Phoenix PSR-M/FTB/ESS/CT Series: Modular Safety I/O, Protection & Interface Solutions - Comprehensive Application & Selection Guide

Product Positioning & Core Value

The Phoenix PSR-M/FTB/ESS/CT Series represents a modular safety-focused product ecosystem engineered for industrial automation, integrating safe I/O expansion, overload protection, power supply, and sensor/actuator interface solutions. Designed to comply with global safety standards (EN ISO 13849-1, IEC 61508), these products work seamlessly with Phoenix safety relays and controllers to build scalable, reliable safety systems for machinery, process control, and manufacturing environments.

Key Value Propositions:

• Modular Flexibility: Interchangeable modules (I/O, protection, power, interface) enable customized safety system design without over-engineering.
• Safety Compliance: Supports up to SIL 3 (IEC 61508) and PL e (EN ISO 13849-1) for safety-critical applications (emergency stops, safety gates, light curtains).
• Diverse Functionality: Covers safe digital I/O expansion, fuse protection, safety power supply, auxiliary contacts, and IO-Link gateway integration.
• Easy Installation: DIN rail mounting, tool-free push-in (PI) or screw (SC) termination, and plug-and-play compatibility with Phoenix safety systems.
• Industrial Durability: IP20 protection, -25°C~+60°C operating temperature, flame-retardant V0 housing, and resistance to electromagnetic interference (EMI).

Product Family Classification

The product lineup is organized into four complementary sub-series, with model suffixes indicating key features (e.g., SC=Screw Connection, PI=Push-In Termination, SDI=Safe Digital Input, SDO=Safe Digital Output):

1. PSR-M Series: Modular Safe I/O Modules

• Function: Safe digital input/output expansion for safety relays/controllers, enabling integration of sensors (emergency stops, light curtains) and actuators (safety contactors, valves).
• Key Variants:
  • EF1/EF2/EF4/EF5: Function class (determines I/O channel count and configuration).
  • SDI: Safe Digital Input (8/16 channels).
  • SDO: Safe Digital Output (4 channels, safety-rated).
  • DO: Standard Digital Output (4/8 channels, non-safety).
  • XC: Extended temperature range (-40°C~+70°C).
• Termination: SC (Screw Connection) or PI (Push-In Termination).

2. PSR-FTB Series: Fuse Terminal Blocks

• Function: Overload and short-circuit protection for safety circuits, integrating fuse holders with terminal blocks for compact, organized protection.
• Key Features: Rated current/voltage marked in model (e.g., 20/86 = 20A, 86V), DIN rail-mounted, compatible with standard cylindrical fuses.

3. PSR-ESS Series: Safety Power & Auxiliary Contact Modules

• Function: Safety-rated power supply modules (M0-H series) and auxiliary contact accessories (ACC-CB1 series) for safety system expansion.
• Key Variants:
  • M0-Hxxx: Power supply (e.g., H220 = 220V input, H100 = 100V input).
  • ACC-CB1: Auxiliary contact blocks (NO=Normally Open, NC=Normally Closed, C3=3-changeover contacts).

4. PSR-CT Series: Sensor/Actuator Interface & IO-Link Gateway

• Function: Safe interface modules for sensors/actuators and IO-Link gateways, enabling seamless integration of field devices with safety systems.
• Key Variants:
  • SEN: Sensor interface (1-8 channels).
  • ACT: Actuator interface.
  • GWY-1DGN-IOL: IO-Link gateway (1-channel, dual-port).

Technical Specifications (Universal Parameters)

Application Scenario Analysis

1. Safety-Critical Machinery (Automotive/Manufacturing)

Recommended Configuration:

• Safe I/O: PSR-M-EF5-SDO4-2A-DO8-PI (2801047) + PSR-M-EF2-SDI16-PI (1104887)
• Protection: PSR-FTB/20/86 (2904477)
• Power: PSR-ESS-M0-H220-2001-C (1221739)
• Auxiliary Contacts: PSR-ESS-ACC-CB1-C3 (1221747)

Advantages:

• 16-channel safe input supports multiple safety sensors (light curtains, emergency stops).
• 4-channel 2A safe output drives high-power safety contactors.
• Fuse terminal block protects safety circuit from overloads.
• SIL 3/PL e compliance meets automotive manufacturing safety requirements.

2. Harsh Environment Safety Systems (Mining/Outdoor)

Recommended Configuration:

• Safe I/O: PSR-M-EF1-XC-SDI8-SDO4-DO4-PI (1337850)
• Sensor Interface: PSR-CT-M-SEN-1-8 (2702975)
• Power: PSR-ESS-M0-H110 (1221757)
• Protection: PSR-FTB/1.5/11.5 (2904476)

Advantages:

• XC variant withstands -40°C~+70°C extreme temperatures.
• Sensor interface module conditions signals in high-EMI environments.
• 1.5A fuse terminal block protects sensitive safety sensors.
• Compact design fits in ruggedized control cabinets.

3. IO-Link-Enabled Safety Networks (Smart Factories)

Recommended Configuration:

• IO-Link Gateway: PSR-CT-GWY-1DGN-IOL-PI (1106407)
• Safe I/O: PSR-M-EF1-SDI8-SDO4-DO4-PI (1104889)
• Auxiliary Contacts: PSR-ESS-ACC-CB1-NO-SC (1221751)
• Power: PSR-ESS-M0-H200-2000-C (1221740)

Advantages:

• IO-Link gateway integrates smart safety sensors/actuators for predictive maintenance.
• Push-in termination enables fast commissioning in smart factory setups.
• Universal power supply adapts to global factory voltage standards.
• Auxiliary NO contacts enable remote safety status monitoring.

4. Legacy System Upgrades (Food & Beverage)

Recommended Configuration:

• Safe I/O: PSR-M-EF4-SDO4-DO4-SC (1104856)
• Power: PSR-ESS-M0-H100 (1221758)
• Protection: PSR-FTB/1.5/11.5 (2904476)
• Auxiliary Contacts: PSR-ESS-ACC-CB1-NC-SC (1221752)

Advantages:

• Screw termination matches legacy system wiring practices.
• 100V power supply compatible with older infrastructure.
• NC auxiliary contacts integrate with existing safety interlocks (safety gates).
• Compact modules fit in existing control cabinets without retrofitting.

Selection Guide

Step 1: Identify Core Functionality

Step 2: Select Termination Type

• Push-In (PI): Fast, tool-free installation (ideal for high-volume commissioning) → PSR-M-xxx-PI, PSR-CT-GWY-1DGN-IOL-PI.
• Screw (SC): Secure connection for high-vibration environments → PSR-M-xxx-SC, PSR-ESS-ACC-CB1-xxx-SC.

Step 3: Confirm Safety & Environmental Requirements

• Safety Level: SIL 3/PL e for critical applications (all PSR-M/CT/ESS models meet this).
• Harsh Environments: Extended temperature (XC) variants → PSR-M-EF1-XC-SDI8-SDO4-DO4-PI.
• Voltage Compatibility: Match power supply to system voltage (100V/110V/200V/220V) → PSR-ESS-M0-Hxxx.

Step 4: Verify Channel Count & Load Requirements

• Input Channels: 8-channel (EF1) or 16-channel (EF2) for sensors → PSR-M-EF1-SDI8-xxx, PSR-M-EF2-SDI16-xxx.
• Output Channels: 4-channel safe output (SDO) + 4/8-channel standard output (DO) → PSR-M-EF4/EF5-xxx.
• Load Current: 2A high-power output (EF5) for heavy actuators → PSR-M-EF5-SDO4-2A-DO8-PI.

Installation & Maintenance Guide

Installation Steps:

1. Mounting: Snap modules onto a 35mm DIN rail, ensuring ≥5mm spacing for heat dissipation. Install safety modules upstream of non-safety components.
2. Wiring:
   • For PI models: Insert stripped conductors (8mm length) into terminals until a "click" is heard.
   • For SC models: Tighten screws to 0.5~0.8Nm (0.5~2.5mm² conductors).
   • Connect power supply, safety sensors/actuators, and auxiliary contacts per terminal markings.
3. Fuse Installation: Insert compatible fuses into PSR-FTB modules (match rated current/voltage).
4. Configuration: Use Phoenix PC Worx software to configure safety logic (for PSR-M/CT series) and verify safety circuit integrity.
5. Testing: Power on the system and confirm LED indicators (green = normal, red = fault). Test safety functions (e.g., trigger emergency stop) to ensure proper shutdown.

Maintenance Points:

• Status Monitoring: Regularly check LED indicators (red = fault) → troubleshoot power, wiring, or load issues.
• Fuse Replacement: Replace blown fuses in PSR-FTB modules with identical rated fuses (do not use higher-rated fuses).
• Module Replacement: Replace safety modules after a fault (red LED) or every 10 years (service life).
• Terminal Inspection: Quarterly check SC terminals for loosening (tighten if needed) and PI terminals for conductor retention.
• Environmental Control: Keep installation area dry (relative humidity 10~90%, non-condensing) and free of dust.

Product Comparison (Phoenix Series vs. Traditional Safety Solutions)

Summary & Next Steps

The Phoenix PSR-M/FTB/ESS/CT Series delivers a comprehensive, modular safety ecosystem for industrial automation, combining safe I/O expansion, protection, power supply, and smart interface capabilities. With global safety certifications, flexible termination options, and seamless integration with Phoenix safety systems, these products enable reliable, compliant safety solutions for diverse applications—from automotive manufacturing to harsh outdoor environments.