1. Introduction

• Function: 40‑channel TMR configurable I/O (In/Out) + valve monitor (conformal coated)

• Channels: 40 × 24 VDC, software‑configurable Input or Output

• Outputs: 24 VDC, 2 A continuous per channel; 8 A per power group

• Inputs: 24 VDC dry contact / voltage sense; 4–20 mA sensor support

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

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

• Isolation: 2500 VDC opto‑galvanic (field ↔ system; ch ↔ ch)

• Diagnostics: Open/short circuit, overload, TMR mismatch, drift

• SOE: 1 ms time‑stamp resolution (events/faults)

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

• Operating Temp: –40 °C to +70 °C (extended harsh range)

2. Product Overview

• Conformal coated PCB and components (acrylic resin)

• Extended operating temperature: –40 °C to +70 °C

• Enhanced resistance to moisture, salt mist, dust, and chemical vapors

• Same TMR core, I/O performance, and safety certification as T8449

• 40 configurable In/Out channels: mix digital outputs (solenoids) and digital inputs (limit switches)

• Dual‑mode signal support: 24 VDC discrete + 4–20 mA analog position sensors

• TMR voting: auto‑corrects single‑slice faults; no single point of failure

• Comprehensive per‑channel diagnostics: open/short, overload, mismatch

• High‑speed SOE: 1 ms resolution for valve state changes and fault events

• Hot‑swap & hot‑standby: online replacement without safety loop interruption

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. 1.2–1.3 kg

• Mounting: T8100 / T8400 chassis slots 1–16

• Termination: T8849 FTA (Valve Monitor FTA, standard or Ex ia)

• Protection: Conformal coated (acrylic) PCB and components

3.2 Electrical

• System Supply: 20–32 VDC (nominal 24 VDC)

• Power Consumption: ≤ 27 W

• Field Supply (Outputs): 18–32 VDC (nominal 24 VDC)

• Channels: 40, grouped into 5 × 8‑channel power groups

• Output Rating: 2 A continuous per channel; 8 A peak surge

• Group Rating: 8 A max per power group

• Input Type: 24 VDC dry contact / voltage sense; 4–20 mA analog

• Isolation: 2500 VDC opto‑galvanic (field ↔ system; ch ↔ ch)

• Leakage Current (Output Off): < 100 µA

• On‑State Voltage Drop (Output): ≤ 1.2 VDC @ 2 A

3.3 Functional

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

• Voting: TriVote™; auto‑corrects single‑slice faults

• Channel Configuration: Each channel = Input or Output (software select)

• Diagnostics:

  • Open/short circuit detection (per channel)

  • Overload / overcurrent protection (per group)

  • TMR mismatch & drift monitoring

  • 4–20 mA sensor range check (input mode)

  • On‑board BIST (periodic self‑test)

• SOE Resolution: 1 ms (valve state changes, faults, trips)

• Response Time: ≤ 1 ms (command to output; input to system)

• Fault Tolerance: Single‑channel/group fault does not affect safety function

3.4 Environmental (Enhanced for Harsh Conditions)

• Operating Temperature: –40 °C to +70 °C

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

• Humidity: 5–95 % RH, non‑condensing (coating reduces condensation risk)

• 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 T8849 Ex FTA)

• Chemical Resistance: Resists salt mist, oil vapors, and common industrial gases

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: < 1.0 × 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

• CH1–CH40 LEDs: Per‑channel status (ON = energized/active; FLASH = fault)

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 T8849 FTA (standard or Ex ia hazardous area)

• Environmental Note: T8449C is mandatory for sites with > 85 % RH, corrosive vapors, or temperature extremes

6. Wiring

• Output Channels: To solenoid valves, relays (24 VDC, 2 A max)

• Input Channels: From limit switches, 4–20 mA position sensors

• Field Power: 18–32 VDC to T8849 FTA (per power group)

• Isolation: Field side isolated 2500 VDC from system/backplane

• Wire Gauge: 16–22 AWG, stranded, with suitable insulation for Ex areas

7. Ordering Information

• T8449: Standard 40‑channel TMR configurable I/O/valve monitor module (0 °C to +60 °C)

• T8449C: Conformal coated 40‑channel TMR configurable I/O/valve monitor module (–40 °C to +70 °C, harsh environments)

• T8849: Dedicated valve monitor FTA for T8449 / T8449C (standard or Ex ia)

• T8100 / T8400: Trusted system chassis