HONEYWELL XS824-25

Description

Product Overview and Description

The HONEYWELL XS824-25 is a high-performance, DIN-rail mounted safety-rated switching amplifier, part of Honeywell’s extensive range of machine safety and control components. This device is specifically designed for safety applications, functioning as an interface between safety controllers or safety relays and solenoid-operated emergency stop (E-stop) devices, safety gates, or other safety actuators. The HONEYWELL XS824-25 takes the low-current, solid-state safety output signals and amplifies them to reliably switch higher current loads required by safety valves and locking mechanisms. It is a critical component in implementing safety control circuits that comply with international safety standards (e.g., IEC 62061, ISO 13849).

Product Parameters

• Device Type: Safety Switching Amplifier / Solid-State Safety Output Module.
• Function: Amplifies safety control signals to switch higher power loads.
• Safety Classification: Typically suitable for use in Safety Integrity Level (SIL) 2/3 and Performance Level (PL) d/e applications as part of a validated safety function.
• Number of Channels: Usually features two independent, monitored output channels for redundant or dual-channel control of a single load.
• Input Signal: Compatible with solid-state safety outputs from devices like safety PLCs (e.g., Honeywell MCS, Siemens Fail-Safe) or safety relays. Input voltage is typically 24V DC.
• Output Specifications:
  • Output Type: Solid-state, short-circuit protected.
  • Output Current: Rated for up to 2.5 A per channel (as indicated by the “-25” in the model), suitable for directly driving most safety solenoids.
  • Output Voltage: Switches the load supply voltage (typically 24V DC, up to 230V AC depending on specific variant).
• Diagnostic Features: Internal diagnostics for overload, short-circuit, and open-circuit conditions. Feedback loop monitoring for wiring integrity.
• Power Supply: Requires 24V DC control voltage.
• Mounting: Standard DIN-rail mount.
• Safety Certifications: Certified by recognized bodies (e.g., TÜV) for relevant safety standards.

Advantages and Key Features

1. Safety-Rated Design: The primary advantage of the HONEYWELL XS824-25 is its certified design for safety-critical applications, incorporating features like cross-circuit detection, short-circuit protection, and diagnostics to ensure fail-safe operation.
2. High Current Capacity: With a 2.5A output rating, it can directly switch most industrial safety solenoids for E-stop valves, safety gate locks, or brake releases without requiring an additional interposing power relay, simplifying the safety circuit.
3. Dual-Channel Reliability: The two independent, monitored output channels support the creation of redundant control paths for a single load, a common requirement for achieving higher Safety Integrity Levels (SIL) and Performance Levels (PL).
4. Integrated Diagnostics: Continuous self-monitoring and load monitoring provide immediate fault detection, allowing the safety controller to initiate a safe state and alert maintenance personnel, which is crucial for machine availability and safety.
5. Compact and Integrated: By combining amplification, protection, and diagnostics in one DIN-rail module, the HONEYWELL XS824-25 saves panel space and reduces wiring complexity compared to traditional relay-based solutions.

Application Cases in Various Fields

• Press & Stamping Machines: Controlling the solenoid of a hydraulic safety valve to drop tooling pressure when a light curtain is breached or an E-stop is pressed.
• Robotic Work Cells: Activating safety-rated brakes on robot axes or locking the access gate solenoid when operators need to enter the safeguarded space.
• Packaging Lines with Danger Zones: Powering the solenoid that releases a guarded interlock on a wrapper or palletizer, ensuring the machine cannot start while guards are open.
• Automated Assembly: Controlling the pneumatic safety exhaust valve for a clamping unit, where the HONEYWELL XS824-25 ensures the clamp releases force when a two-hand control station is not actively engaged.

Comparison with Competing Products

The HONEYWELL XS824-25 competes with safety switching amplifiers from other major safety component manufacturers such as Sick (Flexi Soft), Pilz (PNOZsigma), Banner (SC10-2), and Phoenix Contact (PSR). Compared to using a standard power relay controlled by a safety contact, it offers integrated diagnostics, solid-state reliability, and a certified safety design. Its primary advantage within the Honeywell portfolio is seamless integration with other Honeywell safety controllers and systems, though it is designed to be compatible with any safety device providing the correct input signal. Some competitors may offer modules with different current ratings or additional feedback options, but the core function and safety philosophy are similar.

Selection Suggestions and Precautions

• Selection Advice:
  • Load Verification: Confirm the inrush and holding current of your safety solenoid or actuator. The 2.5A continuous rating of the HONEYWELL XS824-25 must not be exceeded. For higher loads, a higher-rated module or an interposing contactor is required.
  • System Compatibility: Ensure the safety controller’s output type (pulsed, maintained) and voltage are compatible with the amplifier’s input requirements.
  • Safety Validation: The HONEYWELL XS824-25 is a component, not a complete safety function. Its integration into a machine’s safety system must be designed, validated, and documented by a competent safety engineer according to applicable standards.
• Important Precautions:
  • Safety Circuit Design: The wiring of the safety circuit, including the HONEYWELL XS824-25, must follow safe design principles (e.g., positive-guided contacts, separate color coding, protection against tampering).
  • Correct Wiring: Meticulously follow the manufacturer’s wiring diagrams. Incorrectly connecting the diagnostic feedback or mixing channels can prevent the safety function from working or disable the diagnostics.
  • Functional Testing: After installation, the complete safety function must be thoroughly tested to verify proper operation, including response to simulated faults (e.g., short-circuit, wire break).
  • No Substitution: Never substitute a standard, non-safety-rated relay or amplifier for the HONEYWELL XS824-25 in a safety circuit, as this will invalidate the safety certification and create a serious hazard.
  • Qualified Personnel: Installation, configuration, and testing must be performed by personnel trained in functional safety and familiar with the specific device.

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