Compatible, efficient, and usable worldwide

Explosion protection is becoming increasingly important, especially with the growing relevance of green hydrogen. Phoenix Contact therefore offers state‑of‑the‑art interface solutions for explosion‑protected applications.

In measurement and control technology, intrinsic safety (Ex i) has become a cost‑efficient, low‑maintenance protection method. Unlike flameproof enclosures (Ex d), it is more economical and allows maintenance and modifications during operation. Ex i applies to the entire circuit, limiting energy so that even in a fault condition, no ignition can occur from sparks or heat.

An intrinsically safe circuit typically includes:

• Intrinsically safe equipment installed in the Ex area (Ex i field device)
• Associated equipment located in the non‑Ex area (Ex i isolator)
• Connecting cables

Ex i isolators are crucial: they electrically separate the Ex i circuit from the non‑Ex i circuit per IEC/EN 60079‑11, preventing faults from transferring, and they limit the energy entering the Ex area to a non‑ignitable level.

Modern Ex i versions of the Mini Analog Pro and Macx Analog families offer broad compatibility with Ex i field devices and support long cable runs. Their Ex i signal conditioners are ATEX‑approved for use up to Ex zone 0 (gas) and zone 20 (dust), across all zones and substance groups—including IIC for hydrogen. All devices, including non‑Ex i versions, can also be installed in Ex zone 2 under Ex ec, supporting decentralized automation. Additional approvals such as IECEx, UL, CCC, and INMETRO enable global use.

Customized Ex i solutions for all applications

Phoenix Contact’s Ex i signal conditioners and measuring transducers include customized interface solutions, from individually wired DIN‑rail devices for small to medium signal volumes to system‑wiring solutions for large volumes. They also support plug‑and‑play connectivity for standard and universal I/O cards.

Compact Mini Analog Pro product family

The compact Mini Analog Pro Ex i signal conditioners and measuring transducers combine intrinsic safety and SIL 3 (1oo1) functional safety in just 6.2 mm, saving up to 50% space compared to standard devices while covering key functions (AI, AO, DI, DO, temperature). Non‑Ex i versions also offer limit switching, frequency measurement, and signal doubling. They operate from -40°C to 70°C and feature a user‑friendly design, flexible configuration, digitalization options, and optional communication gateways. Pluggable coded terminal blocks simplify replacement and prevent wiring errors, while the service position safely separates signal and supply circuits for commissioning and maintenance. Integrated test points allow current measurement during operation without interrupting the loop.

Macx Analog series with a wide range of functions

The Macx Analog series of functionally safe Ex i signal conditioners and measuring transducers. Proven internationally since 2008 and continually expanded. It offers a wide range of functions in a 12.5 mm width. The portfolio includes single‑ and two‑channel modules for all standard functions (AI, AO, DI, DO, temperature), as well as signal duplicators, limit switches, and specialized Ex i relay modules. Higher‑function modules from 17.5 to 35 mm complete the range, such as universal temperature transducers with three relay outputs plus an analog output, and versions with a wide‑range 24–230 V AC/DC supply.

Functionally safe design

Combinable via a standardized feed-in concept

A key advantage is the easy scalability of the supply system: additional T‑bus connectors can be added with minimal effort. Both product families are fully compatible, allowing Mini Analog Pro and Macx Analog devices to be combined on the same T‑bus using a standardized supply and error‑indication concept. A dedicated divider plate ensures safe mixed installations, from classic measurement and control tasks to SIL 3 and Ex i applications. Integration into third‑party systems is also possible via the T‑Bus PR adapter. This enables Phoenix Contact signal conditioners to fit existing supply infrastructures without costly modifications.

Various configuration options

A manufacturer‑independent FDT/DTM configuration option is also available. Both product families additionally offer DIP‑switch settings with easily accessible interfaces when installed. Mini Analog Pro devices can also be configured via NFC using the free Signal Conditioner App. While the Macx Analog series provides extra module information and a DIP‑switch setting aid.

Digital nameplate and NE 95 type tests

The digital nameplate ensures users always access the correct, revision‑specific documents, data sheets, operating instructions, approvals, drawings, declarations, hardware versions, and relevant firmware. This eliminates time‑consuming searches and saves time, money, and resources.

An independent Namur test laboratory has performed NE 95 type tests on the Macx Analog and Mini Analog Pro families. The reports confirm efficient space use, installation, and maintenance, and full compliance with all tested Namur recommendations and worksheets. This ensures the devices meet the chemical industry’s high requirements and eliminates the need for users to conduct time‑consuming factory tests.

Easy connection to system solutions and digital networks

With plug‑in communication modules, the Mini Analog Pro family enables convenient conversion of field signals into digital protocols without requiring extra space. The modules support Profinet, Modbus/TCP, Modbus/RTU, and Profibus. Up to eight freely combinable signal conditioners form the basis for the gateways, which start up immediately and need no external power supply. Direct signal connection to digital networks, combined with channel‑specific isolation and precise transmission, eliminates the need for an I/O layer and costly special input cards, enabling new, space‑saving applications, including for Ex i signals.

In large process engineering systems, thousands of signals often need processing, and individually wired DIN‑rail devices require extensive installation effort. The Termination Carrier provides a compact alternative, enabling fast, error‑free plug‑and‑play connection to I/O cards from various manufacturers using pre‑assembled system cables. Built on a robust aluminum profile, it accommodates 8 to 32 Mini Analog Pro or Macx Analog signal conditioners and includes a mechanically decoupled marshalling board with a system plug. Its space‑saving, durable design, accessible connections, and easy rail mounting simplify installation and servicing while improving system availability. Users also benefit from needing only one signal‑conditioner housing design for both individual and system applications.

Saving on marshalling and interface cabinets

VIP I/O marshalling provides an interface system for universal I/O cards. With a universal 16‑channel base module, plug‑in function modules, and system cables, it combines signal marshalling and processing in one system. Field signals connect directly to the base element, and functions are adapted by inserting the required modules. This removes the need for marshalling and interface cabinets, eliminates cross‑wiring, and shortens project processing times.

Learn more about Signal conditioners and measuring transducers.