvers in the lower and upper ends of the cabinets, vertical air flow inside and outside the
cabinet must be kept free from obstacles to enhance the “chimney effect” air circulation.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 350 W.

3) Open Cabinets with Forced Ventilation

Open cabinets must operate in clean environments, their heat / power dissipation capability is high with forced ventilation Air is forced into the
louvers on the bottom of cabinet, flows through the equipments, and finally exits at the top of the cabinet, where generally is forced by one or more
fans. The calculation of the required airflow is:

Q = 3.1 * Peff / Δt

where: Q [m³/h] is the required air flow

Peff [W] is the dissipated power (typical 70 % of the maximum power dissipation)
Δt [°C] is the maximum allowed temperature rise in the cabinet

As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 500 W.

4) Closed Cabinets with Forced Ventilation and Heat Exchanger

Closed cabinets with forced ventilation are preferred in high dissipated power and harsh environment where natural convention cabinets cannot be
used. Hot air is extracted from the cabinet by a fan, cooled by a heat exchanger (using a cooling fan with ambient air) and forced back into the
cabinet; depending on the type of engineering the improvement can reach a 5 times higher power dissipation than in case 1.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 1000 W.

12 D1000 series - Intrinsically Safe Isolators Technology for safety

5) Air Conditioned Cabinets

Air conditioned cabinets are preferred in hot climates and / or harsh environments. Cabinet temperature can become equal or even lower than the
ambient temperature. A specific refrigerating system or the existing air conditioning system can be used for cabinet conditioning.
As an example a cabinet sized 600x600 mm and 2000 mm high has a temperature rise of 10 °C for an installed power of 1000 W.

Placement of isolators in cabinet

The placement of the barriers in the cabinet has an important impact on the ambient temperature. The following points should be considered:

1. The sum of the individual dissipated power of the installed barriers plus other devices need to be below the calculated or given maximum
dissipation power of the cabinet.
2. The D1000 series could be installed in horizontal or vertical mounting position. The installation in horizontal position offers an
improved heat transport.
3. Place the units with higher dissipation power in the upper part of the cabinet.
4. If you apply ventilation please consider the following:
a) When applying temperature control you have to install the temperature sensor in the upper part of the cabinet.
b) It is more effective to install a fan into the roof of the cabinet rather than in the lower part of the cabinet.
5. Take care about reasonable distance between D1000 series and cable channels. We recommend a distance of 6 cm.
(see figure 1 and 2). If the place in the cabinet does not allow to keep the distance we strongly recommend to place the DIN rail
away from the back side of the cabinet by means of distance bolts.

A Non I.S. cable duct

A
B D1000 Series

C I.S. cable duct

B

Minimum 6 cm distance
C between isolators and
cable duct.

Fig. 1 Horizontal orientation in the cabinet

A Non I.S. cable duct

B D1000 Series

C I.S. cable duct

A B C

Minimum 6 cm distance
between isolators and
cable duct.

Fig. 2 Vertical orientation in the cabinet

Technology for safety D1000 series - Intrinsically Safe Isolators 13

 Heat dissipation in cabinets

CLOSED VERSION
Natural convection Forced convection by
Internal fan (increasing
~ 250 - 300 W In natural convention)

~ 250 - 300 W

Forced air circulation Heat dissipation a via air

via heat exchanger conditioner (cooling by
(air circulation by two temperature lower than
separate flows internal the ambient temperature
and external)
~ 500 W
~ 1000 W

Power value dissipated per ΔT = 10K (single cabinet)

For installation in a row of cabinets, power dissipated in the first two examples is decreased of about 15%

OPEN VERSION
Air flow Air flow
(Natural convection) (filtered fans)

~ 320 - 350 W ~ 1000 W

Power value dissipated per ΔT = 10K (single cabinet)

For installation in a row of cabinets, power dissipated in the above two examples is decreased of about 5-10%

14 D1000 series - Intrinsically Safe Isolators Technology for safety

 Calculation of radiant surfaces in closed cabinets

Single cabinet Row of cabinets

(all surfaces free of A3
contact)
A3
A3
A3
A3 A1
A1
A2 A1
A1
A2 A1

ATOT = 1 x A1 + 2 x A2 + A3 ATOT = 2 x N x A1 + 2 x A2 + N x A3
Formula for cabinet with no surfaces in contact with the wall (N = Number of cabinets placed side by side)
Formula for row of cabinets with no surface in contact with the wall

Single cabinet Row of cabinets

(one side on the wall) (one side of each
on the wall)

A3
A3
A3 A3
A1
A3
A1
A2 A1 A1
A2 A1

ATOT = 1 x A1 + 2 x A2 + A3 Row of cabinet (one side by the wall)

Formula for cabinet with one side on the wall ATOT = 1 x N x A1 + 2 x A2 + N x A3
Formula for row of cabinets with one side on the wall

Technology for safety D1000 series - Intrinsically Safe Isolators 15

 Approvals and Certifications
Intrinsically Safe products

G.M. International’s products have been granted IS certificates from the most credited Notified bodies in the world.
Certificates are available for ATEX (Europe), IECEX (International), Russian and Ukrainian standards, USA and Canada.

Certificates have been integrally scanned and are available for download from our website.

SIL Certifications according IEC 61508 and IEC 61511

G.M. International offers a wide range of products that have been proved to comply with the most severe quality and safety requirements.
IEC 61508 and IEC 61511 standards represent a milestone in the progress of industry in the achievement of supreme levels of safety through
the entire instrumented system lifecycle.

The majority of our products are SIL certified; reports and analyses from TUV and EXIDA are available for download from our website.

Marine Type Approval

G.M. International offers Type Approval Certificates for its line of Intrinsically Safe Isolators D1000 Series and Power Supplies for use in
Marine and Offshore applications.

Certificates have been released both by Korean Register of Shipping and Det Norske Veritas.

Company Quality System

G.M. International’s Production Quality System is certified by Det Norske Veritas (Norway) to be compliant with ATEX 94/9/EC Directive
and ISO 9001/2000.

This means our production facilities are periodically re-assessed throughout the whole manufacturing process, to ensure that the highest quality
standards are met.

Storage
If after an incoming inspection the unit is not installed directly on a system (parts for spare or expansion with long storage periods) it must be
conveniently stocked. Stocking area characteristics must comply with the following parameters: Temperature: –20 to +60 °C, the –45 to +80 °C
in the data sheet is meant for limited periods, mainly to arrange for air transport, -10 to +30 °C are preferred.
Humidity: 0 to 90 %, long period high humidity affects the package integrity, 0 to 60 % humidity is preferred.
Vibration: no prolonged vibration should be perceivable in the stocking area to avoid loosening of parts or fatigue ruptures of components terminals.
Pollution: presence of pollutant or corrosive gases or vapors must be avoided to prevent corrosion of conductors and degradation of insulating
surfaces.
Disposal
The product should not be disposed with other wastes at the end of its working life. It may content hazardous substances for the health and the
environment, to prevent possible harm from uncontrolled waste disposal, please separate this equipment from other types of wastes and recycle it
responsibly to promote the sustainable reuse of material resources. This product should not be mixed with other commercial wastes for disposal.
Maintenance and Repair
Series D1000 modules do not require particular maintenance under normal operating conditions. They are designed to operate trouble free and
with high stability for long time. If a unit is found not meeting specifications or in a failure condition then it requires recalibration or servicing.
Any repair made by unauthorized personnel may completely invalidate the safety characteristics of the card. Repair not made by GM. International
is prohibited. If a barrier failure condition is actually found, replace the defective card with a good one and send it for repair to the nearest authorized
representative of GM International.

16 D1000 series - Intrinsically Safe Isolators Technology for safety