Comprehensive Review of Phoenix Contact's PSRmodular Safety Relay System: Configurable Safety Modules Explained

Finding cost-effective, space-saving solutions for control cabinets while maintaining high safety standards can feel like a wild goose chase. As the industry quickly moves from using conventional safety relays to integrating programmable safety logic, it will become essential to use strong and reliable controllers to meet safety standards. However, these controllers often come with a hefty price tag, bulky design, and poor flexibility in communication options. Enter the PSRmodular Safety System by Phoenix Contact — a game-changer designed to help address these pain points with cost-effective, space-saving, and intuitive solutions that don’t compromise on safety.

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What is a Safety Relay? | What are Safety Modules? | Phoenix Contact PSRmodular Safety Relay System |  Applications | Unboxing | Installation | Customization and Flexibility | User Interface and Diagnostics | Real-World Performance | Overall Value and Cost-Effectiveness | Frequently Asked Questions

What is a Safety Relay?

A safety relay, crucial in electrical panels, acts as a bridge between two circuits, activated by electrical current to engage mechanical contacts. It monitors safety systems, enabling machine operations or halting them when needed, playing a vital role in electrical safety. These devices are essential for ensuring compliance with Safety Integrity Levels (SIL) standards and are indispensable for failsafe environments. Single-function safety relays, known for their affordability, are perfect for smaller machines that require dedicated safety logic devices. Their self-monitoring feature guarantees consistent safety performance, even if internal components fail.

What are Safety Modules?

On the other hand, a safety module is a more advanced electronic device that integrates multiple safety functions into a single unit—playing a crucial role in the industrial manufacturing industry by continuously monitoring elements like machine operation, temperature, pressure, and hazardous materials. Ensuring the safety and well-being of workers, protecting equipment, and maintaining regulatory compliance. Here are some key functions and features of safety modules in industrial manufacturing:

1. Emergency Stop Functionality: Safety modules are equipped with emergency stop buttons or switches, immediately halting machinery operation in case of an emergency or when a safety hazard is detected, preventing accidents and injuries.
   
   

2. Safety Interlocks: Designed with safety in mind, they have embedded safety interlocking mechanisms that help prevent unauthorized access to hazardous areas of machinery or equipment, ensuring that operators cannot be exposed to dangerous conditions during operation.
   
   

3. Safety Relay Logic: Safety modules utilize advanced relay logic to establish safe operational sequences for machines and equipment, ensuring processes are carried out in a controlled and secure manner to prevent accidents.
   
   

4. Fault Detection and Diagnostics: Safety modules can detect faults in machinery or safety systems and provide diagnostic information to maintenance personnel for timely troubleshooting and repair to maintain optimal safety levels.
   
   

5. Integration with Control Systems: Safety modules easily integrate with existing control systems to enforce safety protocols, coordinate emergency responses, and ensure that safety measures are synchronized with production processes for efficient operation.
   
   

6. Compliance with Standards: Safety modules adhere to industry-specific safety standards and regulations to guarantee that manufacturing facilities meet legal requirements and maintain a safe working environment for employees.

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Meet the Phoenix Contact PSRmodular Safety Relay System

Phoenix Contact’s PSRmodular Safety System is designed to seamlessly integrate multiple safety relays into a single PLC, supporting analog inputs. This system addresses the never-ending need to shrink safety control cabinets for cost-saving and space efficiency. Certified by TÜV, UL, and CSA, it ensures compliance with stringent safety standards.

The PSRmodular Safety System's design highlights:

✔️ Compact and modular design, allowing components to be freely combined to fit various industrial environments

✔️ Narrow housing width of just 22.6 mm, making it space-efficient for crowded control cabinets

PSRmodular Safety Relay System Applications

The PSRmodular Safety System is a product helping create the competitive edge in major industries like:

• Packaging
• Food processing
• Machine tools
• Wind turbine generators

The AC DC configurable small-scale controller is gaining popularity due to its versatility and cost-effectiveness, including its two-channel operation capability. This controller can monitor multiple safety functions within a single application. Its scalability means it can be used in both small applications with three safety functions and large applications requiring up to 160 I/Os.

Designed with durability in mind, the PSRmodular XC safety modules are designed for extreme ambient conditions, making them ideal for applications in the process industry and maritime environments - from small machine builders to large industrial plants.

Unboxing the PSRmodular Safety Relay System: Initial Impressions

Unboxing the PSRmodular Safety System is designed for easy integration and adaptability. The package includes a basic module with eight safe input signals and up to four safe outputs. Diagnostic LEDs are prominently featured on the device, indicating the states of all inputs and outputs.

Additionally, the package includes:

✔️ Free configuration software that uses drag-and-drop for setting up safety logic without programming knowledge

✔️ This software facilitates a fast startup due to its easy hardware and software configuration

✔️ The installation process of the safety door is clearly designed with the user in mind, prioritizing ease and efficiency.

The durability of the PSRmodular Safety System is obvious as soon as you open it's box. The components feel solid and well-built. The system is designed with separate, interchangeable components or modules. This allows for flexibility, easy upgrades, and customization by adding, removing, or modifying individual parts without affecting the whole system.

You'll notice a conformal coating of the printed circuit board protecting from harsh industrial environments, enhancing the system’s longevity. The PSRmodular safety modules are designed to function reliably even under extreme ambient conditions, making them suitable for many different applications.

Installation Process

Thanks to its user-friendly design, installing the PSRmodular Safety System is simple. The system supports tool-free and time-saving installation through Push-in technology. The push-pull fast-locking system and Push-Lock conductor connection further simplify the DIN rail setup, ensuring a reliable and hassle-free installation process. Phoenix Contact’s terminal blocks use Push-IN technology, making wiring processes faster and more efficient.

Diagnostic LEDs on the PSRmodular modules are incredibly useful during installation. They indicate the states of all inputs and outputs, enabling current path troubleshooting. This feature ensures that any issues can be quickly identified and resolved, minimizing downtime and ensuring seamless installation.

Customization and Flexibility

The PSRmodular system is fully customizable and flexible. It can be extended with up to 18 safety-related extension modules, offering additional I/Os for more and more sensors and actuators. These modules can be added via a DIN rail connector, making the system highly adaptable and scalable.

Thanks to the wide range of customization options, users can easily mix and match different analog, motion, and extension modules. The configurable safety modules can also be a stand-alone control system for smaller machines. This adaptability makes the PSRmodular Safety System suitable for applications with up to 160 I/Os and safety ratings up to PL e or SIL 3.

User Interface and Diagnostics

The user interface and diagnostic capabilities of the PSRmodular Safety System are designed to provide easy control and clear diagnostic information for efficient problem-solving and system monitoring. The software is user-friendly and based on function block programming, allowing configuration through intuitive drag-and-drop actions without prior programming knowledge. This makes the system accessible to users with different levels of technical expertise, from beginners to experts.

One of the standout features is the software’s support for full-function test simulations, ensuring a safe state for the system. Users can test safety logic in simulation mode before applying it to the hardware, minimizing the risk of errors and ensuring a smooth implementation. Built-in safety door monitoring and pre-configured function blocks further facilitate troubleshooting and simplify safety task management.

The system also supports remote diagnostics by communicating with a higher-level controller via a fieldbus coupler, enabling real-time monitoring and evaluation of safety systems. These comprehensive and easy-to-understand diagnostics significantly reduce equipment downtime and enhance overall safety.

Real-World Performance

The PSRmodular Safety System is highly reliable in real-world scenarios, even under extreme conditions. The system’s features include:

✔️ Ability to handle extended temperature ranges from -10 to +70°C

✔️ Suitable for the process industry and maritime environments

✔️ Robustness that ensures effective performance in a variety of challenging industrial settings.

The system’s comprehensive and easy-to-understand diagnostics are crucial in minimizing machine downtimes. The diagnostics enable quick error rectification by providing detailed error information, ensuring that operations can continue with minimal interruptions. This is particularly valuable in industries where downtime can result in significant financial losses.

Additionally, the PSRmodular safety modules provide high-level safety up to PL e or safety integrity level (SIL) 3. This ensures that the system meets stringent safety standards, providing peace of mind to users. However, no system is without its challenges. Let’s explore some common troubleshooting issues and how to address them.

Overall Value and Cost-Effectiveness

Phoenix Contact’s PSRmodular family provides an economical approach to custom solutions with easy-to-install expansion modules. The quick installation of these modules leads to significant cost savings, making it a reliable choice for efficient safety solutions, including power supply management.

Compared to other safety-rated controllers available in the market, the PSRmodular system provides a competitive price advantage without compromising on quality or functionality. This makes it attractive for anyone looking to balance cost and safety.

Learn more and consider adding this system to your safety measures. Shop now.

Or contact your local Airline Sales Representative for a quote or more information. New to Airline? Contact us today! 

Additional Resources

• Shop the PSRmodular Safety System
• PSRmodular video experience