1. Introduction

• Function: TMR safety relay (high‑current electromechanical output, SIL 3)

• Channels: 1 relay output (3NO / 1NC contact configuration)

• Coil Supply: 24 VDC (18–30 VDC operating range)

• Contact Rating: 8 A @ 250 VAC / 30 VDC (resistive)

• Safety: IEC 61508 SIL 3 (TÜV), CE, UL, CSA, ATEX, IECEx

• Architecture: 3‑2‑0 TMR, TriVote™ majority voting, single‑fault safe

• Diagnostics: Coil fault, contact wear, open/short circuit, TMR mismatch

• Response Time: ≤ 15 ms (command to contact state)

• Hot‑swap: Supported (Companion Slot / SmartSlot)

• Operating Temp: 0 °C to +60 °C (standard; conformal coated T8510C available)

2. Product Overview

• TMR voting logic: Three independent control slices ensure the relay only energizes on majority vote; single‑slice faults do not affect safety operation.

• Electromechanical relay: Gold‑plated contacts for low‑level signal reliability; high‑current rating for valve/contactor loads.

• Comprehensive diagnostics: Monitors coil continuity, contact state, and TMR consistency; reports faults via front‑panel LED and system alarm.

• Hot‑swap: Can be replaced online without shutting down the safety loop.

• SIL 3 certified: Meets IEC 61508 SIL 3 requirements for safety instrumented systems.

• ESD valve solenoids (high‑current 24 VDC or 120/240 VAC)

• Motor starter contactors (safety trip)

• Fire and gas suppression system triggers

• High‑power alarm beacons/horns

• Burner management system (BMS) fuel valve interlocks

3. Specifications

3.1 Mechanical

• Form Factor: T8000 chassis single‑width module, 6U height

• Dimensions (H × W × D): 266 mm × 31 mm × 303 mm

• Weight: Approx. 1.50 kg (includes relay assembly)

• Mounting: T8100 / T8400 chassis slots 1–16

• Termination: T8850 FTA (Safety Relay FTA, screw terminals)

• Protection: Standard (non‑coated); conformal coated T8510C available for harsh environments

3.2 Electrical

• System Supply: 18–30 VDC (nominal 24 VDC)

• Power Consumption: ≤ 12 W (coil energized); ≤ 4 W (coil de‑energized)

• Relay Type: Electromechanical, TMR‑controlled

• Contact Configuration: 3NO / 1NC (Form C)

• Contact Rating (Resistive):

  • 8 A @ 250 VAC

  • 8 A @ 30 VDC

• Contact Rating (Inductive): 5 A @ 250 VAC (cos φ = 0.4)

• Minimum Load: 100 mA @ 5 VDC (for contact wear diagnostics)

• Mechanical Endurance: ≥ 100,000 operations (full load)

• Electrical Endurance: ≥ 50,000 operations (8 A @ 250 VAC)

• Isolation: 2500 VAC opto‑galvanic (relay coil ↔ system); 1500 VAC (contacts ↔ coil)

• Leakage Current (Contacts Off): < 1 mA @ 250 VAC

3.3 Functional

• Redundancy: TMR (3 slices, 3‑2‑0 fault tolerance)

• Voting: TriVote™; relay energizes only on 2‑of‑3 vote

• Channel Type: Dedicated safety relay (NO/NC contacts)

• Diagnostics:

  • Coil open/short circuit detection

  • Contact state monitoring (NO/NC mismatch)

  • TMR slice mismatch & drift detection

  • Contact wear estimation (based on operation count)

  • On‑board BIST (self‑test interval: 1 minute)

• Response Time: ≤ 15 ms (command to contact state change)

• Fault Tolerance: Single‑slice or contact fault does not prevent safe trip

• Safe State: Relay de‑energized (NO open, NC closed) on system fault/power loss

3.4 Environmental

• Operating Temperature: 0 °C to +60 °C (T8510); –40 °C to +70 °C (T8510C)

• Storage Temperature: –40 °C to +85 °C

• Humidity: 5–95 % RH, non‑condensing

• Vibration: 10–57 Hz ±0.075 mm; 57–150 Hz 1.0 g

• Shock: 15 g, ½ sine wave, 11 ms

• Hazardous Area: ATEX / IECEx Ex ia IIC T4 Ga (with external safety barriers)

3.5 Safety & Certification

• Safety Standard: IEC 61508 SIL 3 (TÜV Certified)

• Approvals: CE, UL, CSA, ATEX, IECEx, FM

• Fault Tolerance: TMR 3‑2‑0; single‑fault safe

• PFHd: < 5.0 × 10⁻⁹ / hour (SIL 3)

4. Front Panel Indicators

• PWR (Green): ON = module power healthy

• RUN (Green): ON = active; FLASHING = BIST/initialization

• FAULT (Red): ON = critical fault; FLASHING = minor fault

• COM (Green): FLASHING = backplane communication active

• RELAY (Yellow): ON = relay energized (NO closed, NC open)

5. Installation

• Chassis: Insert into any vacant slot in T8100 / T8400 chassis

• Hot‑Swap: Supported (Companion Slot / SmartSlot)

• Front‑Panel Screws: Torque 0.8–1.0 Nm

• Termination: Connect to T8850 FTA (screw terminals for NO/NC contacts)

• Environmental Note: Use T8510C for sites with > 85 % RH, corrosive vapors, or temperature extremes

6. Wiring

• Relay Contacts (NO/NC): To ESD valves, contactors, alarms (8 A max)

• Contact Voltage: Up to 250 VAC / 30 VDC (resistive)

• Coil Supply: 24 VDC from system backplane (isolated)

• Isolation: Contacts isolated 1500 VAC from coil; coil isolated 2500 VAC from system

• Wire Gauge: 12–18 AWG, stranded, with suitable insulation for Ex areas

• Safety Note: For hazardous areas, use approved intrinsic safety barriers between contacts and field devices

7. Ordering Information

• T8510: Standard TMR safety relay module (0 °C to +60 °C)

• T8510C: Conformal coated TMR safety relay module (–40 °C to +70 °C, harsh environments)

• T8850: Dedicated safety relay FTA for T8510 / T8510C (screw terminals)

• T8100 / T8400: Trusted system chassis