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User manual UM EN SAFETY RELAY

1. K5 M N Figure 5 9 Two channel emergency stop monitoring with delayed contacts PSR ESD 4x1 30 5 16 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 S12 button S1 and S21 S22 of the safety relay Power The circuit is enabled via the reset button OK1 K2 O K3 t Ka 2 Press reset button S2 Contactors K3 K5 are activated and the mirror contacts N C contacts of K3 K5 in the reset circuit are opened Power k1 k2 k3 t a t Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contacts 13 14 of the button S1 safety relay open immediately which initiates an automatic Power quick stop at the FI quick stop at the iam ks Kay After the preset time has elapsed delay contacts 37 38 and 47 48 deactivate the three contactors K3 K5 with a time delay After the delayed deactivation parallel to the motor the mains supply is disconnected from the FI and brake unlocking is switched off so that the brake blocks the drive Inthe reset circuit the mirror contacts of K3 K5 are closed Power OK1 K2 Ok3 t Ka Notes on the application example For additional diagnostic descriptions please refer to Section
2. 7 6 PHOENIX CONTACT 102597_en_02 Diagnostic description Table 7 4 Diagnostic description for PSR ESD 4x1 30 safety relay PWR K3 t K4 t Error Remedy K1 K2 3 If a cross circuit or surge voltage undervoltage Check the wiring and the operating voltage 0 25 Enable contact s of K1 and K2 faulty Error with internal cause DO 74 0 0 25 Enable contact s of K3 and K4 faulty 5 occurs during the configuration phase the safety Supply module indicates a configuration error Perform a voltage reset S gt 1s 1s aE oO O xX X x Rotary switch delay time was modified during Carry out configuration again o operation ry g gain 1s 1s 1s xt Safety relay faulty 0 25 Replace the safety relay Perform a voltage reset 102597_en_02 PHOENIX CONTACT 7 7 Application manual for PSR safety relays The table is valid for the following safety relays 1 PSR URM4 5x1 2x2 Table 7 5 Diagnostic description for PSR URM4 5x1 2x2 safety relay N Error Remed g l y Supply voltage not present Apply supply voltage es 5 Supply voltage too low Adjust supply voltage 5 0 2o Es c5 foc i i os Input circuit A11 is not being supplied with power 83 xXt Check the input circuit connection xf Input circuit A12 is not being supplied
3. 5 46 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S11 S12 and 11 S22 of the safety relay Power The circuit is enabled via the reset button K1O K2 O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power K1 K2 Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are K1 O closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The connecting cables for the position switches in the sensor circuit safety door example switch should either be laid separately or protected against mechanical damage 2 The position switch is positive opening according to EN 60947 5 1 wo Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 4 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteri
4. closed Start Action Result Diagnostics 1 The light grid is active Both OSSD signals from the light grid provide high signals to there is no object in the enable circuit S10 and S12 of the safety relay Power protected field Contactors K3 and K4 are activated and the mirror contacts K1 N C contacts of K3 and K4 in the reset circuit are opened K2 Stop Action Result Diagnostics 1 The light grid is The safety function is triggered by the interruption of the light interrupted there is an grid and contactors K3 and K4 are opened Power T in the protected In the reset circuit the mirror contacts of K3 and K4 are o a For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The light grid ESPE must meet type 4 requirements from standard EN 61496 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 Arestart should only occur automatically if there is no hazardous situation Please refer to the detailed information in standard EN ISO 12100 6 3 3 2 5 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or t
5. 2 9 Logical representation of subsystem D according to EN 62061 2 9 Cross Circuit detection 2 eeceeecceecceseeeeeeeceeeeseeeeeeeeaeeeeeeeneeesnaeeeeeenaees 3 1 Cable lengths sinini a bil ticles E ae EEE E 3 2 Example stop category O oo eeesseeseeeeenneeeceeeeeeseeeeenaeesseeeeeeneeeennaes 3 4 Example stop Category ooo eeeseeeseeeeesneeeceeeeeeseeeeenaeeeneeeeeenteeeenaes 3 4 Example stop category 2 oo eeeceeeseecseeeeesneeeceeeeeeseeeeeaeeeneeeeeenneeeenaes 3 5 Emergency Stop reina N A ee N 5 1 Single channel emergency stop monitoring with manual reset PSR ESMA A a aa a E aa tapas aeaaea En aR SHEANS 5 2 Single channel emergency stop monitoring with manual reset PSR ESL4 3xX1 1X2 B iai at aiaa aea a ranan eaa aaaea Sae eriei aa h ERr 5 4 Single channel emergency stop monitoring with manual reset PSR ESD 4X1 30 a anit e ah einer ene 5 6 Two channel emergency stop monitoring with manual reset PSR ESAMA4 2X1 1X2 nna e abi as eee i aan aS 5 8 Two channel emergency stop monitoring with manual reset PSR ESM4 3xX1 1X2B visien eree aa ii aa aaa aaa iea Ni 5 10 Two channel emergency stop monitoring with manual reset PSR ESL4 3x1 1X2 B etic ciate beeen chao ea aeaa 5 12 102597_en_02 PHOENIX CONTACT A 1 Application manual for PSR safety relays Figure 5 8 Two channel emergency stop monitoring with manual reset PSR ESAM4 8x1 1X2 nu ishir edits cnuees iia oea esa 5 14 Figure 5 9 Two channel emergency stop monit
6. N S34 S35 4 K74 K3 K4 K5 K6 K7 K8 K5 PENS R ee ee kei Figure 5 28 Application example emergency stop monitoring with contact extension PSR ESAM4 2x1 1x2 and PSR URM4 5x1 2x2 5 62 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics Diagnostics KS1 ssa 1 Unlock emergency stop The emergency stop button closes enable button S1 circuit S11 S12 and S21 S22 of the safety Power relay IN1 2 k1 O ORERE K1 The circuit is enabled via the reset button K2 O K2 O 2 Press reset button S2 Contact extension KS2 and contactors K3 K8 are activated Power The mirror contacts N C contacts of KS2 and IN1 2 Ki K3 K8 in the reset circuit are opened K1 Le K2 Stop Action Result Diagnostics Diagnostics 1 Press emergency stop The safety function is triggered and contact button S1 extension KS2 as well as contactors K3 K8 Power are opened IN1 2 O K1O In the reset circuit the N C contacts of KS2 K1 O K2 O K2 O and K3 K8 are closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive opening according to EN 60947 5 1 example 2 Cont
7. Application examples for modular safety relay system with PSR TBUS connection Function description Start Action Result Diagnostics Diagnostics 1 Close the safety door The safety door circuit closes the first enable circuit via S10 and S11 and closes the second enable circuit via S11 and S12 of the safety Power eee relay N1 N2 K1 t Contactors K3 and K4 are activated and the k lt kK2 mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Stop Action Result Diagnostics Diagnostics 2 Open the safety door The safety function is triggered and contactors K3 and K4 are opened after a preset time Power In the reset circuit the mirror contacts of K3 and K1 t K4 are closed after a preset time Power Oz i IN1 After the preset time has elapsed the delayed a enable contacts of the safety relay are opened K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The connecting cables for the position switches in the sensor circuit safety door example switch should either be laid separately or protected against mechanical damage w The position switch is positive opening according to EN 60947 5 1 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204
8. Enable contact s of K1 faulty Replace the safety relay All Error with internal cause 102597_en_02 PHOENIX CONTACT 7 5 Application manual for PSR safety relays The table is valid for the following safety relays 1 PSR ESD 4x1 30 Table 7 4 Diagnostic description for PSR ESD 4x1 30 safety relay 2 Error Remedy N x mM a x Supply voltage not present Apply supply voltage 5 Supply voltage too low Adjust supply voltage C O zE je e 2o EF G 8 5 74 0 Supply voltage too high Adjust supply voltage gt The enable circuits are connected incorrectly or not connected at all Check the connection of the enable circuits xt Between both enable circuits S11 S12 and x 21 S22 3 2 1s E g for emergency stop or safety door E Remove cross circuit 7 O Sd 5 x oO Between both enable circuits S12 and S22 E g for light grid type 4 1s Short circuit between contact points A1 and A2 i 3 o X 0 O oO Between S11 and 12 Oo Error detection on next demand Remove short circuit E 5 1s lt n X Between S21 and S22 Error detection on next demand Short circuit between A1 and S34 e g faulty reset button No error detection on initial start only once all enable contacts have been opened Remove short circuit Error in reset circuit
9. PSR ESAM4 N A2 S34 N Figure 3 2 Cable lengths 3 2 PHOENIX CONTACT 102597_en_02 Safety technology basics Example Assumed values Technical data for the safety relay Calculated value i For an emergency stop application with the PSR ESAM4 see Figure 3 2 the following calculations can be made Cable cross section A 1 5 mm Electrical conductivity of copper Cu x 56 m Q x mm at 20 C Input data Maximum voltage drop for S11 S12 S21 S22 and S33 S34 approximately 2 V DC corresponds to approximately 50 Q R The specified values can be found in the data sheet for the corresponding safety relay R R1 R2 R3 R 50Q l R_xAx 50 Qx 1 5 mm x 56 m Q x mm 4200 m Where l Permissible cable length RL Cable resistance A Cable cross section x Kappa Electrical conductivity of copper Cu This refers to the forward and return line for both channels in the enable circuit and reset circuit S11 S12 S21 S22 and 812 834 If the application is operated with an automatic start the cable lengths between S12 S35 can be disregarded 102597_en_02 PHOENIX CONTACT 3 3 Application manual for PSR safety relays Stop category 0 Stop category 1 3 3 Stop Stop categories according to EN 60204 1 Every machine must be fitted with emergency stop equipment As per EN 60204 1 this must be implemented in stop category 0 or stop category
10. The table is valid for the following safety relays 1 PSR URM4 4x1 2x2 B Table 7 8 Diagnostic description for PSR URM4 4x1 2x2 B safety relay gt Error Remedy x Apply supply voltage e g via the _ 0 Supply voltage not present PSR T BUS DIN rail connector C O 2 5 O o 2 Supply voltage too low Adjust supply voltage 52 e Q gt The input circuit is connected incorrectly or not lie n connections connected at all 5 Insert PSR T BUS TP dummy plug i gt 2 Short circuit between contact points A1 and A2 Remove short circuit O lt n Confirmation contacts 11 and 12 are faulty Error with internal cause Enable contact s of K1 and K2 faulty Replace the safety relay Table 7 9 1 PSR URD3 4x1 2x1 3 2 PSR URD3 4x1 2x2 3 PSR URD3 4x1 2x2 T2 Diagnostic description for PSR URD3 4x1 safety relays The table is valid for the following safety relays Supply voltage not present Apply supply voltage e g via the PSR T BUS DIN rail connector Supply voltage too low Adjust supply voltage Connection voltage error The input circuit is connected incorrectly or not connected at all Check the PSR T BUS connections between the modules Insert PSR T BUS TP dummy plug 102597_en_02 PHOENIX CONTACT 7 11 Application manual for PSR safety relays Table 7 9 Diagnostic descriptio
11. User manual UM EN SAFETY RELAY APPLICATION Application manual for PSR safety relays OGD OO GD GD OGD OO OD LiXcnic OGD INSPIRING INNOVATIONS User manual Application manual for PSR safety relays 2012 06 20 Designation UM EN SAFETY RELAY APPLICATION Revision 02 Order No 2888712 This user manual is valid for All PSR safety relays from Phoenix Contact 102597_en_02 PHOENIX CONTACT Internet Subsidiaries Published by Please observe the following notes User group of this manual The use of products described in this manual is oriented exclusively to Qualified electricians or persons instructed by them who are familiar with applicable standards and other regulations regarding electrical engineering and in particular the relevant safety concepts Qualified application programmers and software engineers who are familiar with the safety concepts of automation technology and applicable standards Explanation of symbols used and signal words hazards Obey all safety measures that follow this symbol to avoid possible This is the safety alert symbol It is used to alert you to potential personal injury injury or death There are three different categories of personal injury that are indicated with a signal word DANGER This indicates a hazardous situation which if not avoided will result in death or serious injury WARNING This indicates a hazardous situation which if not avoided coul
12. cccecceeesseeeeeeeseeeeeeeecaaeeeeegeeeeeeeaaeeeeeeeaeeeeeeal 5 1 5 1 Emergency Stopssri diare noei din atyp ends Sone Bert a iaai 5 1 5 1 1 PSR ESM4 2x1 1x2 up to PL C SIL 1 woe eeeeeeeeeceeeeeeeeeeeeeestaeeeeeeeeee 5 2 5 1 2 PSR ESL4 3x1 1x2 B up to PL C SIL 1 oo cecceeeeeeeeeeeeeeneeeeeeeeeeeteeeeniees 5 4 5 1 3 PSR ESD 4x1 30 up to PL C SIL 1 woe eeeececceeeeeeeeeeeeeeeeeeeeeetneetneeeneees 5 6 5 1 4 PSR ESAM4 2x1 1x2 up to PL C SIL 3 eee eeeeeeeeeeeeeeeeeeeeteeeteeeneees 5 8 5 1 5 PSR ESM4 3x1 1x2 B up to PL C SIL 3 oo eeeeeeceeeeceeeeeeeeetaeeeeeeaes 5 10 5 1 6 PSR ESL4 3x1 1x2 B up to PL d SIL 2 oo eeeeeeeeeeeeeeeeeteeetaeeeeeeeaes 5 12 5 1 7 PSR ESAM4 8x1 1x2 up to PL C SIL 3 eee ceeeeteeeeeeeeeeteeeeeeeaes 5 14 5 1 8 PSR ESD 4x1 30 up to PL e SIL 3 woe eeceeeceeeeeeceeeeeeeeeneettaeteneeeaes 5 16 5 1 9 PSR ESAM4 3x1 1x2 B up to PL C SIL 3 oo eeeeeeeceeseeeeeeeeeeeteeeeneeenaes 5 18 5 2 Light grids ESPE laser scanners AOPD ceccceseeeeeeeeeeeeaeeeeeeeeeestaeeeeeeeaes 5 21 5 2 1 PSR ESL4 3x1 1x2 B up to PL C SIL 3 oe eeeeececeeeeeeeeeteeetaeeeeeeeaes 5 22 5 2 2 PSR ESD 4x1 30 up to PL e SIL 3 oo ceceeececeeeeceeeeeeeeeeeettaeeeeeeeaes 5 24 5 2 3 PSR ESAM4 8x1 1x2 up to PL C SIL 3 oe eee eeeeceeeeeeeeeeeettaeteneeeaes 5 26 5 2 4 PSR ESD 4x1 30 up to PL d SIL 2 oo eeeceeccceeeseeceeeeeeseneeeeeseesseeeens 5 28 5 3 Movable quards isai pii ariii asai ee ec ed ie eaten 5 31 5 3 1 PSR ESA4 2x1 1x2 up to PL
13. 12 22 13 23 33 4 mM w Ww aes PSR ESL4 3x1 1x2 B TOY el H N N a A2 33 34 35 14 24 34 2 Q Q 9 Q M N Figure 5 3 Single channel emergency stop monitoring with manual reset PSR ESL4 3x1 1x2 B 5 4 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 button S1 and S12 of the safety relay Power The circuit is enabled via the reset button om 2 2 Press reset button S2 Contactor K3 is activated Power K1 K2 Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contactor K3 is button S1 opened Power K1 K2 Notes on the application example For additional diagnostic descriptions please refer to Section 7 a The emergency stop control device is positive opening according to EN 60947 5 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 Proven components and proven safety principles according to EN ISO 13849 2 must be used when applying category 1 The occurrence of a fault can lead to the loss of the safety function The connecting cables for the emergency stop control device should either be laid separately or protected against mechanical damage When using the sa
14. K3 K4 K3 Reset s2 K4 M N Figure 5 16 Two channel safety door monitoring with manual reset PSR ESAM4 2x1 stf aie Bot 5 34 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S11 S12 and 21 S22 of the safety relay Power The circuit is enabled via the reset button pie x K2 O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power IN1 2 K1 K2 Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are Be closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 When using safety hinge switches observe the notes in standards EN 953 EN 1088 example EN ISO 13857 and EN ISO 14119 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 Install the safety relay and contactors together in an installation space according to EN 60204 e g in the control cabinet
15. contactors etc the PFH value is calculated according to the subsystem type using a specific formula see Section 6 7 8 2 of EN 62061 For components that are subject to wear the failure rate is determined based on the number of operating cycles using the B10 value provided by the component manufacturer PHOENIX CONTACT 2 9 Application manual for PSR safety relays 2 3 6 Determination of the achieved safety integrity for the entire SRECS To determine the achieved safety integrity level the PFHg values of the individual subsystems must now be added together The result must lie within the SIL required for the safety function Table 2 2 Determination of the safety integrity level according to EN 62061 Safety Probability of a dangerous failure per hour PFHp integrity level 3 gt 108 to lt 107 2 gt 107 to lt 10 1 gt 10 to lt 10 Furthermore the SIL CL of an individual subsystem determines the maximum achievable SIL for the SRECS For safety components with integrated diagnostics this is provided by the manufacturer For subsystems consisting of discrete components this value must be determined using the table below Table 2 3 Determination of the safety integrity level for a subsystem with discrete components according to EN 62061 Safe failure fraction Hardware fault tolerance 0 1 2 lt 60 Not permitted 2 SIL 1 SIL 2 60 to lt 90 SIL 1 SIL 2 SIL 3 90 to l
16. 1 and must be able to function independently of the operating mode In order to stop a machine three stop categories are defined in EN 60204 1 which describe the stop control sequence independently of an emergency situation e Stopping by immediate removal of power to the machine drives i e an uncontrolled stop Figure 3 3 Stop category 0 example e Acontrolled stop with power available to the machine drives to achieve the stop power is removed only when the stop is achieved Figure 3 4 Stop category 1 example 3 4 PHOENIX CONTACT 102597_en_02 Safety technology basics Stop category 2 e Acontrolled stop with power available to the machine drives Figure 3 5 Stop category 2 example 102597_en_02 PHOENIX CONTACT 3 5 Application manual for PSR safety relays Insulation between input circuit and enabling current path Basic insulation between enabling current paths Reinforced insulation between the enabling current paths 3 4 Safe isolation Depending on the version the PSR safety relays have safe isolation between input and output and between the contacts Applications with 230 V low voltage can be connected reliably and safely PSR safety relays provide safe isolation reinforced insulation and 6 kV between the input circuit and the enabling current paths In EN 50178 safe isolation is required if SELV and PELV are switched together or led directly next to one another in a device
17. 42 2981428 PSR ESD 5x1 1x2 300 xX xX xX 3 21 1 4 e 3 5 44 7 5 2981431 Ordering data can be found PSR ESD T xX xX X 3 21 1 4 e 3 in the catalog 2963721 PSR THC4 X xX 2 1 4 e 3 5 58 7 2 2963983 2963734 PSR URM4 5x1 2x2 Contact extension 5 2 4 e 3 5 62 7 8 2964005 2981033 PSR URM4 5x1 2x2 B Contact extension 5 2 4 e 3 7 9 2981046 1 Delayed contacts only category 3 4 2 PHOENIX CONTACT 102597_en_02 Overview of safe switching devices 4 2 Modular safety relay system with PSR TBUS connection Table 4 2 Overview of PSR SDC4 modular safety relay system Type Application Output contacts Safety approval z e 2 e 2 z Eli Jost gt g 8s ee p 4 th ze i 1 foc al 2 S GB oL 88 33 Zz z are D w m lt A 2981486 6 2 PSR SDC4 2x1 B X X X X 2 12 4 e 3 6 4 7 10 2981499 6 6 2981677 PSR URM4 B Contact extension 4 2 4 e 3 6 10 7 11 2981680 2981732 2 PSR URD3 3 Contact extension 4 De 3 d 2 6 12 7 11 2981745 layed 2981512 2 PSR URD3 30 Contact extension 4 De 3 d 2 2981525 laye 2981703 2 PSR URD3 T2 Contact extension 4 De 3 d 2 2981729 layed 2 Non isolated 102597_en_02 PHOENIX CONTACT 4 3 Application manual for PSR safety relays 4 4 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays 5 App
18. 7 The emergency stop control device is positive opening according to EN 60947 5 1 Contactors K3 K4 and K5 have mirror contacts according to EN 60947 4 1 Stop category 1 describes a controlled stop with power available according to EN 60204 This means that the power is only switched off after the connected machine has stopped The brake is not part of the safety function Install the safety relay Fl and contactors together in an installation space according to EN 60204 e g in the control cabinet This prevents a cross circuit at the output of the safety relay When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 17 Application manual for PSR safety relays 5 1 9 PSR ESAM4 3x1 1x2 B up to PL e SIL 3 Two channel cable operated switch monitoring with manual reset with cross circuit detection Order No 2900509 with screw connection 2900510 with spring cage connection Technical data 24V AC DC 3enabling current paths 1 signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel cable operated s
19. ESAM4 8x1 1x2 up to PL e SIL 3 2 i Two channel emergency stop monitoring with manual reset with cross circuit detection Order No 2963912 with screw connection 2963996 with spring cage connection Technical data 24V AC DC 8 enabling current paths 1 signaling current path Monitored manual or automatic start Reinforced insulation basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring Cross circuit detection Ground fault detection Manual reset S33 S34 Feedback of contactor contacts K3 K4 K8 K9 K10 K11 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 Machine part 1 Machine part 2 Machine part 3 o fe fe o fo Ai S10 S11 S12 S21 S22 13 23 33 43 53 63 73 83 41 W W GND V LI L E PSR ESAM4 8x1 1x2 XAN 4 N MN y A2 33 34 S35 14 24 34 44 54 64 74 84 42 9 9 9 9 9 9 o 9 9 Ko pic K8 Qo Q1 a2 a ics K3 K6 M N gt Figure 5 8 Two channel emergency stop monitoring with manual reset
20. For subsystems consisting of discrete components e g switches contactors valves etc the PFHg value is determined from the category DC and MTTFg For components that are subject to wear the MTTF gis determined based on the number of operating cycles using the B10d value provided by the component manufacturer In addition for category 2 or higher the effect of common cause failure CCF must also be considered 2 2 7 Verification of the achieved PL Each individual subsystem and the entire safety chain must both meet the requirements of the necessary PL This includes both the quantitative evaluation and the consideration of systematic aspects such as proven components and safety principles The systematic aspects include Correct dimensioning of components Consideration of expected operating conditions and ambient conditions Use of basic and proven safety principles Avoidance of specification errors and software errors through testing 2 2 8 Validation The last step should check whether the selected measures achieve the necessary risk reduction and therefore the protection objectives of the risk assessment The result of the validation process is included in the final risk assessment The purpose of the validation process is to confirm the specification and level of conformity of the design of safety related parts of the control system SRP CS within the overall specifications for the safety requirements of th
21. PHOENIX CONTACT Table of contents 1 SMO CU CTO se aerie ae orsi aE esac ayia acide denen der A EE danse oaa a aia 1 1 1 1 Target group for this application MANUAl eeceeeeeeeeeneeeeneeeeeenaeeeeeeeeeeneeeeee 1 1 1 2 What s new in this version ccceccccecesceceeeeceeeeee essences eseeeeseeeesnseeeeseneeseeneeeeees 1 1 1 3 SYMDOIS USED isor eaa ana eaaa ed ae roer eE e aE e SN ENA 1 2 2 Safety of machines and systems ssssneesseeresererrtettrtttttrtsttrtntrtrnttrtntn parece hee aetna 2 1 2 1 Functionalisatety iien e a Oe eee a 2 2 2 2 Practical procedure according to EN ISO 13849 eceeeceeecceseeeeseeeeeeeseeeeeeeenaees 2 2 2 2 1 Definition of the safety function essssiesrreerierrrrrrrrresrireernsrrresns 2 2 2 2 2 Determination of the required performance level PL ssseeeeee 2 3 2 2 3 Technical implementation 0 0 eeeeeseeeeeesneeeeeeeeeenneeeeeaeeeeeeeeeeneeeeee 2 3 2 2 4 Dividing the safety function into subsystems cece eeseeeeeeeeeeeeeeees 2 4 2 2 5 Determination of the achieved PL for each subsystem eee 2 4 2 2 6 Determination of the achieved PL for the overall Savety TUMCON since ess eae fat des EE cated E hee oes 2 6 2 2 7 Verification of the achieved PL eesceeesseeeseeeeeneeesenaeeeeneeeeenaeeeeeaes 2 6 2 2 8 Validation s c 0 cn cave nie Say ae eee 2 6 2 3 Practical procedure according to EN ISO 62061 ccceeeceeecceseeeeeeeeeeeeseeeeeeeenaees 2 7 2 3 1 Speci
22. PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S12 button S1 and S22 of the safety relay Power The circuit is enabled via the reset button OK1 K2 O K3 t Ka 2 Press reset button S2 Contactor K3 is activated Power K1 K2 k3 t k4 t Stop Action Result Diagnostics 3 Press emergency stop The safety function is triggered and contactor K3 is button S1 opened immediately Power OK1 K2 K3 t Ka After the preset time has elapsed the delayed enable contacts of the safety relay are opened Power OK1 K2 Ok3 t Ka Notes on the application example For additional diagnostic descriptions please refer to Section 7 The emergency stop control device is positive opening according to EN 60947 5 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 Proven components and proven safety principles according to EN ISO 13849 2 must be used when applying category 1 The occurrence of a fault can lead to the loss of the safety function The connecting cables for the emergency stop control device should either be laid separately or protected against mechanical damage When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the s
23. SIL 3 l Two channel light grid monitoring with automatic reset ESPE type 4 Order No 2963912 with screw connection 2963996 with spring cage connection Technical data 24V AC DC 8 enabling current paths 1 signaling current path Monitored manual or automatic start Reinforced insulation basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel light grid monitoring Cross circuit detection via the light grid Manual reset S33 S35 Feedback of contactor contacts K3 and K4 at S33 and S35 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Light grid type 4 Receiver gt Te H OssD1 OSSD2 Transmitter 3 Al 10 S11 S12 21 22 13 23 33 43 53 63 73 83 41 K3 4 wo wh v 7 l l PSR ESAM4 8x1 1x2 oe ae a ie mM MW Y N D y N A2 S33 S34 35 14 24 34 44 54 64 74 84 42 7 e e r ee ee A K3 K4 K4 Q M N Figure 5 13 Two channel light grid monitoring with automatic reset PSR ESAM4 8x1 1x2 5 26 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description
24. Stop category 1 describes a controlled stop with power available according to EN 60204 This means that the power is only switched off after the connected machine has stopped The system behavior for category 3 permits that if a fault occurs e g the failure of a switching element in the emergency stop circuit the safety function is still maintained However the requirement that a single fault must be detected does not mean that all faults are detected An accumulation of undetected faults can lead to the loss of the safety function Install the safety relay and contactors together in an installation space according to EN 60204 e g in the control cabinet This prevents a cross circuit at the output of the safety relay When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_ 02 PHOENIX CONTACT 6 13 Application manual for PSR safety relays 6 14 PHOENIX CONTACT 102597_en_02 Diagnostic description 7 Diagnostic description Meaning of the LED symbols in the tables below LED OFF e LED ON X LED flashing 7 0 The table is valid for the following safety relays PSR ESL4 3x1 1x2 B PSR ESA2 4x1 1x2 B PSR ESAM2 8x1 1x2 B PSR ESAM4 3x1 1x2 PSR ESAM4 8x1 1x2 PSR THC4 2
25. Z x X Supply voltage not present Apply supply voltage Supply voltage too low Adjust supply voltage The enable circuits are connected incorrectly or not connected at all Check the connection of the enable circuits Between both enable circuits S11 S12 S10 and A2 S22 E g for emergency stop Cross circuit Between both enable circuits S12 and S10 The error is not detected by the module itself E g for light grid type 4 Remove cross circuit Short circuit between contact points A1 and A2 Between S11 and S12 or S10 and 12 Error detection on next demand Between S11 and S13 The error is detected immediately Between S10 and S12 The error is detected immediately Between A2 and S22 Error detection on next demand Remove short circuit e gt z xle o o o oo o Faulty reset button short circuit between S33 and S34 No error detection on initial start only on first new demand Replace reset button Remove short circuit Enable contact s of K1 faulty Error in reset circuit x Enable contact s of K2 faulty xt xt O A xt xt xt Xe xe 3 Oe et Ee fee st e et lt le fe xe 3A 3E Oe te fe Le le je ile ie xt ttle o ojo o oriolo Enable contact s of K1 and K2 faulty Replace the safety relay 7 10 PHOENIX CONTACT 102597_en_02 Diagnostic description
26. according to EN 62061 2 10 Diagnostic description reenen 7 1 DIN rail plug in CONNECHOTS ee eeeeeteeesteeeeeeeeeeneeeeeaes 6 1 E Emergency Stop iarrar ore sein es 5 1 EN 6206 Tapiterie iiia aa iS 2 7 EN IS W2000 METE ST 2 1 2 2 EN ISO 13849 iii ecg enact enn a 2 2 E able Swie ee a r eae e Ea ERRi 5 49 F Forcibly guided contacts eeeenenen 5 61 F netonalsafetyi osissa ea 2 2 G GUI EE PEE TE E at 5 31 l Interlocking device oo cece eeteeesseeeeeeeeeenneeeeeeeeeeneeees 5 31 L Laser SCANNE 3 ct4 ch essa ese Aerei heian 5 21 PIQMR GMC ETE eet iied lees ies nese thie a bbbastien ood 5 21 O Overview of safe switching devices cceeeeeeee 4 1 P Performance level D terminer an ok aria 2 3 Determine for a SUDSYStOM ceeceeeseeeerteeeeeeees 2 4 Determine for the overall safety function 2 6 Verification of the achieved PL sece 2 6 PRH E aia 2 10 R RISK Graphic piniaria ieee al 2 3 RISK TEGUCHON sirin ae eerie ye eens 2 2 S Safe isolation anain rehires teea 3 6 Safety CQUIDMENK ee ceeeeseeeeeecteeeeeetneeeteeeeeeeees 5 31 Safety function Definition according to EN ISO 13849 2 2 Dividing into subsystems eee eeeeeeeeeeees 2 4 2 8 Safety integrity level SIL eee ceeeeeeeeeeeeeeeeeeeneeenees 2 7 Determine inderne 2 7 Safety lifecycle os eeeceeceeeeeeeeeeeeaeteeeeeeeeeeaeeeaeeeaees 1 1 Safety Service eee ceeceeeeeceneeeeeeeeeeesae
27. examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 button S1 12 and S22 of the safety relay Power The circuit is enabled via the reset button om 2 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit Power are opened K1 K2 Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contactors K3 and button S1 K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are K1O closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive opening according to EN 60947 5 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 13 Application manual for PSR safety relays 5 1 7 PSR
28. fingers 3 Reversible medical treatment 2 Other measures SIL 1 Reversible first aid 1 F Frequency and duration W Probability of a hazardous event P Avoidance lt 1 hour 5 Frequent 5 gt 1 hour to lt 1 day 5 Probable 4 gt day to lt 2 weeks 4 Possible 4 Impossible gt 2 weeks to lt 1 year 3 Seldom 3 Possible 3 gt 1 year 2 Negligible 2 Probable 2 Figure 2 5 Example of specifying the SIL according to EN 62061 2 3 3 Drafting the safety related electrical control system SRECS This step involves the technical pre planning of the safety function taking possible technologies and components into account The safety related components and parts must then be identified for later verification 102597_en_02 PHOENIX CONTACT 2 7 Application manual for PSR safety relays 2 3 4 Dividing the safety function into subsystems Following technical implementation and identification of safety related components a safety related block diagram must be created for further evaluation As a rule a safety function consists of sensor logic actuator see Safety related block diagram according to EN 13849 1 on page 2 4 In the simplest case each one is a subsystem These subsystems are connected in series to form the overall safety function 2 3 5 Determination of the safety integrity for each subsystem A characteristic value when determining the safety integrity level SIL is the PFHg value
29. safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 29 Application manual for PSR safety relays 5 30 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays 5 3 Movable guards Guards with an interlocking device are designed for executing the following functions together with the machine control system The hazardous machine functions covered by the guard cannot be performed until the guard is closed Ifthe guard is opened while the hazardous machine functions are operating a stop command is triggered The hazardous machine functions covered by the guard can be performed as soon as the guard is closed Closing the guard does not automatically initiate the hazardous machine functions Interlocking devices can combine various functions and have a position monitoring function for guards The interlocking device detects whether or not the guard is closed and issues a stop command Some interlocking devices have a guard locking function which locks the guard while the hazardous machine functions are performed A separate status monitoring function for guard locking devices monitors whether the guard locking device is locked and generates a corresponding output signal Relevant standards EN 1088 Safety of machinery Interlocking device
30. the statistical probability of a dangerous failure per hour The safety characteristics for Phoenix Contact products can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet Standard EN 62061 describes the subsystem architectures type A to D which are similar to the categories of EN ISO 13849 1 Subsystem A Subsystem element 1 Subsystem element n J Figure 2 6 Logical representation of subsystem A according to EN 62061 Subsystem B Subsystem element 1 Det Failure resulting from a common cause i Subsystem element 2 De2 Figure 2 7 Logical representation of subsystem B according to EN 62061 2 8 PHOENIX CONTACT 102597_en_02 Safety of machines and systems Subsystem C Subsystem element 1 Det Diagnostic function s Subsystem element n A Den Figure 2 8 Logical representation of subsystem C according to EN 62061 Subsystem D Subsystem element 1 Det Diagnostic function s Subsystem element 2 De2 Failure resulting from a common cause Figure 2 9 Logical representation of subsystem D according to EN 62061 For subsystems with integrated diagnostic functions such as safety devices and safety controllers the achieved PFHg and SIL CL are provided by the manufacturer For subsystems consisting of discrete components e g switches
31. the Machinery Directive which provides standard specifications to support companies when designing safety related machines The aim is to eliminate barriers to trade within the EU However even outside the European Economic Area many European standards are gaining in importance due to their international status The fact that the safety of machines and systems not only depends on the components and technologies used but is mainly affected by the human factor is no surprise However the most important aspect is the way in which this fact is dealt with The main focus should not only be the safety products with their benefits and their functions but also easy handling and associated services The user expects considerably more support in these areas With the slogan simplicity means safety Phoenix Contact has integrated easy planning installation and operation of safety machines or systems and support over their entire lifecycle into its safety concept Safety does not have to be complicated or involve a great deal of additional effort Benefit from our expertise and experience as manufacturers of safety related components by using products with complete application examples and access our qualified service package in all phases of the safety lifecycle Should you have any questions please contact the Safety service team 49 5281 9 462777 safety service phoenixcontact com 1 1 Target group for this application manual Th
32. 1059 with screw connection 2981062 with spring cage connection Technical data 24V AC DC 3 enabling current paths 1 signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel light grid monitoring Cross circuit detection via the light grid Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Light grid type 4 Receiver amp OSSD1 OSSD2 Transmitter fo O fo o Ai 11 12 22 13 23 33 4 K3 4 H WwW w b SEE e PSR ESL4 3x1 1x2 B Ny a MW eS A2 33 S34 35 14 24 34 42 K4 4 Q g Q K4 SA K4 Reset 57 amp M N Figure 5 11 Two channel light grid monitoring with manual reset PSR ESL4 3x1 1x2 B 5 22 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 The light grid is active Both OSSD signals from the light grid provide high signals to there is no object in the enable circuit S12 and S22 of the saf
33. 2 Figure 5 21 Two channel safety door monitoring with delayed contacts and manual reset PSR ESD 5x1 1x2 300 eee 5 44 Figure 5 22 Two channel safety door monitoring with manual reset PSR ESL4 3xX1 1X2 B iip esris ine n eevee sabe vine oie 5 46 Figure 5 23 Three stage enable switch monitoring with automatic reset PSR ESAM4 2x1 1X2 ein enn eieren era a ees En EEEa aS EES 5 50 Figure 5 24 Two stage enable switch monitoring with manual reset PSR ESAM4 3x1 1X2 B oo eeeceeeceeceeeeceeeeeeaeeeeeeeaeeeaaeseeeeeaeeteaeenaees 5 52 Figure 5 25 Three stage enable switch with two channel emergency stop monitoring PSR ESAM4 2Xx1 oo eee teeeee tee teee tee eeneteneees 5 54 Figure 5 26 Structure of a two hand control device ee eee eee eee eeeeeeee 5 57 Figure 5 27 Two hand control device monitoring PSR THC4 2x1 1x2 a se 5 58 Figure 5 28 Application example emergency stop monitoring with contact extension PSR ESAM4 2x1 1x2 and PSR URM4 5x1 2x2 oe 5 62 A 2 PHOENIX CONTACT 102597_en_02 List of figures Section 6 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 PSR SDC4 2x1 B master module e ec eeceeeeeeeeeeeeeeeeeeeeeeeteaeeeneeeeees 6 1 Two channel emergency stop monitoring with manual reset PSR SDC4 2x1 Bs sic ui aosscasi a aea Ween ities 6 2 Two channel light grid monitoring with manual reset PSR SDC4 2x1 Bs ae eanan a aeaa a rate ween tend 6 4 Two channel
34. 2 argent A20 tokvz PSR SDC4 2x1 B K1 K20 tOS33 ees aA 330 poxi M HA MN MN w L9 A2 Y1 33 S34 35 14 24 Y30 9 E 9 9 9 K4 K3 Reset s2 K3 K4 e l M N Figure 6 3 Two channel light grid monitoring with manual reset PSR SDC4 2x1 B 6 4 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection Function description Start Action Result Diagnostics 1 The light grid is active Both OSSD signals from the light grid provide high there is no object in the signals to enable circuit S10 S12 of the safety relay Power protected field ae s K1 O Kx O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Stop Action Result Diagnostics 1 The light grid is interrupted The safety function is triggered by the interruption of the there is an object in the light grid and contactors K3 and K4 are opened protected field In the reset circuit the mirror contacts of K3 and K4 are closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The light grid ESPE must meet type 4 requirements from standard EN 61496 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 Stop category 0 describes an immediate stop by removal of powe
35. 22 of the safety relay K1O oK K2 Kx O 2 Press reset button S2 Contactors K3 K6 are activated and the mirror contacts N C contacts of K3 K6 in the reset circuit are opened kxk1 Ao Stop Action Result Diagnostics Diagnostics 1 Press emergency stop The safety function is triggered and contactors button S1 K3 K6 are opened In the reset circuit the mirror contacts of OK1 K3 K6 are closed He For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive opening according to EN 60947 5 1 example 2 Contactors K3 K4 K5 and K6 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 5 The holding brake is not part of the safety function 102597_en_02 PHOENIX CONTACT 6 11 Application manual for PSR safety relays rg Application example 6 5 2 PSR URD3 4x1 2x2 3 up to PL d SIL 2 Two channel safety door monitoring with delay contact extension and automatic reset Order No 2981732 with screw connectio
36. 2597_en_02 Safety of machines and systems Table 2 1 Explanation of categories Category Summary of requirements System behavior Principle to achieve safety B Safety related parts of control systems The occurrence of a fault can Mainly characterized by the and or their protective equipment as well lead to the loss of the safety selection of components as their components shall be designed function constructed selected assembled and combined in accordance with relevant standards so that they can withstand the expected influences Basic safety principles must be used 1 The requirements of category B must be The occurrence of a fault can Mainly characterized by the met Proven components and proven lead to the loss of the safety selection of components safety principles must be used function but the probability of occurrence is lower than that for category B 2 The requirements of category B andthe use The occurrence of a fault can Mainly characterized by the of proven safety principles must be met lead to the loss of the safety structure The safety function must be tested by the function between the tests machine control system at suitable The loss of the safety function intervals is detected by the test 3 The requirements of category B andthe use When the single fault occurs Mainly characterized by the of proven safety principles must be met the safety function is always structure
37. 2981813 with spring cage connection Technical data 24VDC 2undelayed enabling current paths 2 delayed enabling current paths Adjustable delay time 0 30 s Manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel light grid monitoring Cross circuit detection via the light grid Manual reset A1 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Light grid type 4 Receiver A a S OSSD1 OSSD2 n Al S11 S12 21 22 lt 01 13 23 37 ar Clock W Clock PET ie p a PSR ESD 4x1 30 Dei Yo ora 10 MN N I 2 A2 S34 S35 30 14 24 38 48 9 Q 2 9 9 2 M N Figure 5 12 Two channel light grid monitoring with manual reset PSR ESD 4x1 30 5 24 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 The light grid is active Both OSSD signals from the light grid provide high signals to there is no object in the enable circuit S12 and S22 of the safety relay Power protected field The circuit is enabl
38. 2x1 1x2 Y PSR ESAM4 2x1 1x2 Yy tl M N 7 MN TYT S34 35 14 24 32 A2 S34 S35 14 24 32 9 9 9 9 q 9 9 K5 KS1 T KS2 K5 Enable switch K3 operation Tka Ks Ke K6 A 4 M N Figure 5 25 Three stage enable switch with two channel emergency stop monitoring PSR ESAM4 2x1 5 54 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics Diagnostics KS1 KS2 1 Unlock emergency The emergency stop circuit supplies the safety relay stop button S1 KS1 Power Power IN1 2 IN1 2 O K1 K1 K2 K2 The enable is expected via the reset button S3 2 Press reset button S3 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset Power ape Power circuit are opened IN1 2 IN1 2 O K1 K1 O K2 K2 O Manual mode 1 Switch on switch S2 The switch S2 manual mode supplies the safety relay KS2 Power Power IN1 2 IN1 2 O K1 K1O K2 K2 O Enable 1 Enable switch B1 The enable is expected via the enable switch B1 function stage 1 not activated Power Power IN1 2 IN1 2 O K1 K1 O K2 Kx O 2 Enable switch B1 The enable switch B1 closes sensor circuit S11 stage 2 enable 12 and S21 S22 at the second safety relay KS2 The automatic res
39. 4 2963750 PSR ESA4 2x1 1x2 X xX 2 1 4 e 3 5 32 7 3 2963938 2963705 PSR ESM4 2x1 1x2 xX xX 2 1 4 e 3 5 2 2963718 2963776 PSR ESM4 3x1 1x2 B xX X 3 1 4 e 3 5 10 7 1 2963925 2901430 PSR ESAM2 3x1 1x2 B xX xX 3 1 2 d 2 7 2 2901431 2900525 5 8 5 34 7 2 PSR ESAM4 2x1 1x2 X xX 2 1 4 e 3 2900526 5 50 7 3 5 54 2900509 PSR ESAM4 3x1 B x x 3 1 4 e 3 2900510 24 V AC DC 2901416 PSR ESAM4 3x1 B X X 3 1 4 e 3 2901417 42 48 V AC DC 2901426 PSR ESAM4 3x1 B 5 18 xX X 3 1 4 e 3 5 38 7 1 2901427 60 V AC DC 5 52 2901422 PSR ESAM4 3x1 B X X 3 1 4 e 3 2901425 120 V AC DC 2901428 PSR ESAM4 3x1 B X X 3 1 4 e 3 2901429 230 V AC DC 2981114 PSR ESAM4 3x1 1x2 Xx xX 3 1 4 e 3 5 36 2981127 2963912 5 14 PSR ESAM4 8x1 1x2 xX xX xX 8 1 4 e 3 5 26 7 2 2963996 a 102597_en_02 PHOENIX CONTACT 4 1 Application manual for PSR safety relays Table 4 1 Overview of PSR safety relays Type Application Output contacts Safety approval 5 a aie Ela S Jol v Order z o 18 o gt g 9 No as a Se selo S o o gt 0 88 a g D oe Si onee Z Z fi Se g 2981059 5 4 PSR ESL4 3x1 1x2 B x x x 3 1 4 e 3 255 72 2981062 E 5 46 2981800 5 6 5 16 5 24 PSR ESD 30 xX xX X 2 2 0 4 e 3 5 28 7 7 2981813 7 5 40 5
40. C SIL 3 ooo eeeeeeteeetteeeeeeeeeeetaeeeeeeeaes 5 32 5 3 2 PSR ESAM4 2x1 1x2 up to PL C SIL 3 eee eee eeeeeeeeceeeeeteeeteeeeeeaes 5 34 5 3 3 PSR ESAM4 3x1 1x2 up to PL SIL 3 eee ee eeeeeeeeceeeeeneeeteeeeeeaes 5 36 5 3 4 PSR ESAM4 3x1 1x2 B up to PL C SIL 2 oo eeeeeeececeeeeeeeeeteeetteeeneeenaes 5 38 5 3 5 PSR ESD 4x1 30 up to PL C SIL 2 oo eee ceeeeeeeteeeteeeeeeetneeteaeeeeeeeaes 5 40 5 3 6 PSR ESD 4x1 30 up to PL e SIL 3 oo ceceeeeeceeeeceeeeeeeeeneestaeeeneeeaes 5 42 5 3 7 PSR ESD 5x1 1x2 300 up to PL C SIL 3 oo eeeeeeeteeeeeeeeeeeteeeteeeeeeaes 5 44 5 3 8 PSR ESL4 3x1 1x2 B up to PL d SIL 2 oo eeeeeeceeeeeeeeeeteeetaeeeeeeaes 5 46 5 4 Enable switch sesini lh neck sei eh ete et ghee deine 5 49 5 4 1 PSR ESAM4 2x1 1x2 up to PL C SIL 3 eee eeceeeeeteeeeeeeeeeeeteteeeeeaes 5 50 5 4 2 PSR ESAM4 3x1 1x2 B up to PL C SIL 3 oo eeeeeecceeeeeeeeeeeeeeeeteeeeenaes 5 52 5 4 3 PSR ESAM4 2x1 1x2 up to PL C SIL 3 eee ee eeeeceeeeeeeeeeetteteneeeaes 5 54 5 5 Two hand control device is is ea i venice e a a a ati 5 57 5 5 1 PSR THC4 2x1 1x2 up to PL e SIL 3 snsnnsnnnsnsnsnnnasesnsinsrssnresnsnseneeene 5 58 5 6 Contact extension forcibly guided contacts ecceceeeceeeeceeeeteeeeeeetteeteeeeeeeea 5 61 5 6 1 PSR URM4 5x1 2x2 up to PL C SIL 3 oo eee eeeceeeteeceeeeeeeeeeeeetaeeeeeeenes 5 62 6 Application examples for modular safety relay system with PSR TBUS connection 6 1 6 1 PSR SDC4 2x1 B master MOUIE ccc
41. CONTACT 102597_en_02 Diagnostic description The table is valid for the following safety relays 1 PSR ESD 5x1 1x2 300 2 PSR ESD 5x1 1x2 T Table 7 3 Diagnostic description for PSR ESD 5x1 1x2 safety relays Error Remedy Valid for P K1 K K3 t KA t Supply voltage not present Apply supply voltage Supply voltage too low Adjust supply voltage The enable circuits are connected incorrectly or Check the connection of the enable circuits not connected at all voltage error xe ANANE xt et et fe Connection No bridge between Y1 and Y2 Insert bridge No bridge between S10 and S11 so Insert bridge E g for two channel emergency stop wiring Between both enable circuits S10 S11 S12 and 21 S22 E g for emergency stop or safety door g inde Mat y Remove cross circuit All Between both enable circuits S10 and S12 E g for light grid type 4 Cross circuit Short circuit between contact points A1 and A2 Between S11 and S12 Error detection on next demand Remove short circuit Short circuit Between S21 and S22 Error detection on next demand o x o o o ojo o oo eieie iei e o o e o o ojo o ooo x xR e o o o ojo o o o xt xt Faulty reset button short circuit between S33 and S34 No error detection on initial start only on first new demand Remove short circuit Error in reset circuit
42. Device with a sensor function that is generated by optoelectronic transmit and receive elements which detects the diffuse reflection of optical radiation generated in the device by an object located in a protective field specified in two dimensions Active optoelectronic protective device Device with a sensor function that is generated by optoelectronic transmit and receive elements which detects the interruption of optical radiation generated in the device by an opaque object located in the specified protective field or for an optical data link on the axis of the light beam In DIN EN 692 mechanical presses DIN EN 693 hydraulic presses and EN 12622 hydraulic trimming presses the abbreviation AOS is used as a synonym for AOPD Safety related control function safety function Safety related electric electronic programmable electronic control system 102597_en_02 PHOENIX CONTACT A 1 Application manual for PSR safety relays A 2 PHOENIX CONTACT 102597_en_02 A4 Index A ASSUME CFFCCT nasdena tnng 2 1 C Cable lengths EEEE TEET 3 2 Example fis Asta ink eee 3 3 Category s s oe hence tienes 2 4 2 5 Contact extension cceccccseeeceeeeeeeeeeeeeeseeeeeeeeeees 5 61 Cross circuit detection eeeeeceeeteeeeeeeeeeeeeeeseeeereeens 3 1 D Determination of the safety integrity level according to EN 62061 2 10 Determination of the safety integrity level for a subsystem with discrete components
43. Due to the internal structure and the insulation properties between the input and the contacts in Phoenix Contact PSR safety relays 230 V AC for example can be switched without any limitations Depending on the type the output contacts 13 14 23 24 etc are isolated from one another using basic insulation or reinforced insulation Impulse voltage withstand level 4 kV A mixture of SELV and PELV is strictly prohibited Only switch 230 V AC at one of the enable contacts if the adjacent contact carries the same potential Impulse voltage withstand level 6 kV Reinforced insulation e g greater air and creepage distances between conductive paths is designed for a higher surge voltage category than basic insulation Therefore SELV circuits U lt 25 V AC or U lt 60 V DC and circuits with higher voltages can be mixed 3 6 PHOENIX CONTACT 102597_en_02 Overview of safe switching devices 4 Overview of safe switching devices Phoenix Contact offers a comprehensive range of products for safety functions in mechanical engineering 4 1 PSR safety relays Table 4 1 Overview of PSR safety relays Type Application Output contacts Safety approval a o gt 9 Va D Order oa s a8 es a 2 No as 22 SO sea a amp So e za lZ A 2 S 2 2 g Zz Z al S 3 Ww Ww lt a 2963802 PSR ESA2 4x1 1x2 B X xX 4 1 2 d 3 7 2 296395
44. FETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 53 Application manual for PSR safety relays 5 4 3 PSR ESAM4 2x1 1x2 up to PL e SIL 3 Three stage enable switch with two channel emergency stop monitoring cross circuit detection Order No 2900525 with screw connection 2900526 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Three stage enable switch monitoring Two channel emergency stop monitoring Cross circuit detection Ground fault detection S11 S12 only Manual reset S12 S34 at safety relay KS1 Automatic reset S12 S35 at safety relay KS2 Feedback of contactor contacts K5 and K6 at S35 at safety relay KS2 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Emergency stop q S1 o Y amp bet cane Emergency stop operation iss oS K4 Al S11 S12 21 22 13 23 31 Al S11 S12 21 22 13 233 31 w GND w J 4 GND v Ill PSR ESAM4
45. NAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 51 Application manual for PSR safety relays 5 4 2 PSR ESAM4 3x1 1x2 B up to PL e SIL 3 Two stage enable switch monitoring with manual reset cross circuit detection Order No 2900509 with screw connection 2900510 with spring cage connection Technical data 24V AC DC 3 enabling current paths 1 signaling current path Manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two stage enable switch monitoring Cross circuit detection Ground fault detection S11 S12 only Manual reset S12 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Enable switch 1 92 1 E1 E2 m BA Ai s11 s12 s2 y i 22 v GND 4 K4 4 PSR ESAM4 3x1 1x2 B A2 S34 S35 t f Reset S2 K3 K3 K4 M N Figure 5 24 Two stage enable switch monitoring with manual reset PSR ESAM4 3x1 1x2 B sets paii Bot o A A p 5 52 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function descrip
46. NIX CONTACT 102597_en_02 Application examples for PSR safety relays 5 5 Two hand control device According to EN 574 the simultaneity of two hand control devices must be monitored to be lt 0 5 seconds The time is reliably checked and evaluated by corresponding category type Ill modules Two hand control devices are localized safety equipment The operator must keep his her hands on the control device during dangerous machine movements Table 5 1 Requirements according to EN 574 Requirements according to EN 574 Type Type Il Type Ill Use of both hands simultaneous actuation Relationship between input signals and output signals only both input signals gt output signal Prevention of accidental operation Prevention of defeat x x x Re initiation of an output signal only once both input signals are finished gt re initiation of the output signal is possible lt X Xx Xx xX KK XxX XD xX XX X XxX 0O xX X Xx XxX X Synchronous actuation simultaneous actuation within 0 5 seconds Safety category 1 application EN 954 1 Safety category 2 application EN 954 1 Safety category 3 application EN 954 1 Manual control e g emergency stop button Control device Input command 1st hand 2nd hand Synchronous actuation input signal Initiation of the 1st Initiation of the 2nd Cessation of the
47. PSR ESAM4 8x1 1x2 5 14 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 S12 button S1 and S21 S22 of the safety relay Power The circuit is enabled via the reset button 3 2 Press reset button S2 Contactors K3 K4 K8 K9 K10 and K11 are activated and the mirror contacts N C contacts of K3 K4 K8 K9 K10 Power K11 in the reset circuit are opened K1 Once alarm contacts 41 and 42 of the safety relay have been K2 opened the PLC activates contactors K5 K6 and K7 depending on the user program All three machine parts are activated Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and machine parts 1 3 are button S1 deactivated Power In the reset circuit the mirror contacts of K3 K4 K8 K9 K1O K10 and K11 are closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive opening according to EN 60947 5 1 example 2 Contactors K3 K4 K8 K9 K10 and K11 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the
48. S34 S35 14 24 K4 4 Q 34 _ K3 k4 Reset ese Ez T K4 M N Figure 5 17 Two channel safety door monitoring with manual reset PSR ESAM4 3x1 5 36 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S11 S12 and 21 S22 of the safety relay Power The circuit is enabled via the reset button os 3 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power K1 K2 Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are A closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The position switch is positive opening according to EN 60947 5 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety charact
49. SR safety relays 5 60 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Forced guidance 5 6 Contact extension forcibly guided contacts Often more contacts are required than are available as standard For these applications the forcibly guided contact extension modules are used They can be connected as modules as required Standard EN 50205 makes a distinction between two groups of relays with forcibly guided contacts Application type A relay with forcibly guided set of contacts Application type B relay with a forcibly guided set of contacts and other contacts which are not forcibly guided as well as a contact set with PDTs The definition of forced guidance according to EN 50205 is The relay must be designed so that none of the mechanically connected N C contacts can close if a N O contact is closed and none of the mechanically connected N O contacts can close if a N C contact is closed These requirements apply for the entire service life of the relay and for reasonably foreseeable failure conditions The effects of reasonably foreseeable breaks and or wear on parts of the elementary relay must not cause the mechanical forced guidance to fail During the entire relay service life specified by the manufacturer the contact distances of opened contacts must be greater than 0 5 mm for a single N C contact and greater than 0 3 mm each for a double interrupt Mechanical forced gu
50. Safety related parts must be designed so performed Some but not all that faults are detected An Asingle fault in accumulation of undetected faults can lead to the loss of any of these parts does not lead to the loss the safety function of the safety function and the single fault is detected whenever this is feasibly possible 4 The requirements of category B andthe use When the single fault occurs Mainly characterized by the of proven safety principles must be met Safety related parts must be designed so that A single fault in any of these parts does not lead to the loss of the safety function and the single fault is detected on or before the next demand of the safety function If detection is not possible an accumulation of undetected faults must not lead to the loss of the safety function the safety function is always performed The detection of accumulated faults reduces the probability of the loss of the safety function high DC The faults are detected in time to prevent a loss of the safety function structure 102597_en_02 PHOENIX CONTACT 2 5 Application manual for PSR safety relays 2 2 6 Determination of the achieved PL for the overall safety function For subsystems with integrated diagnostic functions such as safety devices and safety controllers the achieved PFHg and PL are provided by the manufacturer with the specification of the category
51. This prevents a cross circuit at the output of the safety relay 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 35 Application manual for PSR safety relays mg 5 3 3 PSR ESAM4 3x1 1x2 up to PL e SIL 3 F Two channel safety door monitoring with manual reset with cross circuit detection Order No 2981114 with screw connection 2981127 with spring cage connection Technical data 24 230 V AC DC 3 enabling current paths 1 signaling current path Manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel safety door monitoring with two position switches Cross circuit detection Ground fault detection S11 S12 only Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Safety door open AI sio s11 Si2 S21 22 K3 p 4 GND 4 l l l PSR ESAM4 3x1 VARAS a H MN WwW yr A2 33
52. actors K3 to K8 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 The system behavior for category 4 permits that if a single fault occurs the safety function is always executed and the single fault is detected on or before the next demand of the safety function Install the safety relay with the contact extension in an installation space e g in the control cabinet This prevents a cross circuit at the output of the safety relay When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 63 Application manual for PSR safety relays 5 64 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection 6 Application examples for modular safety relay system with PSR TBUS connection 6 1 PSR SDC4 2x1 B master module Automatic mode selection The intelligent master safety relay automatically identifies the desired operating mode via the sensor connections This means that switches do not have to be set on the device The clearly arranged design of the modular safety relays helps you to quickl
53. agnostic description for PSR ESAM4 and PSR ESA4 Safety roly Sisiane i a aaa e a a tah 7 3 Diagnostic description for PSR ESD 5x1 1x2 safety relays 7 5 Diagnostic description for PSR ESD 4x1 30 safety relay 7 6 Diagnostic description for PSR URM4 5x1 2x2 safety relay 7 8 Diagnostic description for PSR URM4 5x1 2x2 B safety relay 7 9 Diagnostic description for PSR SDC4 2x1 B safety relay 7 10 Diagnostic description for PSR URM4 4x1 2x2 B safety relay 7 11 Diagnostic description for PSR URD3 4x1 safety relays 7 11 102597_en_02 PHOENIX CONTACT A 5 Application manual for PSR safety relays A 6 PHOENIX CONTACT 102597_en_02 Performance level PL Category Safety integrity level claim limit SIL CL Probability of a dangerous failure per hour PFHg Mission time ty Probability of failure on demand low demand PFD DC MTTF AOPDDR AOPD SRCF SRECS A3 Explanation of terms Classification of the ability of safety functions to meet a safety requirement Classification of the resistance to faults according to EN ISO 13849 1 SIL claim limit suitability Probability of a dangerous failure per hour Duration of use Probability of failure relative to the number of demands Diagnostic coverage Mean time to failure Active optoelectronic protective device responsive to diffuse reflection
54. al reset PSR ESAM4 3x1B 5 38 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close and lock the safety The safety door circuit closes enable circuit S11 S12 and door 21 S22 of the safety relay Power The circuit is enabled via the reset button pie x K2 O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power IN1 2 K1 K Stop Action Result Diagnostics 1 Unlock guard locking B1 The safety function is triggered and contactors K3 and K4 via button S3 are opened Power 2 Open the safety door In the reset circuit the mirror contacts of K3 and K4 are Be closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The safety guard locking is positive opening according to EN 60947 5 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet
55. anual reset PSR ESM4 3x1 1x2B 5 10 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 button S1 12 and S21 S22 of the safety relay Power The circuit is enabled via the reset button S 5 K2 O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit Power are opened IN1 2 K1 K2 Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contactors K3 and button S1 K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are IN1 2 O closed K1 O K2 O Notes on the application example For additional diagnostic descriptions please refer to Section 7 a The emergency stop control device is positive opening according to EN 60947 5 1 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 Install the safety relay and contactors together in an installation space according to EN 60204 e g inthe control cabinet This prevents a cross circuit at the output of the safety relay When using the safety relay take into consideration the maximum permissible n
56. ay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 33 Application manual for PSR safety relays rg Application example 5 3 2 PSR ESAM4 2x1 1x2 up to PL e SIL 3 Two channel safety door monitoring with manual reset with cross circuit detection Order No 2900525 with screw connection 2900526 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Two channel safety door monitoring with one safety hinge switch Cross circuit detection Ground fault detection S11 S12 only Manual reset S12 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L 24V B Safety hinge switch ziel COR H a Jane fo ea iets Sane uo 12 1 22 Q o fo K4 lt keJ O o A1 S11 12 21 S22 v GND 4 PSR ESAM4 2x1 1x2 N M A2 34 S35 __
57. ccording to EN 62061 Application example Single channel emergency stop monitoring Manual reset S33 S34 Stop category 0 Safety level of the example up to PL c EN ISO 13849 1 and SIL 1 EN 62061 L L1 Emergency stop qn S1 Ai S11 12 21 22 13 23 31 W GND 4 ti gh 5 PSR ESM4 2x1 1x2 EN K3 H N y y A2 33 S34 14 24 32 i Q Q 9 Reset SA S2 Lks M N 4 Figure 5 2 Single channel emergency stop monitoring with manual reset PSR ESM4 2x1 1x2 5 2 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop circuit supplies the safety relay button S1 The circuit is enabled via the reset button Be z K1 K2 O 2 Press reset button S2 Contactor K3 is activated Power IN1 2 K1 K2 Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contactor K3 is button S1 opened Power IN1 2 O K1 Kx O Notes on the application example For additional diagnostic descriptions please refer to Section 7 i The emergency stop control device is positive opening according to EN 60947 5 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element accord
58. ceeecceeeeeeeeeceeeeeaeeeeeeceaeeeaeeseeeeseeeeeeenaees 6 1 6 2 PSR SDC4 2x1 B up to PL C SIL 3 0 cee eee eee see sees eeeeeecesesseeeseesesensneeneees 6 2 6 3 PSR SDC4 2x1 B up to PL e SIL 3 eeeceeeceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeseeeeseeseeeenaees 6 4 6 4 PSR SDC4 2x1 B up to PL e SIL 3 eeeeeecceeseeeeeeeeaeeeaeeeeeeeaesteeeeneeesaeeeeeeenaees 6 6 6 5 Contact extension forcibly guided contacts eeeeeceeeeeeeeeeeteeeteeteeeecneeeeaeeeeeeesas 6 9 6 5 1 PSR URM4 4x1 2x2 B up to PL SIL 3 ooo eeeceeeeeceeeeeeeeeteeeteeeeeeeaes 6 10 6 5 2 PSR URD3 4x1 2x2 3 up to PL d SIL 2 ooo eececeeceseeeeeeeeeeeesteeeeeeeaes 6 12 ii PHOENIX CONTACT 102597_en_02 Table of contents Z Diagnostic description cerceii hed a teen eRe eee 7 1 A Appendix for document liStSxiccccscectiiteatinn nation ieelasexiecceatasands Gaede cnteeie eases eee A 1 A1 Eist OF TIQUIOS zns naon aae Aled oaao EE a a aai A 1 A2 ROKE oE EE EE E EE AA AT A 5 A4 INGOX sie A tities Sia ea a ada ie a ea A 3 102597_en_02 PHOENIX CONTACT iii Application manual for PSR safety relays iv PHOENIX CONTACT 102597_en_02 Introduction 1 Introduction The term safety derives from Latin and refers to astate that is free from unacceptable risks This fundamental human requirement is also enshrined in basic EU law The safety of machines and systems mainly depends on the correct application of standards and directives In Europe the basis for this is
59. d result in death or serious injury CAUTION This indicates a hazardous situation which if not avoided could result in minor or moderate injury This symbol together with the signal word NOTE and the accompanying text 1 alert the reader to a situation which may cause damage or malfunction to the device hardware software or surrounding property This symbol and the accompanying text provide the reader with additional information or refer to detailed sources of information How to contact us Up to date information on Phoenix Contact products and our Terms and Conditions can be found on the Internet at www phoenixcontact com Make sure you always use the latest documentation It can be downloaded at www phoenixcontact net catal If there are any problems that cannot be solved using the documentation please contact your Phoenix Contact subsidiary Subsidiary contact information is available at www phoenixcontact com PHOENIX CONTACT GmbH amp Co KG FlachsmarktstraBe 8 32825 Blomberg GERMANY Should you have any suggestions or recommendations for improvement of the contents and layout of our manuals please send your comments to tecdoc phoenixcontact com PHOENIX CONTACT Please observe the following notes General terms and conditions of use for technical documentation Phoenix Contact reserves the right to alter correct and or improve the technical documentation and the products described in the technica
60. descriptions please refer to Section 7 Notes on the application 1 The cable operated switch is positive opening according to EN 60947 5 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 19 Application manual for PSR safety relays 5 20 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Relevant standards Examples of use 5 2 Light grids ESPE laser scanners AOPD Light grids Light grids consist of a transmit and receive unit and have a two dimensional monitoring range Light grids are electrosensitive protective elements used to protect operating personnel working on or in the vicinity of dangerous machines Compared to mechanical systems they offer the advantage of contact free and therefore wear free operation Please note the following factors when using light grids The light grids must be installed in such a way that it is impossible to access the protected field from above below or behind If this is n
61. e machinery Before validation of the design of the SRP CS or the combination of SRP CS that contains the safety function the specification requirement for the safety function must be confirmed Validation involves performing analysis and function tests under normal conditions in accordance with the validation plan EN ISO 13849 2 contains detailed requirements and describes the basic procedure for the individual validation processes 2 6 PHOENIX CONTACT 102597_en_02 Safety of machines and systems 2 3 Practical procedure according to EN ISO 62061 In practice the following steps have proven effective when designing safe controllers according to EN 62061 2 3 1 Specification of requirements for the safety related control function SRCF The safety function must be defined first This information is derived from the risk assessment Example Trigger event Opening the safety door Response The robot drive is set to a safe stop state The power semiconductor pulses are disabled Safe state Power circuit has no power 2 3 2 Determination of the required safety integrity level SIL The required SIL is determined in combination with the safety function within the framework of the higher level risk assessment Effect Severity Class Class Class Class Class S 3 4 5 7 8 10 11 13 14 15 Death loss of an eye or arm 4 SIL 2 SIL 2 SIL 2 SIL 3 SIL 3 Permanent loss of
62. ease refer to Section 7 Notes on the application 1 The magnetic safety switch must meet the requirements of EN 60947 5 3 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 6 7 Application manual for PSR safety relays 6 8 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection Forced guidance 6 5 Contact extension forcibly guided contacts Often more contacts are required than are available as standard For these applications the forcibly guided contact extension modules are used They can be connected as modules as required Standard EN 50205 makes a distinction between two groups of relays with forcibly guided contacts Application type A relay with forcibly guided set of contacts Application type B relay with a forcibly guided set of contacts and other contacts which are not forcibly guided as well as a contact set with PDTs The definition of forced guidance according to EN 50205 is The relay must be designed so that none of the mechanically connected N C contacts can close if a N O contact is c
63. ed via the reset button OK1 K2 O K3 t Ka 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power K1 K2 K3 t a t Stop Action Result Diagnostics 1 The light grid is The safety function is triggered by the interruption of the light interrupted there is an grid and contactors K3 and K4 are opened Power cea inne protected In the reset circuit the mirror contacts of K3 and K4 are OK1 K2 ie closed k3 t Kae After the preset time has elapsed the delayed enable contacts of the safety relay are opened Power OK1 K2 Ok3 t Ka For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The light grid ESPE must meet type 4 requirements from standard EN 61496 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 25 Application manual for PSR safety relays E 5 2 3 PSR ESAM4 8x1 1x2 up to PL e
64. eeeeeeeeesnaeeeeeeeaes 1 1 SAG ivissdeaniiesdstaitei ied ede 2 7 SRECS critic dst te caliper sacar tie mosis aan 2 7 Stop category Ou eeceeceessesseeceeeeceeeteeeeeeeeesaeeneeeeaees 3 4 Stop category Tiani onat Aen doled 3 4 Stop category 2 acc iieiiitens cilsevscetescifseghits dstanasatiwiates 3 5 T BUS ssc ene a ee eee 6 1 Two hand Control devices 5 57 102597_en_02 PHOENIX CONTACT A 3 Application manual for PSR safety relays A 4 PHOENIX CONTACT 102597_en_02
65. el safety door monitoring with automatic reset PSR ESA4 2x1 1x2 5 32 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S11 S12 and 21 S22 of the safety relay Power Contactors K3 and K4 are activated and the mirror contacts IN1 2 N C contacts of K3 and K4 in the reset circuit are opened es Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are IN1 2 O closed K1 O K2 O Notes on the application example For additional diagnostic descriptions please refer to Section 7 a The position switch is positive opening according to EN 60947 5 1 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 A restart should only occur automatically if there is no hazardous situation Please refer to the detailed information in standard EN ISO 12100 6 3 3 2 5 Install the safety relay and contactors together in an installation space according to EN 60204 e g inthe control cabinet This prevents a cross circuit at the output of the safety relay When using the safety rel
66. eristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 37 Application manual for PSR safety relays mg 5 3 4 PSR ESAM4 3x1 1x2 B up to PL d SIL 2 F Two channel safety door monitoring with manual reset with cross circuit detection Order No 2900509 with screw connection 2900510 with spring cage connection Technical data 24V AC DC 3enabling current paths 1 signaling current path Manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel safety door monitoring with guard locking Cross circuit detection Ground fault detection S11 S12 only Manual reset S12 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 L L1 unlock F s3 Downtime monitor oR Safety switch with B1 guard locking O L E1 a Ro Pye a 7 11 12 21 22 E2 N koJ O O oO fo A1 S11 12 S21 22 13 23 3 4 4 GND 4 l l PSR ESAM4 3x1 1x2 B tsr a M M Y 1 9 Figure 5 18 Two channel safety door monitoring with manu
67. et function closes enabling current Power Power paths 13 14 and 23 24 at the second safety relay B ye k KS2 K2 k2 Holding down the enable switch B1 keeps the safety function at the first safety relay KS1 active Stop Action Result Diagnostics Diagnostics KS1 KS2 1 Enable switch stage 3 The safety function is triggered and contactors K3 pushed through K6 are opened immediately Power Power In the reset circuit the mirror contacts N C contacts w2 aes of K3 K6 of both safety relays KS1 and KS2 are K2 O Kz O closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive opening according to EN 60947 5 1 example 2 When using enable switches observe the notes in standards EN 60204 EN ISO 10218 EN 1088 and EN ISO 13849 1 3 Contactors K3 K4 K5 and K6 have mirror contacts according to EN 60947 4 1 4 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 102597_en_02 PHOENIX CONTACT 5 55 Application manual for PSR safety relays 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 5 56 PHOE
68. ety relay Power protected field The circuit is enabled via the reset button os 3 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power K1 K2 Stop Action Result Diagnostics 1 The light grid is The safety function is triggered by the interruption of the light interrupted there is an grid and contactors K3 and K4 are opened Power o in theprotected In the reset circuit the mirror contacts of K3 and K4 are A closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The light grid ESPE must meet type 4 requirements from standard EN 61496 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 23 Application manual for PSR safety relays 5 2 2 PSR ESD 4x1 30 up to PL e SIL 3 Two channel light grid monitoring with manual reset ESPE type 4 Order No 2981800 with screw connection
69. evel of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 7 Emergency stop ox f page eee S1 O fo O Al 22 10 S11 S12 S13 13 23 Foar W w W Alo loa2 GND aN A20 os33 PSR SDC4 2x1 B x 33301 i mH WwW Sw Le A2 Y1 S33 S34 S35 14 24 Y30 Q 2 9 Q k KS K3 Reset K4 s2 K4 M N Figure 6 2 Two channel emergency stop monitoring with manual reset PSR SDC4 2x1 B 6 2 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes the first enable circuit via button S1 10 S11 and S12 and the second enable circuit via A2 and Power S22 of the safety relay N2 s The circuit is enabled via the reset button ae z 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Stop Action Result Diagnostics 1 Press emergency stop The safety function is triggered and contactors K3 and K4 button S1 are opened In the reset circuit the mirror contacts of K3 and K4 are closed For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The emergency stop control device is positive o
70. fety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 5 Application manual for PSR safety relays Application example 5 1 3 PSR ESD 4x1 30 up to PL c SIL 1 Single channel emergency stop monitoring with manual reset Order No 2981800 with screw connection 2981813 with spring cage connection Technical data 24V DC 2 undelayed enabling current paths 2 delayed enabling current paths Adjustable delay time 0 30 s Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Single channel emergency stop monitoring Manual reset A1 S34 Stop category 0 Safety level of the example up to PL c EN ISO 13849 1 and SIL 1 EN 62061 L L1 Emergency stop M N qe 7 S1 o 6 A1 S11 12 S21 S22 13 23 a a Clock 4 Clock 4 a PSR ESD 4x1 30 TA k3 wm w ys A2 34 S35 14 24 38 48 f Reset s2 L7 ks Figure 5 4 Single channel emergency stop monitoring with manual reset PSR ESD 4x1 30 5 6 PHOENIX CONTACT 102597_en_02 Application examples for
71. fication of requirements for the safety related control function SAGE eaaa a co Aaah eed tints Sieh anne A oka 2 7 2 3 2 Determination of the required safety integrity level SIL eeee 2 7 2 3 3 Drafting the safety related electrical control system SRECS 2 7 2 3 4 Dividing the safety function into subsystems eee ee eseeeeeeeeeeeeeeeees 2 8 2 3 5 Determination of the safety integrity for each subsystem 2 8 2 3 6 Determination of the achieved safety integrity for the entire SREGS E E E EE E detain 2 10 2 3 7 Verification of the achieved SIL eseeseeseeseeeeseeeeresesiesrrssresrreresses 2 10 2 3 8 Validation inisesin e i a es deara aa 2 11 3 Safety technology basics cceccececeesseeeeeeeeeeneeeeesaeeeesaaeeeeesaaeaeeeeeaaaaeesnaaaeeeesssaeeeseeneeaeeeeenes 3 1 3 1 Cross circ it detections a ea aE EEES 3 1 3 2 Maximum cable lengths csccecceecceeeeeeeeeeeeeeseneeeeneeeesaeceeeeeeeneeeeesnseeeeeeneeeees 3 2 3 3 Sra O AE E a E ee 3 4 3 4 Sate isolato snn a a aa ad E 3 6 4 Overview of safe switching devices eeeeceee ete eeeeeeeeeeeeeeeeeeeeeaaeeeeeaaaeeseeeaeeeeeeeaaaeeeeenaeeeeeees 4 1 4 1 PSRisalety relays pierin a etait hates dae ad 4 1 4 2 Modular safety relay system with PSR TBUS Connection eccecceeeeeeeeeeeees 4 3 102597_en_02 PHOENIX CONTACT i Application manual for PSR safety relays 5 Application examples for PSR safety relayS
72. g analysis and function tests under normal conditions in accordance with the validation plan EN ISO 13849 2 contains detailed requirements and describes the basic procedure for the individual validation processes 102597_en_02 PHOENIX CONTACT 2 11 Application manual for PSR safety relays 2 12 PHOENIX CONTACT 102597_en_02 Safety technology basics 3 Safety technology basics 3 1 Cross circuit detection In both category 3 and category 4 a first fault must never lead to the loss of the safety function This often makes it necessary to provide redundancy in the control structure Cross circuit detection has the ability to detect short circuits bridges or short circuits to ground between two channels either immediately or within the framework of cyclic self monitoring A cross circuit may be due to one of the following reasons Squeezing High temperatures Chips Acids L L1 S11 S12 S21 22 GND v UV Ww S33 S34 N Figure 3 1 Cross circuit detection 102597_en_02 PHOENIX CONTACT 3 1 Application manual for PSR safety relays i 3 2 Maximum cable lengths Depending on the size of the machine or system a considerable amount of cabling may be required to wire the sensors Make sure that the specified cable lengths are not exceeded so as to ensure error free operation of the safety relay L L1 S11 S12 21 22 WY GND V
73. he SISTEMA library 102597_en_02 PHOENIX CONTACT 5 27 Application manual for PSR safety relays 5 2 4 PSR ESD 4x1 30 up to PL d SIL 2 Two channel laser scanner monitoring with manual reset ESPE type 3 _ _ Order No 2981800 with screw connection 2981813 with spring cage connection Technical data 24V AC DC 2undelayed enabling current paths 2 delayed enabling current paths Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel laser scanner monitoring Cross circuit detection via laser scanner Manual reset A1 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 L Nees PSR ESD 4x1 30 L1 Light grid type 3 F1 a go o a o K3 Al S11 12 21 22 lt 01 13 23 37 a7 j Clock Clock WW TT MN N S34 S35 i nano sss On A2 K4z a K3 K4 M N Figure 5 14 Two channel laser scanner monitoring with manual reset PSR ESD 4x1 30 5 28 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Functi
74. idance of contacts means that none of the N C contacts can close if a N O contact does not open for the non activated relay In addition none of the N O contacts can close if a N C contact does not open when the relay is activated 102597_en_02 PHOENIX CONTACT 5 61 Application manual for PSR safety relays 5 6 1 PSR URM4 5x1 2x2 up to PL e SIL 3 2 l Two channel emergency stop monitoring with contact extension and manual reset with cross circuit detection Order No 2963734 with screw connection 2964005 with spring cage connection Technical data 24V AC DC 5 enabling current paths 1 signaling current path and 1 alarm contact Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring with contact extension Cross circuit detection Ground fault detection S11 S12 only Manual reset S12 S34 at safety relay KS1 Feedback of contactor contacts K3 K8 and KS2 at S34 at safety relay KS1 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Emergency stop otf S1 BA iio 12 23 33 43 53 63 71 Lag PSR URM4 5x1 2x2 B A1 11 12 S21 S22 A1 v GND 4 PSR ESAM4 2x1 1x2
75. ing to EN 60204 Proven components and proven safety principles according to EN ISO 13849 2 must be used when applying category 1 The occurrence of a fault can lead to the loss of the safety function The connecting cables for the emergency stop control device should either be laid separately or protected against mechanical damage When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 3 Application manual for PSR safety relays 5 1 2 PSR ESL4 3x1 1x2 B up to PL c SIL 1 Single channel emergency stop monitoring with manual reset Order No 2981059 with screw connection 2981062 with spring cage connection Technical data 24V AC DC 3 enabling current paths 1 signaling current path Monitored manual or automatic start Basic insulation Stop category 0 Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Single channel emergency stop monitoring Manual reset S33 S34 Stop category 0 Safety level of the example up to PL c EN ISO 13849 1 and SIL 1 EN 62061 L L1 Emergency stop qn S1 i i 9 o Al S11
76. input signal input signals E t lt 0 5s Synchronous actuation Figure 5 26 Structure of a two hand control device gt Time Time period for simultaneous actuation 102597_en_02 PHOENIX CONTACT 5 57 Application manual for PSR safety relays ry 5 5 1 PSR THC4 2x1 1x2 up to PL e SIL 3 i i Two hand control device monitoring Order No 2963721 with screw connection 2963983 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Reinforced insulation Two hand and safety door control module according to EN 574 type IIIC Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two hand control device monitoring Cross circuit detection ground fault detection Automatic reset Y1 Y2 Feedback of contactor contacts K3 and K4 at Y1 and Y2 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Two hand control device siE S2E 11 S14 S12 21 S24 S22 T eo A1 S11 S14 22 S11 13 23 3 K3 22 24 GND wv w aE eee a PSR THC4 2x1 1x2 tot 4 A2 Y1 Y2 14 24 32 K4 9 Q 9 9 Q Q K3 K4 M N Figure 5 27 Two hand control device monitori
77. ion Cross circuit detection Ground fault detection S11 S12 only Manual reset S33 S34 Feedback of contactor contacts K3 K6 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 k3 Emergency stop K44 qh A s1 A1 22 10 S11 12 S13 13 23 Al K1 11 12 23 33 43 53 61 Ba xy OO Moree Sea unnl ly na ya 20 10 PSR URM4 Tl azoj e 883 PSR SDC4 2x1 B NER Kose 4x1 2x2 B an T kuk2o BS peri MN H NMA ouer ev viol tolg 3 Y1 S33 834 S35 14 24 Y30 A2 Y1 24 34 44 54 62 9 9 2 Q Q 9 Q i 2 q Q i an Reset S2 K6 M N Figure 6 5 Two channel emergency stop monitoring with contact extension and manual reset PSR SDC4 2x1 B and PSR URM4 4x1 2x2 B 6 10 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection Function description Start Action Result Diagnostics Diagnostics 1 Unlock emergency stop The emergency stop button closes the first button S1 enable circuit via S10 S11 and S12 and Power closes the second enable circuit via A2 and i S
78. is manual is aimed at all designers of safety controllers This manual should provide a simple introduction to the technology of safety related machines and systems and an overview of safety technology basics You must always ensure you are familiar with the directives standards and regulations relevant to the field of application 1 2 What s new in this version New standards for functional safety New application examples New diagnostics concept 102597_en_02 PHOENIX CONTACT 1 1 Application manual for PSR safety relays 1 3 Symbols used Emergency stop Movable guard AOPD light grid T 8 AOPDDR laser scanner a Two hand control device Enable switch 1 2 PHOENIX CONTACT 102597_en_02 Safety of machines and systems 2 Safety of machines and systems In modern industrial production the amount of complex technical equipment used is constantly increasing The purpose of safety technology is to reduce the risk to people working animals the environment and machines as far as possible and to at least a reasonable degree The availability of production equipment should not be restricted any more than is absolutely necessary Safety is relative There is no such thing as an absolutely safe machine However since the opening of the European single market manufacturers and operators of machines and technical equipment are legally bound to observe European directives for the design and operatio
79. l documentation at its own discretion and without giving prior notice insofar as this is reasonable for the user The same applies to any technical changes that serve the purpose of technical progress The receipt of technical documentation in particular user documentation does not constitute any further duty on the part of Phoenix Contact to furnish information on modifications to products and or technical documentation You are responsible to verify the suitability and intended use of the products in your specific application in particular with regard to observing the applicable standards and regulations All information made available in the technical data is supplied without any accompanying guarantee whether expressly mentioned implied or tacitly assumed In general the provisions of the current standard Terms and Conditions of Phoenix Contact apply exclusively in particular as concerns any warranty liability This manual including all illustrations contained herein is copyright protected Any changes to the contents or the publication of extracts of this document is prohibited Phoenix Contact reserves the right to register its own intellectual property rights for the product identifications of Phoenix Contact products that are used here Registration of such intellectual property rights by third parties is prohibited Other product identifications may be afforded legal protection even where they may not be indicated as such
80. l or automatic start Reinforced insulation basic insulation Application example Two channel safety door monitoring with two position switches Cross circuit detection ground fault detection S11 S12 only Manual reset S33 S34 Feedback of contactor contacts K3 K6 at Y1 and Y2 Release delay at K5 and K6 Stop category 0 1 Monitoring of external contactors Safety level of the example drive 1 PL e EN ISO 13849 1 and SIL 3 IEC 62061 Safety level of the example drive 2 PL d EN ISO 13849 1 and SIL 2 IEC 62061 L L1 Drive 1 Drive 2 closed 14 3 A1 10 S11 S12 21 S22 13 23 33 4 57 67 K3 4 W GND v i r 2 ON PSR ESD 5x1 1x2 300 amp TEA YA fl 5 yN H N N amp amp Ri y gt a A2 33 S34 S35 Y1 Y2 14 24 34 42 58 68 K4 4 j j fe ce Q Q 9 Q m fe ese S2 fka if K3 K5 K5 Jke K4 amp K6 a N i L Figure 5 21 Two channel safety door monitoring with delayed contacts and manual reset PSR ESD 5x1 1x2 300 5 44 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enab
81. le Trigger event Opening the safety door Response The robot drive is set to a safe stop state The power semiconductor pulses are disabled Safe state Power circuit has no power 2 2 PHOENIX CONTACT 102597_en_02 Safety of machines and systems 2 2 2 Determination of the required performance level PL The PL is determined in combination with the safety function within the framework of the higher level risk assessment For each safety function the required PL is estimated using the risk graph below Low risk P1 a r P2 S1 P1 Start L F2 Required P2 c performance Fi a level _ P2 P1 F2 P2 e High risk Figure 2 2 Risk graph according to EN 13849 1 S1 Meaning of individual parameters S severity of injury S1 Slight normally reversible injury S2 Serious normally irreversible injury F frequency and duration of exposure to the hazard F1 Seldom to not very frequent or exposure to hazard is brief F2 Frequent to continuous or exposure to hazard is long P possibility of avoiding or limiting damage P1 Possible under specific conditions P2 Scarcely possible 2 2 3 Technical implementation This step involves the technical pre planning of the safety function taking possible technologies and components into account The safety related components and parts must then be identified for later verification 102597_en_02 PHOENIX CONTACT 2 3 Ap
82. le circuit S11 S12 and 21 S22 of the safety relay Power Contactors K3 K6 are activated and the mirror contacts gt N C contacts of K3 K6 in the reset circuit are opened K3 t O K4 t O 2 Press reset button S2 Contactors K3 K6 are activated and the mirror contacts N C contacts of K3 K6 in the reset circuit Y1 Y2 are opened Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened immediately Power After the preset time has elapsed delay contacts 57 58 and 67 68 deactivate contactors K5 and K6 with a time delay Power Inthe reset circuit the mirror contacts of K3 K6 are closed i S K3 t O K4 t O Notes on the application example For additional diagnostic descriptions please refer to Section 7 a The position switch is positive opening according to EN 60947 5 1 Contactors K3 K4 K5 and K6 have mirror contacts according to EN 60947 4 1 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 Stop category 1 describes a controlled stop with power available according to EN 60204 This means that the power is only switched off after the connected machine has stopped When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific applicati
83. lication examples for PSR safety relays Emergency stop according to EN ISO 13850 EN 60204 1 5 1 Emergency stop An emergency operation intended to stop a process or a movement that would become hazardous stop The emergency stop function is triggered by a single operator operation This function must be available and operational at all times according to EN ISO 13850 In this case the operating mode is not taken into consideration Figure 5 1 Emergency stop The emergency stop function should not be used as a substitute for safety equipment or other safety functions but should be designed as additional safety equipment The emergency stop function must not adversely affect the effectiveness of safety equipment or equipment with other safety functions Furthermore it must be designed so that when faced with the decision to activate the manual emergency stop control the operator does not have to consider the resulting effects 102597_en_02 PHOENIX CONTACT 5 1 Application manual for PSR safety relays 5 1 1 PSR ESM4 2x1 1x2 up to PL c SIL 1 Single channel emergency stop monitoring with manual reset Order No 2 2 963718 with screw connection 963705 with spring cage connection Technical data 24 V AC DC 2 enabling current paths 1 signaling current path Monitored manual start Reinforced insulation Cross circuit detection Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 a
84. losed and none of the mechanically connected N O contacts can close if a N C contact is closed These requirements apply for the entire service life of the relay and for reasonably foreseeable failure conditions The effects of reasonably foreseeable breaks and or wear on parts of the elementary relay must not cause the mechanical forced guidance to fail During the entire relay service life specified by the manufacturer the contact distances of opened contacts must be greater than 0 5 mm for a single N C contact and greater than 0 3 mm each for a double interrupt Mechanical forced guidance of contacts means that none of the N C contacts can close if a N O contact does not open for the non activated relay In addition none of the N O contacts can close if a N C contact does not open when the relay is activated 102597_en_02 PHOENIX CONTACT 6 9 Application manual for PSR safety relays Application example 6 5 1 PSR URM4 4x1 2x2 B up to PL e SIL 3 Two channel emergency stop monitoring with contact extension and manual reset with cross circuit detection Order No 2981677 with screw connection 2981680 with spring cage connection Technical data 24V AC DC 4 enabling current paths 1 signaling current path and 1 alarm contact Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Two channel emergency stop monitoring with contact extens
85. maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 15 Application manual for PSR safety relays ry 5 1 8 PSR ESD 4x1 30 up to PL e SIL 3 Two channel emergency stop monitoring with delay contacts with cross circuit detection Order No 2981800 with screw connection 2981813 with spring cage connection Technical data 24VDC 2undelayed enabling current paths 2 delayed enabling current paths Adjustable delay time 0 30 s Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring with controlled stop Cross circuit detection Ground fault detection Manual reset A1 S34 Feedback of contactor contacts K3 K5 at S34 Stop category 1 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 L2 L3 L1 Emergency stop 4 4 Fl S1 Quick stop To o fo Al 11 12 21 22 Clock Clock y PSR ESD 4x1 30 Ww Ww A2 34 S35 o 9 9 Reset s2 h j
86. n 2981745 with spring cage connection Technical data 24VDC 4 delayed enabling current paths 1 signaling current path and 1 alarm contact Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Two channel safety door monitoring with delay contact extension Ground fault detection Automatic reset S33 S35 Y1 Feedback of contactor contacts K3 and K4 at S35 and Y1 Stop category 0 Stop category 1 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 M N SSS SSO xX 2 F a e a z L1 L2 L3 FI Quick stop to A1 22 S10 S11 S12 S13 13 23 A1 _K1 15 16 feat i oN K HWW mohoa JK u 1 mo A20 OA2 FOK1 K2 PSR SDC4 2x1 B 7 K1 K20 0K1 K2 PSR URD3 0 5 Keo 1 o ol 3 fos33 330 40S11_ 4x1 2x2 3 6 Y1 M HW MN WL_Yorov1 ASRS Yi A2 Y1 33 834 S35 14 24 Y30 A2 Y1 28 38 48 58 66 Q Q Q q 9 Q Q Q Q J PSR TBUS TP 2981716 hi fa tes Figure 6 6 Application example safety door with delay contact extension PSR SDC4 2x1 B and PSR URD3 4x1 2x2 3 6 12 PHOENIX CONTACT 102597_en_02
87. n for PSR URD3 4x1 safety relays Short circuit Short circuit between contact points A1 and A2 Remove short circuit Confirmation contacts 15 and 16 are faulty Enable contact of K1 t is faulty Error with internal cause Xe 34 3 xt Enable contact of K2 t is faulty Replace the safety relay 7 12 PHOENIX CONTACT 102597_en_02 A Appendix for document lists Section 2 Section 3 Section 5 Al Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 3 1 Figure 3 2 Figure 3 3 Figure 3 4 Figure 3 5 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 5 7 List of figures Risk reduction IN MACHINES ee eeeeceeeeeeeeteeceeeeeeseeeeeesaeeeeeeeeeesaeeeeenas 2 1 Risk graph according to EN 13849 1 ooo eeeeeeceeeeeeeeeeeeeeteeeeeeeeeeees 2 3 Safety related block diagram according to EN 13849 1 5 2 4 Relationship between PL category DC and MTTFd according to EN 13849 1 oo ee eeceeeeeeeteeeeeeeeeeeeeecaeseeeesneeeeaeeeeeeenas 2 4 Example of specifying the SIL according to EN 62061 0 2 7 Logical representation of subsystem A according to EN 62061 2 8 Logical representation of subsystem B according to EN 62061 2 8 Logical representation of subsystem C according to EN 62061
88. n of machines and systems When adhering to harmonized standards assumed effect which apply to a machine or piece of technical equipment it is assumed that they comply with legal regulations when launched The Machinery Directive is one of the most important single market directives It is of such importance because machine construction is one of the industrial mainstays of the European Economic Area The Machinery Directive defines the requirements machinery must meet before it can be placed on the market and operated in the European Economic Area It also contains essential health and safety requirements for the planning and construction of machinery and safety components Every machine or system poses a risk According to the requirements of the Machinery Directive a risk assessment must be carried out for every machine If the risk is greater than the level of risk that can be tolerated risk reduction must be implemented Standard EN ISO 12100 Safety of machinery General principles for design Risk assessment and risk reduction describes the risks to be considered and the general principles for design to reduce risk and describes risk assessment and risk reduction as a repetitive process to achieve safety All phases in the life of the machine are therefore assessed Procedure All implemented All implemented Risk Figure 2 1 Risk reduction in machines 102597_en_02 PHOENIX CONTACT 2 1 Application man
89. nected machine has stopped A restart should only occur automatically if there is no hazardous situation Please refer to the detailed information in standard EN ISO 12100 6 3 3 2 5 The holding brake is not part of the safety function When the safety door has been opened it should not be possible to access the danger zones during the controlled stop of the hazardous movement observe safety distance Install the safety relay and contactors together in an installation space according to EN 60204 e g in the control cabinet This prevents a cross circuit at the output of the safety relay When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 41 Application manual for PSR safety relays 5 3 6 PSR ESD 4x1 30 up to PL e SIL 3 Two channel safety door monitoring with delay contacts and manual reset with cross circuit detection Order No 2981800 with screw connection 2981813 with spring cage connection Technical data 24VDC 2undelayed enabling current paths 2 delayed enabling current paths Adjustable delay time 0 30 s Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 acc
90. ng PSR THC4 2x1 1x2 5 58 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Both buttons on the two The enable is expected via both buttons hand control device are Power not pressed K1O K2 O 2 Press both buttons onthe Contactors K3 and K4 are activated and the mirror contacts two hand control device N C contacts of K3 and K4 are opened Power simultaneously K1 K2 Stop Action Result Diagnostics 1 Both buttons on the two The safety function is triggered and contactors K3 and K4 hand control device are are opened Power not actuated The mirror contacts of K3 and K4 are closed K1 O K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 Two hand operation according to EN 574 type IIIC 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY example CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 59 Application manual for P
91. nnel emergency stop monitoring with manual reset PSR ESAM4 2x1 1x2 5 8 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Unlock emergency stop The emergency stop button closes enable circuit S11 S12 button S1 and S21 S22 of the safety relay Power The circuit is enabled via the reset button pie x K2 O 2 Press reset button S2 Contactors K3 K6 are activated and the mirror contacts N C contacts of K3 K6 in the reset circuit are opened Power IN1 2 K1 K Stop Action Result Diagnostics 1 Press emergency stop button S1 The safety function is triggered and contactors K3 K6 are opened Inthe reset circuit the mirror contacts of K3 K6 are closed Power IN1 2 O K1 O K2 O Notes on the application example For additional diagnostic descriptions please refer to Section 7 The emergency stop control device is positive opening according to EN 60947 5 1 2 Contactors K3 K4 K5 and K6 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 Install the safety relay and contactors together in an installation space according to EN 60204 e g in the control cabinet This prevents a cross circuit at the output of the safety relay 5 When
92. on The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 45 Application manual for PSR safety relays rag 5 3 8 PSR ESL4 3x1 1x2 B up to PL d SIL 2 i Two channel non equivalent safety door monitoring with manual reset Order No 2981059 with screw connection 2981062 with spring cage connection Technical data 24VDC 3 enabling current paths 1 signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel non equivalent safety door monitoring with two position switches Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 L L1 Safety door xd BS X SS xy lt lt LX O O ced io o Al S11 12 22 13 23 33 4 K3 W W w En PSR ESL4 3x1 1x2 B yaa eee ee A H N Ww A2 S33 S34 S35 14 24 34 42 K4 f 3 g i Q 2 io Reset 52 j K4 K3 52 N as Figure 5 22 Two channel safety door monitoring with manual reset PSR ESL4 3x1 1x2 B
93. on description Start Action Result Diagnostics 1 The laser scanner is Both OSSD signals from the laser scanner provide high active there is no objectin signals to enable circuit S12 and S22 of the safety relay Power the protected field The circuit is enabled via the reset button OK1 K2 O K3 t Ka 2 Press reset button S1 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power K1 K2 K3 t a t Stop Action Result Diagnostics 1 The laser scanner is The safety function is triggered by the interruption of the interrupted there is an laser scanner and contactors K3 and K4 are opened In the Power object in the protected reset circuit the mirror contacts of K3 and K4 are closed ORIRE field kat Kay After the preset time has elapsed the delayed enable contacts of the safety relay are opened Power OK1 K2 Ok3 t Ka For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 The laser scanner must meet type 3 requirements from standard EN 61496 3 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL
94. or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 39 Application manual for PSR safety relays age 5 3 5 PSR ESD 4x1 30 up to PL d SIL 2 i Two channel safety door monitoring with delay contacts and automatic reset with cross circuit detection Order No 2981800 with screw connection 2981813 with spring cage connection Technical data 24VDC 2undelayed enabling current paths 2 delayed enabling current paths Adjustable delay time 0 30 s Manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel safety door monitoring with two position switches and controlled stop Cross circuit detection ground fault detection Automatic reset A1 S35 Feedback of contactor contacts K3 and K4 at S35 Stop category 1 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 L 7 i L1 L2 L3 L1 Safety doorG Sjen FI closed 14 Quick stop To A1 11 S12 21 S22 lt 01 13 23 37 47 Clock Q Clock N r os 3 PSR ESD 4x1 30 Gai Nw N as N w 20 A2 34 35 30 14 24 38 48 M N Figure 5 19 Two channel safety door monitoring with delayed contacts and automa
95. ording to EN 62061 Application example Two channel contact free safety switch Cross circuit detection via contact free safety switch Manual reset A1 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Contact free safety switch WM 2 ossD1 OSSD 2 9 9 Transponder m Al an 12 pel 22 lt 04 13 23 373 47 Clock N Clock S2 m 7 PSR ESD 4x1 30 GE 3 AA 40 gt A MN N L 20 A2 34 35 30 14 24 38 48 9 9 9 9 F F K3 K4 K3 Reset K4 s2 M N Figure 5 20 Two channel safety door monitoring with delayed contacts and manual reset PSR ESD 4x1 30 5 42 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S12 and S22 of the safety relay Power OK1 K2 Ok3 t Ka 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power k1 k2 k3 t k t S
96. oring with delayed contacts PSR ESD 4X1 30 o ececceececeeeeceeeeeeeeeeeeceaeeeaeeeeeeeseetaeeneees 5 16 Figure 5 10 Two channel cable operated switch monitoring with manual reset PSR ESAM4 3x1 1X2 B ooo ce eecceeeececceeeeceeeeeecaeeeeeecaeeesaeeeeeeseeneaeeniees 5 18 Figure 5 11 Two channel light grid monitoring with manual reset PSR ESL4 3xXA 1K2 B ira srs re a eee ee 5 22 Figure 5 12 Two channel light grid monitoring with manual reset PSR ESD 4x1 30 cei nain n S E E eect ee 5 24 Figure 5 13 Two channel light grid monitoring with automatic reset PSReESAM4 8X1 1X2 aisiais oinas aeiae E a K EEES 5 26 Figure 5 14 Two channel laser scanner monitoring with manual reset PSR ESD 4X1 30 sissies nini eee e davidson 5 28 Figure 5 15 Two channel safety door monitoring with automatic reset PSR ESA4 2xX1 1X2 vorisini iior ior tan iore aori i 5 32 Figure 5 16 Two channel safety door monitoring with manual reset nET TAA A EE E EE ET 5 34 Figure 5 17 Two channel safety door monitoring with manual reset PSR ESA MAI a a E ar araa Aaaa aa e eaha seteaatiuasass 5 36 Figure 5 18 Two channel safety door monitoring with manual reset PSR ESAM4 8X1 B iisi prisnin ee aiis ao anaa ea Ee daaa EO Raa a 5 38 Figure 5 19 Two channel safety door monitoring with delayed contacts and automatic reset PSR ESD 4x1 30 eee 5 40 Figure 5 20 Two channel safety door monitoring with delayed contacts and manual reset PSR ESD 4xX1 30 0 e eee eee 5 4
97. oss circuit Short circuit between contact points A1 and A2 Between S11 and S12 Error detection on next demand Between S11 and S22 Error detection on next demand Short circuit Between S11 and S12 or S11 and S14 Error detection on next demand Between S21 and S22 or S21 and S24 Error detection on next demand Remove short circuit All 1 4 5 1 4 5 Error in reset circuit x o Faulty reset button short circuit between S33 and S34 No error detection on initial start only on first new demand Remove short circuit 1 2 3 4 5 Enable contact s of K1 faulty xt Enable contact s of K2 faulty Error with internal cause Xe XE SE 3A IE EE 3t O xt x ie oe xtle o Enable contact s of K1 and K2 faulty Replace the safety relay All 7 2 PHOENIX CONTACT 102597_en_02 Diagnostic description The table is valid for the following safety relays 1 PSR ESAM4 2x1 1x2 2 PSR ESAM4 8x1 1x2 B 3 PSR ESA4 2x1 1x2 4 PSR ESA4 3x1 1x2 B 5 PSR ESM4 3x1 1x2 B Table 7 2 Diagnostic description for PSR ESAM4 and PSR ESA4 safety relays N Error Remedy Valid for rr N Z x X O Supply voltage not present Apply supply voltage All THEY co Q 5 5 oO 2 2 X X Supply voltage too low Adjust supply voltage 2 cs Q S O
98. ot guaranteed additional safety equipment must be installed The machine control system must be capable of being influenced electrically and permit dangerous states to be exited immediately in each operating phase The ambient conditions must not adversely affect the effectiveness of the light protective system Electrosensitive protective equipment ESPE does not provide protection from flying parts EN 61496 1 EN 61496 2 Requirements for electrosensitive protective systems EN ISO 13855 Positioning of safeguards with respect to the approach speeds of parts of the human body Laser scanners Laser scanners scan the shape of the environment like a type of optical radar The distance to an object is determined by a runtime measurement A mirror integrated in the devices is used to achieve two dimensional scanning The protected fields that are used for shutdown in the event of a hazardous situation can be defined using software As the distance increases the resolution of the scanner decreases and this therefore affects the required minimum distance Protection of the danger zone for presses Protection of the danger zone for production cells Back step protection for insert areas of robot cells 102597_en_02 PHOENIX CONTACT 5 21 Application manual for PSR safety relays Two channel light grid monitoring with manual reset ESPE type 4 F 5 2 1 PSR ESL4 3x1 1x2 B up to PL e SIL 3 H Order No 298
99. pecific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 7 Application manual for PSR safety relays 5 1 4 PSR ESAM4 2x1 1x2 up to PL e SIL 3 Two channel emergency stop monitoring with manual reset with cross circuit detection Order No 2900525 with screw connection 29600526 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Monitored manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring Cross circuit detection Ground fault detection S11 S12 Manual reset S12 S34 Feedback of contactor contacts K3 K6 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L1 ii 230V 24 T Emergency stop oe Ep S S1 E fe fe Al S11 12 S21 S22 13 23 31 K3 K5 22 2 v GND 4 l P PSR ESAM4 2x1 FY F M N yT B A2 eae 35 14 24 32 K4 4 K6 4 rm 5 7 Ka K4 T xs f K6 Reset S2 A o a Figure 5 5 Two cha
100. pening according to EN 60947 5 1 example 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 6 3 Application manual for PSR safety relays 6 3 PSR SDC4 2x1 B up to PL e SIL 3 Two channel light grid monitoring with manual reset ESPE type 4 Order No 2981486 with screw connection 2981499 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 semiconductor signaling current path Manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel light grid monitoring Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Light grid type 4 Receiver amp OSSD1 OSSD2 Transmitter A1 22 10 S11 S12 13 13 23 Loat W W Ww Ww w Ae LOA
101. plication manual for PSR safety relays 2 2 4 Dividing the safety function into subsystems In the next step a safety related block diagram must be created for further evaluation As a rule a safety function consists of sensor logic actuator In the simplest case each one is a subsystem These subsystems are connected in series to form the overall safety function Figure 2 3 Safety related block diagram according to EN 13849 1 2 2 5 Determination of the achieved PL for each subsystem A characteristic value when determining the performance level is the PFHg value the statistical probability of a dangerous failure per hour The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library The diagram below shows the basic relationship between PL and the safety characteristics category DC and MTTFy PFH MTTF a low 10 b MTTF L a oo medium c MTTF 7 10 high d 10 A l l l l Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat 3 Cat 4 Dey none De none DCavg low Dc mediumDc low Dc mediumDc high Figure 2 4 Relationship between PL category DC and MTTFd according to EN 13849 1 The category is an important parameter when determining the PL The category term has been taken from the previous standard EN 954 1 The requirements for the categories are listed below 2 4 PHOENIX CONTACT 10
102. r by interrupting a machine or drive element according to EN 60204 The system behavior for category 4 permits that if a single fault occurs the safety function is always executed and the single fault is detected on or before the next demand of the safety function The advantage of category 4 compared to category 3 is that an accumulation of undetected faults does not lead to the loss of the safety function When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 6 5 Application manual for PSR safety relays 6 4 PSR SDC4 2x1 B up to PL e SIL 3 Two channel non equivalent safety door monitoring with manual reset Order No 2981486 with screw connection 2981499 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 semiconductor signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel non equivalent safety door monitoring with a magnetic safety switch Ground fault detection Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop categor
103. s Function description Start Action Result Diagnostics 1 Enable switch stage 1 not The enable is expected via the enable switch activated Power IN1 2 K1 0 K2 O 2 Enable switch stage 2 The enable switch closes enable circuit S11 S12 and S21 enable 22 of the safety relay Contactors K3 and K4 are activated Power and the mirror contacts N C contacts of K3 and K4 in the IN1 2 reset circuit are opened K1 K Stop Action Result Diagnostics 1 Enable switch stage 3 The safety function is triggered and contactors K3 and K4 pushed through are opened immediately Power In the reset circuit the mirror contacts of K3 and K4 are Be closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 When using enable switches observe the notes in standards EN 60204 and example EN ISO 10218 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 Arestart after a stop from stage 3 of the enable switch should only occur automatically if there is no hazardous situation 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIO
104. s XX KE Xt i The enable circuits are connected incorrectly or A oe xf amp amp not connected at all Check the connection of the enable circuits 1 gt oO O Between both enable circuits 11 S12 and 7 21 S22 Remove cross circuit All 8 E g for emergency stop e Short circuit between contact points A1 and A2 All z 2e D Between S11 and S12 oe amp g Remove short circuit All Error detection on next demand N Between S21 and S22 All xy xy xy Error detection on next demand Replace reset button xf xf xf Faulty reset button Remove short circuit short circuit between S12 and S34 c 5 No error detection on initial start only on first new Replace reset button _ demand 2 6 X xf Remove short circuit ui g o Faulty reset button 5 X y O X short circuit between S33 and S34 Replace reset button 5 No error detection on initial start only on first new demand Remove short circuit 102597_en_02 PHOENIX CONTACT 7 3 Application manual for PSR safety relays Table 7 2 Diagnostic description for PSR ESAM4 and PSR ESA4 safety relays oc ijn Error Remedy Valid for z Z g g xf xy e xf Enable contact s of K1 faulty sg aj Ss xf xf xf e Enable contact s of K2 faulty Replace the safety relay All ug L X X Enable contact s of K1 and K2 faulty 7 4 PHOENIX
105. s associated with guards prEN 14119 Safety of machinery Interlocking devices associated with guards 102597_en_02 PHOENIX CONTACT 5 31 Application manual for PSR safety relays rag 5 3 1 PSR ESA4 2x1 1x2 up to PL e SIL 3 i Two channel safety door monitoring with automatic reset with cross circuit detection Order No 2963750 with screw connection 2963938 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel safety door monitoring with two position switches Cross circuit detection Ground fault detection S11 S12 only Automatic reset bridge S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Safety door open 21 ne PL se eee 22 closed KXXERS KS iS OSS oie REX 1 Oo koJ O Al S11 S12 21 S22 Y GND v PSR ESA4 2x1 1x2 4 A2 33 S34 Q9 9 K4 a N A AT zo T ET og l 4 9o K3 K4 amp M N Figure 5 15 Two chann
106. safety door monitoring with manual reset PSR SDC4 2x1 B sistance eae tins e ai aie tiee 6 6 Two channel emergency stop monitoring with contact extension and manual reset PSR SDC4 2x1 B and PSR URM4 4x1 2x2 B 6 10 Application example safety door with delay contact extension PSR SDC4 2x1 B and PSR URD3 4x1 2X2 3 ecccesssseeeseeeeeeeeees 6 12 102597_en_02 PHOENIX CONTACT A 3 Application manual for PSR safety relays A 4 PHOENIX CONTACT 102597_en_02 Section 2 Section 4 Section 5 Section 7 A2 Table 2 1 Table 2 2 Table 2 3 Table 4 1 Table 4 2 Table 5 1 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 7 6 Table 7 7 Table 7 8 Table 7 9 List of tables Explanation of categories eeeeceeeseeeeeneeeeeeeeeeeneeeseaeeeeneeeensaeeesenaes 2 5 Determination of the safety integrity level according to EN 62061 eececeeeeeeeeeeeceeeeeeeeeeeeeeseaeeeeeeeteeeaeeeneeeaes 2 10 Determination of the safety integrity level for a subsystem with discrete components according to EN 62061 0 00 essere 2 10 Overview of PSR Safety relayS eeceecceeeeeeeeceteeeeaeeeeeeeeeeeeeeeeeeeenaes 4 1 Overview of PSR SDC4 modular safety relay system 4 3 Requirements according to EN 574 eesecesseeeseeeeeeneeeeeeeeeeneeeeeas 5 57 Diagnostic description for PSR ESL4 PSR ESA2 PSR ESAM2 PSR ESAM4 and PSR THC4 safety relays 7 1 Di
107. stics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 47 Application manual for PSR safety relays 5 48 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays 5 4 Enable switch An enable switch is an additional manually operated device that is used together with a startup control and permits machine operation while it is held down Enable devices are frequently used together with emergency stop devices for the temporary suspension of safety functions Simply pressing an enable switch must not start machine operation see EN 60204 1 The hazardous movement should only be triggered by activating an additional control device Enable devices with the following properties should be selected Designed according to ergonomic principles a For a type with two position settings Position 1 off function of the switch actuator is not operated Position 2 enable function actuator is operated b For a type with three position settings Position 1 off function of the switch actuator is not operated Position 2 enable function actuator is operated and in its mid position Position 3 off function actuator is operated past its mid position Returning from position 3 to position 2 does not activate the enable function 102597_en_02 PHOENIX CONTACT 5 49 Application manual for PSR safety relays 5 4 1 PSR ESAM4 2
108. t 99 SIL 2 SIL 3 SIL 3 2 99 SIL 3 SIL 3 SIL 3 1 A hardware fault tolerance of N means that N 1 faults can lead to a loss of the SRCF 2 See EN ISO 62061 Section 6 7 7 2 3 7 Verification of the achieved SIL Each individual subsystem and the entire safety chain must both meet the requirements of the necessary SIL This includes both the quantitative evaluation and the consideration of systematic aspects The systematic aspects include Correct dimensioning of components Consideration of expected operating conditions and ambient conditions Use of basic and proven safety principles Avoidance of specification errors and software errors through testing 2 10 PHOENIX CONTACT 102597_en_02 Safety of machines and systems 2 3 8 Validation The last step should check whether the selected measures achieve the necessary risk reduction and therefore the protection objectives The result of the validation process is included in the final risk assessment The purpose of the validation process is to confirm the specification and level of conformity of the design of safety related parts of the control system SRP CS within the overall specifications for the safety requirements of the machinery Before validation of the design of the SRP CS or the combination of SRP CS that contains the safety function the specification requirement for the safety function must be confirmed Validation involves performin
109. tic reset PSR ESD 4x1 30 5 40 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes enable circuit S11 S12 and 21 S22 of the safety relay Power Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened aa Stop Action Result Diagnostics 1 Open the safety door The safety door is opened and contacts 13 14 of the safety relay open immediately which initiates an automatic quick Power stop at the FI OK1 K2 K3 t kay After the preset time has elapsed delay contacts 37 38 and 47 48 deactivate contactors K3 and K4 with a time delay After the delayed deactivation parallel to the motor the mains supply is disconnected from the FI and brake unlocking is switched off so that the brake blocks the drive In the reset circuit the mirror contacts of K3 and K4 are closed Power OK1 K2 O K3 t ka Notes on the application example For additional diagnostic descriptions please refer to Section 7 The position switch is positive opening according to EN 60947 5 1 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 Stop category 1 describes a controlled stop with power available according to EN 60204 This means that the power is only switched off after the con
110. tion Start Action Result Diagnostics 1 Enable switch stage 1 The enable is expected via the enable switch not activated Power IN1 2 O K1O K O 2 Enable switch stage 2 The circuit is enabled via the reset button enable Power IN1 2 K1 O K2 O 3 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power IN1 2 K1 K2 Stop Action Result Diagnostics 1 Enable switch stage 1 The safety function is triggered and contactors K3 and K4 not activated are opened immediately Power In the reset circuit the mirror contacts of K3 and K4 are ae closed K2 O For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 When using enable switches observe the notes in standards EN 60204 and example EN ISO 10218 2 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 3 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 4 Depending on the level of risk the use of a two stage enable switch may only be permitted together with an emergency stop device 5 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SA
111. top Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened Power In the reset circuit the mirror contacts of K3 and K4 are closed a ks kay After the preset time has elapsed the delayed enable contacts of the safety relay are opened Power OK1 K2 OkK3 t Ka For additional diagnostic descriptions please refer to Section 7 Notes on the application 1 Contactors K3 and K4 have mirror contacts according to EN 60947 4 1 example 2 Stop category 0 describes an immediate stop by removal of power by interrupting a machine or drive element according to EN 60204 3 When using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 43 Application manual for PSR safety relays ga 5 3 7 PSR ESD 5x1 1x2 300 up to PL e SIL 3 F Two channel safety door monitoring with delay contacts and manual reset with cross circuit detection Order No 2981428 with screw connection 2981431 with spring cage connection Technical data 24VDC 3undelayed enabling current paths 2 delayed enabling current paths 1 signaling current path Adjustable delay time 0 2 300 s Manua
112. ual for PSR safety relays 2 1 Functional safety Safety related parts of machine control systems are frequently assigned to provide safety functions The contribution to the overall risk reduction of machinery by the safety related parts of a control system is determined according to EN ISO 12100 In order to achieve the necessary functional safety of a machine or system it is essential for the safety related parts of the safety equipment and control devices to operate correctly and in the event of failure for the system to remain in the safe state or enter a safe state The requirements for achieving functional safety are based on the following objectives Avoidance of systematic errors Control of systematic errors Control of random faults or failures The requirements of the safety related parts of a machine control system are specified in EN ISO 13849 and EN 62061 The standard specifies the various safety levels in the form of the performance level and safety integrity level SIL for the safety related parts according to the degree of risk and describes the characteristics of the safety functions 2 2 Practical procedure according to EN ISO 13849 In practice the following steps have proven effective when designing safe controllers according to EN ISO 13849 2 2 1 Definition of the safety function The safety functions must be defined first This information is derived from the risk assessment Examp
113. umber of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 11 Application manual for PSR safety relays 5 1 6 PSR ESL4 3x1 1x2 B up to PL d SIL 2 Two channel emergency stop monitoring with manual reset Order No 2981059 with screw connection 2981062 with spring cage connection Technical data 24V AC DC 3 enabling current paths 1 signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL d EN ISO 13849 1 and SIL 2 EN 62061 L L1 Emergency q3 stop S1 A1 S11 S12 S22 13 23 33 41 K3 H w w b a ane i PSR ESL4 3x1 1x2 B y A H MN WwW RRN A2 33 S34 S35 14 24 34 42 k4 Q J 9 Q p 9 M N Figure 5 7 Two channel emergency stop monitoring with manual reset PSR ESL4 3x1 1x2 B 5 12 PHOENIX CONTACT 102597_en_02 Application
114. using the safety relay take into consideration the maximum permissible number of cycles for observing the SIL PL safety characteristics in the specific application The safety characteristics can be found in the FUNCTIONAL SAFETY CHARACTERISTICS data sheet or the SISTEMA library 102597_en_02 PHOENIX CONTACT 5 9 Application manual for PSR safety relays 5 1 5 PSR ESM4 3x1 1x2 B up to PL e SIL 3 Two channel emergency stop monitoring with manual reset with cross circuit detection Order No 2963776 with screw connection 2963925 with spring cage connection Technical data 24V AC DC 3 enabling current paths 1 signaling current path Monitored manual reset Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring Cross circuit detection Ground fault detection S11 S12 only Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 I Emergency AI S11 s12 21 s22 3S Kec GND 4 L O amp PSR ESM4 3x1 1x2 B TAE H N i A2 33 S34 14 24 34 42 T ERENS PORA e Q Q 2 Q K3 Reset K4 s2 K4 M N Figure 5 6 Two channel emergency stop monitoring with m
115. witch monitoring Cross circuit detection Ground fault detection Manual reset S12 S34 Feedback of contactor contacts K3 and K4 at S34 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Cable I i Il operated switch S1 A1 S11 S12 21 S22 4 GND v PSR ESAM4 3x1 1x2 B Eyra t 19 A2 S34 S35 14 24 34 42 K4 s 2 9 9 9 9 9 K4 K3 M N Figure 5 10 Two channel cable operated switch monitoring with manual reset PSR ESAM4 3x1 1x2 B 5 18 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relays Function description Start Action Result Diagnostics 1 Cable operated switch S1 The cable operated switch closes enable circuit S11 S12 is not activated and S21 S22 of the safety relay Power The circuit is enabled via the reset button pie x K2 O 2 Press reset button S2 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Power IN1 2 K1 K2 Stop Action Result Diagnostics 1 Pull cable operated The safety function is triggered and contactors K3 and K4 switch S1 are opened Power In the reset circuit the mirror contacts of K3 and K4 are Be closed K2 O For additional diagnostic
116. with power c gt Short circuit between contact points A11 and A2 TOS pas or between A12 and A2 Remove short circuit 2 n Confirmation contacts 11 and 12 are faulty 0 s5 Sa xf Enable contact s of K1 faulty 2 Replace the safety relay Perform a voltage 5O T reset E ui o X Enable contact s of K2 faulty S Enable contact s of K1 and K2 faulty 7 8 PHOENIX CONTACT 102597_en_02 Diagnostic description Table 7 6 The table is valid for the following safety relays 1 PSR URM4 5x1 2x2 B Diagnostic description for PSR URM4 5x1 2x2 B safety relay Supply voltage not present Apply supply voltage Supply voltage too low Adjust supply voltage The input circuit is connected incorrectly or not connected at all Check the input circuit connection Connection voltage error 5 Oo A A m iS Short circuit between contact points A1 Remove short circuit E and A2 p 2 2 Confirmation contacts 11 and 12 are faulty lt 8 Replace the safety relay Perform a voltage E reset 5 S oO Enable contact s of K1 and K2 faulty wis 102597_en_02 PHOENIX CONTACT 7 9 Application manual for PSR safety relays Table 7 7 Diagnostic description for PSR SDC4 2x1 B safety relay The table is valid for the following safety relays 1 PSR SDC4 2x1 B Connection voltage error g K Error Remedy N Z
117. x1 1x2 oa A ON Table 7 1 Diagnostic description for PSR ESL4 PSR ESA2 PSR ESAM2 PSR ESAM4 and PSR THC4 safety relays Error Remedy Valid for PWR K1 K2 Supply voltage not present Apply supply voltage All Supply voltage too low Adjust supply voltage All Connection voltage error xt Xt 3t 34 The enable circuits are connected incorrectly or Check the connection of the enable circuits All not connected at all eieie o o x o No bridge between Y1 and Y2 Insert bridge 6 102597_en_02 PHOENIX CONTACT 7 1 Application manual for PSR safety relays Table 7 1 Diagnostic description for PSR ESL4 PSR ESA2 PSR ESAM2 PSR ESAM4 and PSR THC4 safety relays PWR x Error Remedy Valid for xt Between both enable circuits S11 S12 and 11 S22 Error detection on next demand E g for emergency stop or safety door xt xt xt Between both enable circuits S11 S22 and 11 S12 Error detection on next demand E g for emergency stop or safety door Cross circuit Between enable circuit S11 S12 and S21 S22 xt Between both enable circuits S12 and S22 The error is not detected by the module itself E g for light grid type 4 Remove cross circuit 4 5 Cross circuit Between enable circuit S11 S14 S12 and 21 S24 S22 Remove cr
118. x1 1x2 up to PL e SIL 3 Three stage enable switch monitoring with automatic reset cross circuit detection Order No 2900525 with screw connection 2900526 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 signaling current path Manual or automatic start Reinforced insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Three stage enable switch monitoring Cross circuit detection Ground fault detection S11 S12 only Automatic reset S12 S35 Feedback of contactor contacts K3 and K4 at S35 Stop category 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 L L1 Enable switch Ws Start 323 s1 B1 1 E1 F E3 E4 10 2 3 Ej a ai T PLC 13 14 23 24 31 32 41 42 Qo Q 9 9 5 TN o So 02 o8 Jp Qo 08 l 0 A1 S11 s12 S21 S22 13 K3 v GND 4 l PSR ESAM4 2x1 1x2 YAN MN N NN A2 34 S35 14 24 K4 4 f 5 9 9 Q K3 A w K4 M N Figure 5 23 Three stage enable switch monitoring with automatic reset PSR ESAM4 2x1 1x2 5 50 PHOENIX CONTACT 102597_en_02 Application examples for PSR safety relay
119. y 0 Monitoring of external contactors Safety level of the example up to PL e EN ISO 13849 1 and SIL 3 EN 62061 Magnetic safety switch oT pon 11 12 13 14 o 6 Al 22 10 S11 S12 S13 13 23 oat W W D w wv Ato ikim GND kamao losas PSR SDC4 2x1 B ER S330 eu M H MN N onas A2 Y1 33 S34 35 14 24 Y30 Q Q Q Q K3 f K3 Reset K4 S1 l fa M N Figure 6 4 Two channel safety door monitoring with manual reset PSR SDC4 2x1 B 6 6 PHOENIX CONTACT 102597_en_02 Application examples for modular safety relay system with PSR TBUS connection Function description Start Action Result Diagnostics 1 Close the safety door The safety door circuit closes the first enable circuit via 10 S11 and S12 and opens the second enable circuit Power via S10 S11 and S13 of the safety relay ae s The circuit is enabled via the reset button ae z 2 Press reset button S1 Contactors K3 and K4 are activated and the mirror contacts N C contacts of K3 and K4 in the reset circuit are opened Stop Action Result Diagnostics 1 Open the safety door The safety function is triggered and contactors K3 and K4 are opened In the reset circuit the mirror contacts of K3 and K4 are closed For additional diagnostic descriptions pl
120. y localize errors in your safety circuits Your advantages Fast installation Error free startup Easy error localization Figure 6 1 PSR SDC4 2x1 B master module Safe cross wiring with PSR TBUS DIN rail plug in connectors help establish a rugged and safe connection PSR TBUS between the master module and extension modules This renders the usual cross wiring for the supply voltage the enable signal and the confirmation current path redundant Fast system expansion Up to ten safety relays can be easily connected to a PSR TBUS DIN rail plug in connector to create a safety system with 42 contacts 102597_en_02 PHOENIX CONTACT 6 1 Application manual for PSR safety relays 6 2 PSR SDC4 2x1 B up to PL e SIL 3 el Two channel emergency stop monitoring with manual reset with cross circuit detection Order No 2981486 with screw connection 2981499 with spring cage connection Technical data 24V AC DC 2 enabling current paths 1 semiconductor signaling current path Monitored manual or automatic start Basic insulation Cat 4 PL e according to EN ISO 13849 1 SIL CL 3 according to EN 62061 Application example Two channel emergency stop monitoring Cross circuit detection Ground fault detection S11 S12 only Manual reset S33 S34 Feedback of contactor contacts K3 and K4 at S33 and S34 Stop category 0 Monitoring of external contactors Safety l

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