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User Manual UM EN SAFETY RELAY APPLICATION

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1. 3 41 3 9 5 PSR SDC4 Application Example 5 3 42 3 9 6 PSR SDC4 and PSR URM4 4X1 Extension Module Application Example 6 3 43 3 9 7 PSR SDC4 and PSR URD3 Extension Module Application Example 7 22 3 44 PSR ES 4 Connection of Several Safety Relays 3 45 3 10 1 X PSR ES 4 Application Example 1 3 45 3 10 2 PSR ESA2 Application Example 2 3 46 3 10 3 PSR ES 4 and PSR URM4 Extension Module ADDIICATION Example are pestis ee rod pt tas ede 3 47 PSR ESAM4 PSR ESA4 Machines in Integrated 3 48 3 11 1 PSR ESAM4 PSR ESA4 Application Example 1 3 48 102597 01 Table of Contents A Approvals and COMING ALS ee ee ee A 1 A 1 ADDIOVAlS en 1 2 CCIE CANO ENTER een 3 2 1 sinne nase A 4 M22 5 A23 7 WU MEN Si Ti eR EH ERR A 9 A2959 PSP ESP R A 10 A206 PoORESD P A 11 Ordening Nah B 1 Er 1 C 1 LISTO FIJUG T EM
2. 2 1 Activity performed by the injured party at the time of the accident 2 3 Incorrect operation of the machine 2 3 Cause of accident Technical defect 2 4 Safety equipment 2 6 Strategy diagr ann te an nee 2 7 European Economic Area EEA 2 8 Relationship between OSHA and consensus standards 2 14 Functional safety of electrical electronic programmable electronic safety related systems E E PES 2 19 Structure OFEN 61508 xui u u yu uu uns e 2 19 Relationship between risk graph according to EN 954 1 and VEC 61506 ce E 2 21 Selection of category B 1 2 3 and 4 for safety related parts of 6 5 ee na 2 22 Salely category 2 24 Salely Category vu 2 25 CaleGOly ein 2 26 Salely Calegony 4 uuu ee 2 27 PSR ESAA Application example 1 3 1 PSR ESAA Application example 2 3 3 PHOENIX CONTACT 1 SAFETY RELAY APPLICATION 2 PHOENIX CONTACT Figure 3 3 Figure 3 4 Figure 3 5 Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 3 11 Figure 3 1
3. Jd Ze CN N ps En amp L E HCENIX k i h 4 C NTACT h i 4 TU p kk E 4 INSPIRING INNOVATIONS INTERFACE User Manual UM EN SAFETY RELAY APPLICATION Order No 2888712 Application Manual for PSR Safety Relays INTERFACE User Manual Application Manual for PSR Safety Relays Designation UM EN SAFETY RELAY APPLICATION Revision 01 Order No 2888712 This user manual is valid for All PSR safety relays from Phoenix Contact 102597 01 en 05 2006 PHOENIX CONTACT SAFETY RELAY APPLICATION p PHOENIX CONTACT Please Observe the Following Notes In order to ensure the safe use of the product described we recommend that you read this manual carefully The following notes provide information on how to use this manual 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 national standards and other regulations regarding electrical engineering and in particular the relevant safety concepts Phoenix Contact accepts no liability for erroneous handling or damage to products from Phoenix Contact or third party products resulting from disregard of information contained in this manual Explanation of Symbols Used The attention symbol refers to an operating procedure which if not ca
4. 3 15 3 3 6 PSR ESAMA 3X1 Application Example 3 16 PSR THC4 Two Hand 3 17 3 4 1 PSR THC4 Application Example 1 With Fault Monitoring 3 17 PHOENIX CONTACT i SAFETY RELAY APPLICATION PHOENIX CONTACT 3 9 3 6 3 7 3 8 3 9 3 10 3 11 3 4 2 PSR THC4 Application Example 2 3 18 3 4 3 PSR THC4 Application Example 3 19 PSR ESL4 Light Grid 3 20 3 9 1 PSR ESL4 Application Example 1 With Fault Monitoring 3 20 3 5 2 PSR ESL4 Application Example 2 3 22 39 0 PSR ESL4 Application Example 3 23 3 9 4 PSR ESL4 Application Example 4 3 24 PSR ESP4 Process Technology Applications 3 25 3 6 1 PSR ESP4 Application Example 1 3 25 3 6 2 PSR ESP4 Application Example 2 With Fault Monitoring 3 26 3 6 3 PSR ESP4 Application Example 3 27 PSR ESD Emergency Stop With Delayed Contacts 3 28 3 7 1 PSR ESD A
5. 2 533 534 14 24 34 42 102597 005 Figure 3 5 PSR ESMA Application example 2 102597_01_en PHOENIX CONTACT 3 7 SAFETY RELAY APPLICATION 3 2 3 PSR ESM4 Application Example 3 PSR ESM4 Application Features Emergency stop monitoring Two channel S11 S12 S21 S22 Up to safety category 4 EN 954 1 3 contacts 1 contact Cross circuit detection 511 512 521 522 Us 24 V DC AC Manual activation 533 534 Monitored start Monitored contact extension Stop category 0 24 V DC AC 2 2 gt 1 S12 521 522 13 23 33 41 K1 STOPA 13 es dd 4 PSR ESM4 24 34 2 533 534 14 24 34 42 ex M K2 ex OV 102597 006 Figure 3 6 PSR ESMA Application example 3 8 PHOENIX CONTACT 102597_01_en Wiring Examples 3 3 PSR ESAM4 Emergency Stop Applications With Start Button Monitoring 3 3 1 PSR ESAM4 Application Example 1 With Fault Monitoring PSR ESAM4 Application Features Emergency stop monitoring Two channel 511 512 521 522 bridge 510 511 Up to safety category 4 EN 954 1 8 N O contacts 1 N C contact Cross circuit detection 511 512 521 522 Us 24 V DC AC Manual activation S33 S34 Monitored start Stop category 0 24 V DC AC Fault 1 Fault 2 poo 5 m AR DDS DIDS O Wi 2 92 aa 54 p Fault 5
6. A2 S33 S34 S35 S21 S22 14 24 OV Features Two channel with semiconductor output OUT1 at S10 OUT2 at S12 bridge Y1 Y2 21 S22 3 undelayed N O contacts 2 delayed N O contacts 1 N O contact Us 24 V DC Manual activation S33 S34 Monitored start Stop category 0 1 N gt 02 04 0 6 0 8 1 1 2 2 0 8 1 6 24 32 4 4 2 S a gt gt mm mm ma A 113 123 133 PSR ESD 22582 l ON 64 128 19 2 25 32 38 ON JP 50 100 150 200 250 300 A B 67 167 68 IPHCENIX Power 1 ul K3 t 102597 022 Figure 3 25 PSR ESD Application example 3 102597_01_en PHOENIX CONTACT 3 31 SAFETY RELAY APPLICATION 3 8 PSR RSM PSR SSM Speed and Downtime Monitoring 3 8 1 PSR RSM Application Example 1 Most Basic Machine PSR RSM Application Features Evaluation of a safe speed 4 N O contacts Encoder sensors Us 24 V DC Connection via RJ45 Automatic activation bridge 533 535 Up to safety category 3 EN 954 1 Stop category O SIL 3 according to EN 61508 SIL data on request 424 V DC gt 2 Z QD L aL At MI I3
7. ER 1 1 1 1 Phoenix Contact The Innovative 1 1 1 2 Wide Range of Products in Slim Housing 1 2 1 2 1 Emergency Stop Safety Door 1 2 1 2 2 Light Curtain uae ere ele dose save mcus 1 5 1 2 3 1 6 1 2 4 Contact Extension Positively Driven Contacts 1 8 1 2 5 Sale FUNCION ua a ps 1 8 1 2 6 CERE aa 1 9 1 2 7 Safe Isolation 1 11 1 2 8 PROCESS Technology sss eet arnt S 1 11 1 2 9 Speed and Downtime Monitoring 1 12 1 2 10 Connection Terminal Blocks 1 12 1 3 DOCUMEMAUO a An 1 12 2 Safety Technology 3 Wiring Examples 102597 01 en 3 2 3 3 3 4 2 1 Accidents al Me E ee else 2 1 Strategies for Preventing Accidents at Work 2 5 Standards and Direelives a 2 dex Ec UE ER 2 8 2 3 1 Useful Addresses for Information About Standards and PROGUIATIOINS EUR 2 10 2 3 2 Interesting Li
8. SAFETY RELAY APPLICATION PSR ESD Description Emergency stop and safety door monitoring with delayed and undelayed contacts 24 V DC single and two channel adjustable from 200 ms to 300 s with without cross circuit detection Emergency stop and safety door monitoring with delayed and undelayed contacts 24 DC single and two channel with without cross circuit detection with fixed times 0 5 1 30 5 see table PSR RSM Description Speed and downtime monitoring 24 DC two channel automatic control via cable adapter or two initiators B 2 PHOENIX CONTACT Activation Manual and automatic Manual and automatic Type PSR SCP 24DC ESD 5X1 1X2 300 PSR SPP 24DC ESD 5X1 1X2 300 PSR SCP 24DC ESD 5X1 1X2 T PSR SPP 24DC ESD 5X1 1X2 T With start button monitoring Activation Manual and automatic PSR ESD T Order Versions Type Screw Connection PSR SCP 24DC ESD 5X1 1X2 0T5 PSR SCP 24DC ESD 5X1 1X2 T1 PSR SCP 24DC ESD 5X1 1X2 1T5 PSR SCP 24DC ESD 5X1 1X2 T2 PSR SCP 24DC ESD 5X1 1X2 2T5 PSR SCP 24DC ESD 5X1 1X2 T3 PSR SCP 24DC ESD 5X1 1X2 T4 PSR SCP 24DC ESD 5X1 1X2 T5 PSR SCP 24DC ESD 5X1 1X2 T6 PSR SCP 24DC ESD 5X1 1X2 T10 PSR SCP 24DC ESD 5X1 1X2 T15 PSR SCP 24DC ESD 5X1 1X2 T20 PSR SCP 24DC ESD 5X1 1X2 T30 Type Spring Cage Connection PSR SPP 24DC ESD 5X1 1X2 0T5 PSR SPP 24DC ESD 5X1 1X2 T1 PSR SPP 24DC ESD 5X1 1X2 1T5 PSR SPP 24DC ESD 5X1 1X2 T2 P
9. Fault 4 FF KI N 1 S10 511 512 S21 S22 13 23 33 43 53 63 73 83 9 113 123 433 443 153 463 4673 183 91 O PSR ESAM4 Yu Yos 34 Na 54 Na A2 533 534 535 14 24 34 44 54 64 74 84 92 1 321522 2 83 63 64 13 14 23 24 84 73174 Fault 3 Reset OV 102597A007 Figure 3 7 PSR ESMAA Application example 1 102597_01_en PHOENIX CONTACT 3 9 SAFETY RELAY APPLICATION 3 10 PHOENIX CONTACT Fault Monitoring Fault 1 Short circuit S11 S12 Power ON K1 ON K2 OFF Fault 2 Short circuit 521 522 Power ON K1 OFF K2 ON Fault 3 Restart not possible following initial emergency stop actuation Emergency stop safety function provided Power ON K1 OFF 2 Fault 4 No bridge or interrupt Power ON K1 OFF K2 OFF Fault 5 Cross circuit between the two emergency stop channels Conductive connection between the two emergency stop channels Power OFF K1 OFF K2 OFF 102597 01 Wiring Examples 3 3 2 PSR ESAM4 Application Example 2 PSR ESAM4 Application Features Emergency stop monitoring Two channel 511 512 521 522 bridge 510 511 Up to safety category 4 EN 954 1 8 N O contacts 1 N C contact Cross circuit detection 511 512 521 522 Us 24 V DC AC Automatic activation bridge 533 535 Stop category 0 424 V DC AC wos 2090 2094 512654654554 ss 5 s
10. UN EK ex AW Disconnect wiping relay Figure 2 14 Safety category 2 O C V Danger 2 P OFF C E FOI sol 4 KO C ON F KOI 502 Warning Y OFF 4 52 F O 2 KOIL Dangerous drive Safety circuit When the safety grid is opened disconnect wiping relay K2 is supplied with power When the safety grid is closed K2 picks up for a brief period and switches K1 on remaining locked The safety circuit is enabled If K1 does not drop out when the safety grid is opened relay K3 picks up and triggers an alarm that remains on even when the safety grid is closed again PHOENIX CONTACT 2 25 SAFETY RELAY APPLICATION Safety Category 3 Single Channel Control Redundant The requirements of category B and the use of proven safety principles must be met Safety related parts must be designed so that single fault in one of these parts does not lead to the loss of the safety function Whenever feasibly possible the single fault is detected on or before the next demand of the safety function System behavior in the When the single fault occurs the safety function is always performed event of a fault Some but not all faults are detected An accumulation of undetected faults can lead to the loss of the safety function Movable guard Open Safety circuits Closed Positively 1 actuated 4
11. CERTIFICATE Pr fgegenstand Sicherheits Relais Product tested Nr No 968 EL 200 01 04 Hersteller Phoenix Contact GmbH amp Co Manufacturer FlachsmarktstraBe 8 D 32825 Blomberg Typbezeichnung PSR SCP 24DC ESPA 2X1 1X2 Verwendungs Sicherheits Relais f r Not Aus Type designation psR SPP 24DC ESPA 2X1 1X2 ZWECK und Schutzt ranwendungen Pr fgrundlagen Codes and standards forming the basis of testing Pr fungsergebnis Test results Besondere Bedingungen Specific requirements Intended application DIN VDE 0116 10 1989 EN 954 1 1996 EN 50178 1998 EN 60204 1 1998 61508 Teile 1 7 EN 50156 1 2004 Unter Beachtung der Hinweise in der Betriebsanleitung werden die Anforderungen der Sicherheitskategorie 4 nach EN 954 1 SIL3 nach der Normenreihe IEC 61508 und Sicher heitsniveau 3 gem EN 50156 1 f r Feuerungsanlagen im Dauerbetrieb erf llt Das Betriebsintervall von 6 Monaten zwischen zwei Funktions pr fungen gem EN 50156 1 Tabelle 2 darf nicht ber schritten werden Die Einsatzzeit nach der IEC 61508 betr gt 48 Monate Inner halb dieses Zeitraums ist SIL3 eingehalten Dar ber hinaus wird SIL 3 verlassen Der Pr fbericht Nr 968 EL 200 01 04 vom 2004 09 08 ist Bestandteil dieses Zertifikates Dieses Zertifikat ist nur g ltig f r Erzeugnisse die mit dem Pr fgegen stand bereinstimmen Es wird ung ltig bei jeglicher nderung der Pr fgrundlagen f r den angegebenen Verwendung
12. 0Y1 A2 Y1 24 34 44 54 62 Yl 18 Figure 3 38 Wiring via T BUS DIN rail connector 102597 01 en PHOENIX CONTACT 3 43 SAFETY RELAY APPLICATION PSR SDC4 424 V DC x TBUS 3 9 7 PSR SDC4 and PSR URD3 Extension Module Application Example 7 Application Features Emergency stop monitoring Two channel A2 S22 S11 S12 bridge S10 S11 Up to safety category 4 EN 954 1 2 N O contacts undelayed contacts Delayed contacts 4 N O contacts 1 N C contact Up to safety category 3 EN 954 1 Us 24 V DC delayed contacts Cross circuit detection A2 S22 and S11 S12 Manual activation S33 S34 Monitored start Stop category 1 13 23 PSR SDC4 S a TBUS OV A2 14 24 102597A047 Figure 3 39 PSR SDC4 and PSR URD3 extension module Application example 7 MO OA Ki 15 16 27 37 47 57 65 a A20 2 PSR SDC Ki 1 20 1 2 PSR URD3 2 m 10 533 0 Y Y Y 16 EN 19 28 38 48 58 66 Y1 _ Figure 3 40 Wiring T BUS DIN rail connector 3 44 PHOENIX CONTACT 102597_01_en PSR ES 4 24 V Reset EMERGENCY STOP A2 OV 102597_01_en Wiring Examples 3 10 PSR ES 4 Connection of Several Safety Relays 3 10 1 Application Emergency stop monitoring Up to safety category 4 EN 954 1 A1 S11 S12 S21 S22 S33 S34 13 23 233 A1
13. PHOENIX CONTACT 2 15 UM SAFETY RELAY APPLICATION ANSI B11 19 2003 The B11 19 standard provides performance requirements for the design construction Performance Criteria for installation operation and maintenance of safeguards when applied to machine tools Safeguarding ANSI B11 19 includes general requirements for safeguarding and does not provide application specifics Special requirements can be found in B11 standards Table 2 4 ANSI B11 standards 2 16 PHOENIX CONTACT 102597 01 en Other areas covered ANSI standards 102597 01 Safety Technology Below is a partial list of industrial machinery covered by ANSI standards Machine tools Packaging Power transmission Housing Compressors Copper connections Injection molding Forging Printing ink vertical post mixers Rubber hoses belts Commercial laundry dry cleaning Overhead hoists Foundry Plastics Refuse collection compacting Casting Automotive lifts Scrap metal processing National Fire Protection Association NFPA NFPA is an international non profit membership organization founded in 1896 as the National Fire Protection Association NFPA develops publishes and disseminates more than 300 consensus codes and standards intended to minimize the possibility and effects of fire and other risks Virtually every building process service design and installation in soci
14. BK may be followed by DP V1 may be followed by PAC and Type VARIO BK DP V1 Din mountable safety relays Types PSR P 24UC PSR P 24DC PSR P 24UC or PSR P 120UC followed by alpha numeric characters Types PSR SCP24UC ESLA 3X1 1X2 B and PSR SPP24UC ESLA 3X1 1X2 B Types PSR P 24DC ESD 5X1 1X2 followed by xTy Tz or 300 Types PSR SCF 24UC URM 2X21 and PSR SCF 120UC URM 2X21 Last Updated on 2004 11 18 Page Top Notice of Disclaimer Questions Previous Page UL Listed and Classified UL Recognized Products Certified Products Components for Canada This page and all contents are Copyright 2005 by Underwriters Laboratories Inc The appearance of a company s name or product in this database does not in itself assure that products so identified have been manufactured under UL s Follow Up Service Only those products bearing the UL Mark should be considered to be Listed and covered under UL s Follow Up Service Always look for the Mark on the product UL permits the reproduction of the material contained in the Online Certification Directory subject to the following conditions 1 The Guide Information Designs and or Listings files must be presented in their entirety and in a non misleading manner without any manipulation of the data or drawings 2 The statement Reprinted from the Online Certifications Directory with permission from Underwriters Laboratories Inc must appear adjacent to the extracted material In additi
15. Emergency stop monitoring Up to safety category 4 EN 954 1 24 V DC AC EMERGENCY A1 S11 S12 S21 S22 13 23 3 PSR ESA4 DEM A PSR ESM4 Va 24 Boo PSR URM4 Features Two channel 511 512 521 522 x contacts x contacts Us 24 V DC AC Cross circuit detection S11 S12 and S21 S22 Manual activation without start button monitoring for PSR ESA 533 534 Manual activation with start button monitoring for PSR ESM 533 534 Contact extension by PSR URM4 Feedback circuit for monitoring contact extension 1 11 23 33 43 53 63 71 11 423 433 443 453 163 471 b 24 34 54 64 A2 533 534 14 24 32 A2 A2 12 12 24 34 44 54 64 72 102597 A030 Figure 3 43 PSR ES 4 and PSR URM4 extension modules Application example 3 102597_01_en PHOENIX CONTACT 3 47 SAFETY RELAY APPLICATION 3 11 PSR ESAM4 PSR ESA4 Machines in Integrated Systems 3 11 1 PSR ESAMA PSR ESA4 Application Example 1 PSR ESAMA PSR ESA4 Application of Machine 1 Features of Machine 1 Emergency stop monitoring Two channel 511 512 521 522 bridge S10 S11 Up to safety category 4 EN 954 1 x N O contacts x N C contacts Us 24 V DC AC Manual activation with reset button monitoring 533 534 Monitored contact extension PSR ESAMA PSR ESA4 Application of Machine 2 Features of Machine 2 Emergency stop monitoring Two channel via machine 1 511 512 521 522 Up to safety categor
16. SAFETY RELAY APPLICATION 1 12 PHOENIX CONTACT 1 2 9 Speed and Downtime Monitoring Monitoring modules for detecting downtimes and speeds in setup mode and in special operating modes with safety doors open on machines and systems Advantages configured SIL approval With cable adapter or initiators Compact design 1 2 10 Connection Terminal Blocks Keyed plug in connection terminal blocks ensure that there are no faults in the fixed wiring should servicing be required It is no longer possible to mix up the cables Screw connection and spring cage connection versions are available 1 3 Documentation Make sure you always use the latest documentation Changes or additions to this document can be found on the Internet at www download phoenixcontact com When working with the PSR safety relays you must always keep this user manual and other items of product documentation to hand and observe the information therein SAFETY INTRO UM E Order No 2699202 Introduction to safety technology and overview of standards INF EN DE PSR IL SAFE Order No 5148802 Safety technology basics FLY EN DE SAFETY RELAY Order No 5106873 Overview of the Phoenix Contact safety relay range 102597_01_en Safety Technology 2 Safety Technology Accident at work 102597_01_en 2 1 Accidents at Work An accident at work is understood to be a personal injury to an employee that Occurs during the
17. to monitor safety doors 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 requirement 24 V 21 EMERGENCY 1 S11 512 521 522 13 23 31 4 WW fh A2 533 S34 535 14 24 32 OV 102597A036 Figure 1 1 Cable lengths 1 2 PHOENIX CONTACT 102597_01_en Assumed values Technical data for the safety relay Calculated value 102597 01 Introduction Using the example of an emergency stop application with the PSR ESAA see Figure 1 1 the following calculations can be made Cable A 1 5 mm Specific conductivity for Cu 56 mm at 20 C Input data Maximum voltage drop for 511 512 and 521 522 2 V DC approximately corresponds to 22 approximately R1 R2 220 1 22 Q 1 5 mm 56 mm 1848 m Where 1 Permissible cable length R Cable resistance A Cable cross section K Kappa conductivity Cu Copper This refers to the forward and return line for both channels S11 S12 and S21 S22 The cable length for S33 S34 must be taken into consideration here since the application operates with automatic start PHOENIX CONTACT 1 3 SAFETY RELAY APPLICATION Cross Circuit Detection In both ca
18. 12 523524525 13 23 3343 A s11 S12 S21 S22 13 23 33 41 24 V 3 113 123 133 INT Bere 2 PSR ESM4 124 134 142 S A2 S33 534 14 24 984 42 Q 5 8 5 8 8 5 8 RJ45 A2 FO 1 MO2 14 24 34 44 _ K3 o K4 o 102597A023 OV Figure 3 26 PSR RSM Application example 1 most basic machine SK Safety contact UK Monitoring contact 3 32 PHOENIX CONTACT 102597_01_en 3 8 2 Monitored Drive PSR RSM Application Downtime monitoring Monitoring of parameterized speeds 12 Encoder sensors Connection via RJ45 Up to safety category 3 EN 954 1 SIL 3 according to EN 61508 SIL data on request 424 V DC Operating mode switch OV Figure 3 27 SK Safety contact UK Monitoring contact 102597_01_en Wiring Examples PSR RSM Application Example 2 Basic Machine With a Features 4 N O contacts Us 24 V DC Automatic activation bridge S33 S35 Stop category 0 cy W O 20 L ol m Al Mi I3 12 5335345355 1323 3343 A1 S11 S12 S21 S22 13 23 33 4 M g 113 123 133 ut 15 ANE Mi en A 2 PSR RSM 5 5 2 533 534 14 24 34 42 RJ45 A2 FO 1 2 K3 D KA 102597 024 PSR RSM Application example 2 basic machine with monitored drive PHOENIX CONTACT 3 33 SAFETY RELAY APPLICATION 3 8 3 PSR RSM Application Example 3 Machine To
19. 4 Control signals at PLC input optocoupler 71 1 NIANON Y Not positively actuated Figure 2 15 Safety category 3 2 26 PHOENIX CONTACT 102597_01_en Safety Technology Safety Category 4 Single Channel Control Redundant and Testing The requirements of category B and the use of proven safety principles must be met Safety related parts of the control system must be designed so that single fault in any of these parts does not lead to the loss of the safety function single fault is detected on or before the next demand of the safety function If this is not possible then an accumulation of faults must not lead to the loss of the safety function System behavior in the When faults occur the safety function is always performed event of a fault The faults will be detected in time to prevent the loss of the safety function Movable guard Open Closed e was x p Tenat Figure 2 16 Safety category 4 102597 01 Positively actuated Not positively actuated Safety circuits PHOENIX CONTACT 2 27 SAFETY RELAY APPLICATION 2 28 PHOENIX CONTACT 102597 01 en Wiring Examples 3 Wiring Examples This section contains application examples for PSR safety relays In some of the examples faults are illustrated such as cross circuits short circuits or wiring faults which can occur in the circuit A description of the fa
20. 5 UM SAFETY RELAY APPLICATION A 6 PHOENIX CONTACT PHOENIX TEST LAB GmbH K nigswinkel 10 T T D 32825 Blomberg Germany Typpr fbescheinigung des Pr flabors Phone wad Denn Type Certificate of the Test Laboratory Fax 4449 5235 9500 10 Pr fgebiet EMV Konformit tspr fung Scope Pr fvorschriften Werknorm 10 Test Standards Pr fgegenstand Equipment under Test Pr fberichtsnummer Test Report Number Auftraggeber Client Datum der Pr fung Date of Test Pr fergebnis Test Result Blomberg den 16 11 2000 Blomberg 16 11 2000 G P L basierend auf EN 50081 2 1993 EN 61000 6 2 1999 PSR SCP 24UC ESM4 2X1 1X2 Artikel Nr 2963718 E00442 Fa Phoenix Contact GmbH amp Co Flachsmarktstra e 8 28 32825 Blomberg 07 08 14 08 2000 Das gepr fte Baumuster ist konform zu den genannten Pr fvorschriften The examined type is in conformity with the above mentioned test standards verantwortlicher Pr fer M Pohl Laborleiter D Pelz Examiner Laboratory Director EMC and Radio Accreditation Safety and Environment Accreditation Deutscher Deutscher Akkeecditienungs Akkseditierungs Rat Rat RR Registration No TTI P G071 94 01 Registration No DAT P 105 00 00 Examiner M Pohl Test Report No 00442 Date of issue 15 10 2000 Order No 00442 page 1 of 1 102597 01 en 102597 01 Approvals and Certificates A 2 3 PSR ESAM4 e Fachausschuss Elekt
21. Area EEA Each member state of the EEA is obliged to adopt the single market guidelines in national legislation without any alterations These guidelines are then valid in particular for manufacturers National legislation 4 National legislation Rn EC directive EU member states EU candidate countries Ev 102597 A033 Figure 2 7 European Economic Area EEA 2 8 PHOENIX CONTACT 102597_01_en Safety Technology Meaning As standards are no longer set at national level since the integration of the EU EEA interested EU member states can form their own standards committees which work together to draw up international standards Operators who design or build their machines according to the specifications in these standards can assume that they are meeting the requirements of EU directives or national legislation regarding machinery directives This assumption gains particular weight if there is a question of guilt following an accident at work Even if not required by law it is always advisable to observe the standards Classification In order to implement the EU directives it was first necessary to create uniform standards for all of Europe To cope with this enormous task without delay the standards were divided up into different types which enabled work to be done on different levels at the same time Type A B and C standards were created in this way see Table 2 1 Table 2 1 Typical examples of
22. C 1 C2 Listol TabieStu u uruy yun C 5 T D 1 102597_01_en PHOENIX CONTACT iii SAFETY RELAY APPLICATION 102597 01 1 Introduction 102597 01 Introduction 1 1 Phoenix Contact The Innovative Company Phoenix Contact is an innovative company in the world of connection technology between wires and PCBs in the world of automation technology electrical interface technology and the world of surge protection Over 6000 employees work in partnership with customers and business partners to create innovative products for markets across the world Phoenix Contact subsidiaries and agencies support users globally with their applications on all continents Company History It was from copper and ideas that Phoenix Elektrizit tsgesellschaft Kn mann 4 Co was founded in Essen Germany in 1923 Intensive cooperation with energy suppliers in Germany led to the development of modular terminal blocks that can be aligned The Group now has over 30 sales offices worldwide Phoenix Contact GmbH amp Co KG is based in Blomberg in the East Westphalia region of Germany INTERFACE PSR Safety Relays From Phoenix Contact Simplicity means safety for people machines and the environment It is a generally accepted fact that best solutions are often the simplest This applies in
23. ESD 5X1 1X2 300 PSR SPP 24DC ESD 5X1 1X2 300 PSR SCP 24DC ESD 5X1 1X2 0T5 PSR SPP 24DC ESD 5X1 1X2 0T5 PSR SCP 24DC ESD 5X1 1X2 T1 PSR SPP 24DC ESD 5X1 1X2 T1 PSR SCP 24DC ESD 5X1 1X2 1T5 PSR SPP 24DC ESD 5X1 1X2 1T5 PSR SCP 24DC ESD 5X1 1X2 T2 PSR SPP 24DC ESD 5X1 1X2 T2 PSR SCP 24DC ESD 5X1 1X2 2T5 PSR SPP 24DC ESD 5X1 1X2 2T5 PSR SCP 24DC ESD 5X1 1X2 T3 PSR SPP 24DC ESD 5X1 1X2 T3 PSR SCP 24DC ESD 5X1 1X2 T4 PSR SPP 24DC ESD 5X1 1X2 T4 PSR SCP 24DC ESD 5X1 1X2 T5 PSR SPP 24DC ESD 5X1 1X2 T5 PSR SCP 24DC ESD 5X1 1X2 T6 PSR SPP 24DC ESD 5X1 1X2 T6 PSR SCP 24DC ESD 5X1 1X2 T10 PSR SPP 24DC ESD 5X1 1X2 T10 PSR SCP 24DC ESD 5X1 1X2 T15 PSR SPP 24DC ESD 5X1 1X2 T15 PSR SCP 24DC ESD 5X1 1X2 T20 PSR SPP 24DC ESD 5X1 1X2 T20 PSR SCP 24DC ESD 5X1 1X2 T30 PSR SPP 24DC ESD 5X1 1X2 T30 PSR SCP 24DC RSM AX1 PSR SPP 24DC RSM AX1 PSR SCP 24DC SSM 2X1 PSR SPP 24DC SSM 2X1 PHOENIX CONTACT CE BG T V CUL Fuel Technology EN 50156 1 VDE 0116 EN 954 1 IEC 61508 SIL 3 102597 01 en Approvals and Certificates A2 Certificates Underwriters Laboratories Inc NKCR7 E140324 Auxiliary Devices Certified for Canada Page Bottom Print friendly version Questions Previous Page Auxiliary Devices Certified for Canada See General Information for Auxiliary Devices Certified for Canada PHOENIX CONTACT GMBH amp COKG E140324 FLACHSMARKTSTRASSE 8 32825 BLOMBERG GERMANY Controllers Types IL PB
24. Example 2 PSR ESD 300 Application Features Emergency stop monitoring Single channel S11 S12 bridge S10 S12 Y1 Y2 Up to safety category 2 EN 954 1 3 undelayed N O contacts 2 delayed N O contacts 1 N O contact Up to safety category 4 only when using Us 24 V DC positive opening switches and installing cable in separate cable sheaths Manual activation S33 S34 Monitored start Stop category 0 1 424 V DC N gt gt o n 2 x 0 2 0 4 0 6 0 8 EMERGENCY 08 16 24 32 4 42 STOP qu d 6 4 12 8 19 2 25 32 38 gt NN MH a z T 50 100 150 200 250 300 1 Y2 S10 11 512 13 23 33 57 67 167 113 123 133 41 41 PSR ESD T Yo4 42 58 68 Power 1 2 O K3 t EN 57 67 41 13 23 24 A2 533 934 535 521 522 14 24 34 PSR ESD Reset OV 102597A021 Figure 3 24 PSR ESD Application example 2 3 30 PHOENIX CONTACT 102597_01_en Wiring Examples 3 1 3 PSR ESD Application Example 3 PSR ESD 300 Application Limit switch monitoring Up to safety category 4 EN 954 1 depending on limit switch 424 V DC Semiconductor output GND 24 V DC OUT1 JOUT2 A1 Y1 Y2 S10 11 S12 13 23
25. ON K1 OFF K2 OFF Fault 3 During operation all LEDs lit up K1 and K2 OFF Restart not possible Undervoltage at 1 2 Power ON K1 OFF lights up only faintly K2 ON PHOENIX CONTACT 3 21 SAFETY RELAY APPLICATION 3 5 2 PSR ESL4 Application Example 2 PSR ESL4 Application Emergency stop monitoring Up to safety category 3 EN 954 1 24 V DC AC gt 2 K1 IL TL A1 11 S12 822 13 23 33 41 113 123 Yo4 io A2 S33 534 535 14 24 34 42 5 777 PSR ESL4 K4 K3 OV Features Two channel 511 512 511 522 3 contacts 1 contact Us 24 Manual activation S33 S34 Monitored start Monitored contact extension S33 S34 Stop category 0 102597A014 Figure 3 17 PSR ESL4 Application example 2 3 22 PHOENIX CONTACT 102597_01_en PSR ESL4 24 V DC AC K1 A1 EMERGENCY iub 3 5 3 Application Emergency stop monitoring Up to safety category 2 EN 954 1 11 S12 522 PSR ESL4 A2 33 534 535 102597 01 Figure 3 18 13 23 33 41 41 4 13 123 133 Yo4 14 24 34 42 Wiring Examples PSR ESL4 Application Example 3 Features Single channel 511 512 bridge 512 522 3 contacts 1 contact Us 24 Manual activation S33 S34 Monitored start Stop category 0 102597A015 PSR ESL4 Appl
26. OSHA machine safety standards 102597 01 Safety Technology OSHA s machine guarding safety standards including those from the Code of Federal Regulations Title 29 1910 Subpart Machinery and Machine Guarding listed in Table 2 3 Table 2 3 OSHA machinery and machine guarding standards 1910 218 Forging machines 1910 219 Mechanical power transmission apparatus 3067 Concepts amp Techniques of Machine Safeguarding Important note Standards from other organizations which are incorporated by reference have the same force and effect as the standard itself Only the mandatory provisions i e provisions containing the word shall or other mandatory language of standards incorporated by reference are adopted American National Standards Institute ANSI The American National Standards Institute ANSI is a private non profit organization that administers and coordinates the U S voluntary standardization and conformity assessment system It facilitates the development of American National Standards ANS by accrediting the procedures of standards developing organizations These groups work cooperatively to develop voluntary national consensus standards The Institute s mission is to enhance both the global competitiveness of U S business and the U S quality of life by promoting and facilitating voluntary consensus standards and conformity assessment systems and safeguarding their integrity
27. S11 S12 S21 S22 S33 S34 13 23 33 PSR ESMA 13 23 99 PSR ESMA 13 23 99 PSR ESA4 34 PSR ESA4 UM 34 14 24 34 Figure 3 41 A2 PSR ES 4 Application Example 1 Features Two channel 511 512 521 522 x contacts x contacts Us 24 V DC AC Cross circuit detection S11 S12 and S21 S22 Manual activation of several safety relays with a monitored reset button A1 S34 the button is only monitored for PSR ESM EMERGENCY STOP 14 24 84 102597A028 PSR ES 4 Application example 1 PHOENIX CONTACT 3 45 SAFETY RELAY APPLICATION 3 10 2 PSR ESA2 Application Example 2 PSR ESA2 Application Features Emergency stop monitoring Single channel 511 512 Up to safety category 2 EN 954 1 x N O contacts x N C contacts Us 24 V DC AC Manual activation of several safety relays with a monitored reset button A1 S34 the button is not monitored 24 V DC AC EMERGENCY STOPA gt 2 gt STOPA 1 511 512 533 534 13 23 33 43 51 1 611 512 533 534 13 23 33 113 423 133 PSR ESA2 Via Von a 14 24 34 113 423 433 443 PSR ESA2 Ma 15 A2 14 24 34 44 52 OV 102597A029 Figure 3 42 PSR ESA2 Application example 2 3 46 PHOENIX CONTACT 102597_01_en Wiring Examples 3 10 3 PSR ES 4 and PSR URM4 Extension Module Application Example 3 PSR ES 4 PSR URM4 Application
28. SDC4 ES A2 S22 102597A044 Figure 3 35 PSR SDC4 Application example 4 PHOENIX CONTACT 3 41 SAFETY RELAY APPLICATION 3 9 5 PSR SDC4 Application Example 5 PSR SDC4 Application Features Light grid monitoring Two channel OSSD1 S10 OSSD2 S12 bridge A2 S22 Up to safety category 4 EN 954 1 2 N O contacts Us 24 V DC Automatic activation bridge Y1 S33 S35 Cross circuit detection OSSD1 OSSD2 fault detected by light grid Stop category 0 24 V DC 13 23 13 123 Ya Ya 14 24 102597A045 Figure 3 36 PSR SDC4 Application example 5 3 42 PHOENIX CONTACT 102597_01_en Wiring Examples 3 9 6 PSR SDC4 and PSR URMA AX1 Extension Module Application Example 6 PSR SDC4 Application Features Emergency stop monitoring Two channel A2 S22 511 512 bridge S10 S11 Up to safety category 4 EN 954 1 5 N O contacts 1 N C contact Us 24V DC Cross circuit detection A2 S22 and 511 512 Manual activation S33 S34 Monitored start Stop category 0 24 V DC 1 Yi 18 23 1 2 11 12 23 Ir PSR SDC4 PSR URM4 4X1 R i 2 2 TIBUS 102597 046 Figure 3 37 PSR SDC4 PSR URM4 4X1 extension module Application example 6 0 0 0 0 0 0 0 0 0 10 5 1 Al 1 11 12 2 j i M 61 Al PSR SDC SS T PSR URM4 B Ki Sel K1 K20 OK1 K2 Ko 833 0 011 VH 129794 8 Y19
29. SPP 24 230UC ESAM4 3X1 1X2 2963802 02 PSR SCP 24UC ESA2 4X1 1X2 B 2963954 00 PSR SPP 24UC ESA2 4X1 1X2 B 2981020 01 PSR SCP 240 5 4 2 1 1 2 2981017 01 PSR SPP 24DC ESP4 2X1 1X2 2981059 02 PSR SCP 24UC ESL4 3X1 1X2 B 2981062 02 PSR SPP 24UC ESL4 3X1 1X2 B 2963721 03 PSR SCP 24UC THC 2X1 1X2 2963983 00 PSR SPP 24UC THC 2X1 1X2 2981677 00 PSR SCP 24DC URM4 4X1 2X2 B 2981680 00 PSR SPP 24DC URM4 4X1 2X2 B 2963734 03 PSR SCP 24UC URM4 5X1 2X2 2964005 00 PSR SPP 24UC URM4 5X1 2X2 2981033 00 PSR SCP 24UC URM4 5X1 2X2 B 2981046 00 PSR SPP 24UC URM4 5X1 2X2 B 2963747 03 PSR SCP 24UC URM 5X1 2X2 2963970 00 PSR SPP 24UC URM 5X1 2X2 2981402 01 PSR SCP 120UC URM 5X1 2X2 2981415 00 PSR SPP 120UC URM 5X1 2X2 2981363 00 PSR SCF 24UC URM 2X21 2981376 00 PSR SCF 120UC URM 2X21 2981486 00 PSR SCP 24DC SDC4 2X1 B 2981499 00 PSR SPP 24DC SDC4 2X1 B 2981512 00 PSR SCP 24DC URD3 4X1 2X2 2981525 00 PSR SPP 24DC URD3 4X1 2X2 102597 01 PHOENIX CONTACT UM SAFETY RELAY APPLICATION Order No 2981428 02 2981431 02 2981101 00 2981130 00 2981143 00 2981156 00 2981169 00 2981172 00 2981125 00 2981198 00 2981208 00 2981211 00 2981224 00 2981237 00 2981240 00 2981253 00 2981266 00 2981279 00 2981282 00 2981295 00 2981088 01 2981091 03 2981305 00 2981318 00 2981321 00 2981334 00 2981347 00 2981350 00 2963538 00 2963541 00 2963567 00 2963570 00 2 PSR SCP 24DC
30. URD Description Type Extension module with off delay contacts PSR SCP 24DC URD3 AX1 2X2 with single channel control 24 V DC with interface for DIN rail PSR SPP 24DC URD3 AX1 2X2 connector PSR URM Description Type Extension module PSR SCP 24DC URM4 4X1 2X2 B with single channel control 24 V DC with interface for DIN rail PSR SPP 24DC URM4 4X1 2X2 B connector Extension module PSR SCP 24 UC URM4 5X1 2X2 with single or two channel control 24 V AC DC PSR SPP 24UC URM4 5X1 2X2 Extension module PSR SCP 24UC URM4 5X1 2X2 B with single channel control 24 V AC DC PSR SPP 24UC URM4 5X 1 2 2 8 Universal safety relay with positively driven contacts 24 V AC IDC PSR SCP 24UC URM 5X1 2X2 PSR SPP 24UC URM 5X1 2X2 120 V AC DC PSR SCP 120UC URM 5X1 2X2 PSR SPP 120UC URM 5X1 2X2 Universal safety relay with positively driven contacts 24 V AC DC PSR SCF 24UC URM 2X21 120 V AC DC PSR SCF 120UC URM 2X21 Universal safety relay with positively driven contacts 24 V AC DC PSR SCF 24UC URM 4X1 2X2 PSR SPF 24UC URM AX1 2X2 120 V AC DC PSR SCF 120UC URM AX1 2X2 PSR SPF 120UC URM AX1 2X2 Accessories Description Type DIN rail connector yellow for PSR applications PSR TBUS Terminating connector PSR TBUS TP Documentation Description Type Introduction to Safety Technology user manual SAFETY INTRO UM E Safety technology basics INF EN DE PSR IL SAFE Overview of the Phoenix Contact safety relay range FLY EN DE SAFETY RELAY 102
31. a result of machine failure the incorrect behavior of employees or the bypassing of safety equipment Preventive health and safety protection for people in the workplace e g to protect against heat radiation flying parts etc Prevention of costs which result directly or indirectly from machine failure or the incorrect behavior of employees e g production failure damage to expensive machine parts and tools liability for quality defects compensation for injured persons etc Prevention of distortion of competition as a result of different safety requirements in international trade Safety Equipment Figure 2 5 on page 2 6 provides a selection of safety equipment from which the safety expert can select suitable solutions for his her application following a risk assessment Source Maschinenbau BG Professional Association for Mechanical Engineering 102597 01 PHOENIXCONTACT 2 5 SAFETY RELAY APPLICATION For safeguarding Enclosing guard _____ Fencing off _____ Figure 2 5 Safety equipment Establishing Machine Safety Strategies for improving machine and system safety are described in generic standard EN 292 It is first necessary to exploit all options where accidents can be prevented by design Measures relating to the ergonomics of operating desks and the like to suit the individual Avoiding sharp corners and edges in
32. cross circuit could not be tolerated A monitoring function is required that can control this fault see example in Figure 2 16 on page 2 27 1 22 Light Grid Light Curtain Light grids consist of a transmit and receive unit and have a two dimensional monitoring range Light grids are electrosensitive protective systems 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 way that it is impossible to access the protected field from above below or behind If this is not 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 environmental conditions must not adversely affect the effectiveness of the light protective system Door controls in elevators Detection of small parts and monitoring of parts in packaging machines Paper tear monitoring in printing presses Reliable measurement of grid boxes Profile and height control of pallets in warehouses and conveying technology Looms e g prevention of weft breakage EN 61496 1 EN 61496 2 IEC 61496 1 IEC 61496 2 Requirements for electrosensitive pr
33. liability associations are related to metal machining and processing machines These include presses cutters lathes drilling milling and grinding machines saws and special machinery and systems These accidents often result in serious injuries For machines that are built according to the EC Machinery Directive 98 37 EC the manufacturer is obliged to perform a hazard assessment to determine all the hazards linked to the machine The manufacturer must then design and build the machine in accordance with this analysis However the extent to which machines are really safe and whether all the hazards and risks have been estimated correctly is often only determined in practice Therefore following any accidents it is essential that their exact cause be determined and evaluated Evaluation of Accident Investigation Reports For the following diagrams 132 accident investigation reports from 1998 to 2000 were evaluated Although the investigation carried out is insufficient for a statistical evaluation due to its limited scope abnormalities could nevertheless be detected The following criteria were considered Injured party related characteristics Machine related characteristics Technical causes Behavior based causes Organizational causes Machine Type The evaluation of the accident investigation reports showed that accidents at work involving presses were the most common at around 34 followed by accident
34. nach IEC 61508 wird eingehalten sofern die ermittelte Einsatzzeit von 34 Monaten nicht berschritten und nach dieser Zeit eine Funktionspr fung durchgef hrt wird Die Installationsbedingungen und Anwendungshinweise in der Betriebsanleitung m ssen beachtet werden Der Pr fbericht Nr 968 EL 355 00 05 vom 2005 09 05 ist Bestand teil dieses Zertifikates Dieses Zertifikat ist nur g ltig f r Erzeugnisse die mit dem Pr f gegenstand bereinstimmen Es wird ung ltig bei jeglicher nde rung der Pr fgrundlagen f r den angegebenen Verwendungszweck The test report no 968 EL 355 00 05 dated 2005 09 05 is an integral part of this certificate This certificate is valid only for products which are identical with the product tested It becomes invalid at any change of the codes and standards forming the basis of testing for the intended application T V Industrie Service GmbH Gesch ftsfeld ASI Automation Software und tnformationstechnologie Am Grauen Stein 51105 K ln bid Postfach 91 09 61 61101 K ln 2 LH Datum Date Firmenstempel Company seal Unterschrift Signature A 8 PHOENIX CONTACT 102597 01 en Approvals and Certificates A 2 4 PSR THC m IE LK A T TUV EG Baumusterbescheinigung Richtlinie 98 37 EG Anhang VI Sicherheitsbauteile nach Mlaschinenrichtlinie Registrier Nr BB 60006385 0001 Bericht Nr 21109759 001 Inhaber der Bescheinigung Hersteller Phoenix Contact Gm
35. standards that are referenced as requirements by OSHA standards are expected to follow soon If a specific area of safety is not covered by an OSHA standard the related consensus standard s must be observed Figure 2 8 on page 2 14 illustrates the relationship between OSHA and the consensus standards The mission of the Occupational Safety and Health Administration is to save lives prevent injuries and protect the health of America s workers To accomplish this federal and state governments must work in partnership with more than 100 million working men and women and their six and a half million employers who are covered by the Occupational Safety and Health Act of 1970 To carry out this mission OSHA uses three basic strategies 1 Strong fair and effective enforcement safety inspections of the workplace 2 Outreach education and compliance assistance 3 Partnerships and other cooperative programs PHOENIX CONTACT 2 13 SAFETY RELAY APPLICATION issues standards to be followed by employers for a wide variety of workplace hazards including Toxic substances Machine hazards Harmful physical agents Dangerous atmospheres Electrical hazards Fire and explosion hazards Fall hazards Infectious diseases Trenching hazards Hazardous waste Figure 2 8 Relationship between OSHA and consensus standards 2 14 PHOENIX CONTACT 102597 01 en
36. with cross circuit detection PSR ESL Description Light grid emergency stop and safety door monitoring 24 V AC DC single and two channel 102597_01_en Activation Manual Manual and automatic Manual Manual and automatic Manual and automatic Manual and automatic Activation Manual and automatic Manual and automatic Activation Automatic Activation Manual and automatic Type PSR SCP 24UC ESM4 2X1 1X2 PSR SPP 24UC ESM4 2X1 1X2 PSR SCP 24UC ESAM 2X1 1X2 PSR SPP 24UC ESA4 2X1 1X2 PSR SCP 24UC ESM4 3X1 1X2 B PSR SPP 24UC ESMA 3X1 1X2 B PSR SCP 24UC ESA4 3X1 1X2 B PSR SPP 240 5 4 3 1 1 2 PSR SCP 24UC ESA2 AX1 1X2 B PSR SPP 24UC ESA2 AX1 1X2 B PSR SCP 24DC ESP4 2X1 1X2 PSR SPP 24DC ESP4 2X1 1X2 Type PSR SCP 24UC ESAM4 8X1 1X2 PSR SPP 24UC ESAMA 8X1 1X2 PSR SCP 24 230UC ESAMA 3X1 1X2 PSR SPP 24 230UC ESAM4 3X1 1X2 Type PSR SCP 240 4 2 1 1 2 PSR SPP 24UC THC4 2X1 1X2 Type PSR SCP 24UC ESL4 3X1 1X2 B PSR SPP 24UC ESL4 3X1 1X2 B With start button monitoring Ordering Data Order No 2963718 2963705 2963750 2963938 2963776 2963925 2963763 2963941 2963802 2963954 2981020 2981017 Order No 2963912 2963996 2981114 2981127 Order No 2963721 2963983 Order No 2981059 2981062 Pcs Pck gt gt Pcs Pck Pcs Pck Pcs Pck PHOENIX CONTACT B 1
37. 2 Figure 3 13 Figure 3 14 Figure 3 15 Figure 3 16 Figure 3 17 Figure 3 18 Figure 3 19 Figure 3 20 Figure 3 21 Figure 3 22 Figure 3 23 Figure 3 24 Figure 3 25 Figure 3 26 Figure 3 27 Figure 3 28 Figure 3 29 Figure 3 30 Figure 3 31 Figure 3 32 Figure 3 33 Figure 3 34 Figure 3 35 Figure 3 36 PSR ESAA Application example 3 4 PSR ESMA Application example 1 3 5 PSR ESMA Application example 2 3 7 PSR ESMA Application example 3 8 PSR ESMAd Application example 1 3 9 PSR ESMAd Application example 2 3 11 PSR ESMAd Application example 3 12 PSR ESMAA 3X1 Application example 1 3 13 PSR ESMAA 3X1 Application example 2 3 15 PSR ESMAA 3X1 Application example 3 16 PSR THC4 Application example 1 3 17 PSR THC4A Application example 2 3 18 PSR THC4A Application example 3 19 PSR ESL4 App
38. 2597 01 en PSR THC4 24 V DC AC PSR THC4 A2 102597_01_en 3 4 3 Application Two hand control Up to safety category 4 EN 954 1 Wiring Examples PSR THC4 Application Example 3 Features 2 N O contacts 1 N C contact Us 24 V DC AC Synchronous activation monitoring lt 0 56 Monitored contact extension 1 2 According to EN 574 type IIIC 511 514 512 521 13 23 31 522 524 31 123 fo 102597 012 Figure 3 15 PSR THC4A Application example PHOENIX CONTACT 3 19 SAFETY RELAY APPLICATION 3 5 PSR ESL4 Light Grid Applications 3 5 1 PSR ESL4 Application Example 1 With Fault Monitoring PSR ESL4 Application Light grid monitoring Up to safety category 4 EN 954 1 24 V DC AC 1 11 S12 22 13 23 33 41 41 PSR ESL4 You fe A2 533 534 535 14 24 34 42 Features Two channel 0 01 12 OSSD2 S22 3 contacts 1 contact Cross circuit detection OSSD1 OSSD2 fault detected by light grid Us 24 V DC AC Manual activation S33 S34 Monitored start Stop category 0 102597 A013 Figure 3 16 PSR ESL4 Application example 1 3 20 PHOENIX CONTACT 102597 01 en 102597 01 Wiring Examples Fault Monitoring Fault 1 Cross circuit of both light grid channels OSSD1 and OSSD2 Power ON K1 OFF K2 OFF Fault 2 Light grid channels OSSD1 and OSSD2 not connected OSSD1 S12 OSSD2 S22 S11 not connected Power
39. 511 512 S21 S22 Up to safety category 2 EN 954 1 N O contacts 1 contact Us 24 V DC AC Manual activation S33 S34 Monitored start Stop category 0 24 V DC AC gt 2 4 Fault 1 2 0 e l A1 511 812 521 522 13 23 33 41 41 PSR ESM4 ee A2 33 S34 14 24 34 42 gt v Fault 2 OV 102597A004 Figure 3 4 PSR ESMA4 Application example 1 102597_01_en PHOENIX CONTACT 3 5 SAFETY RELAY APPLICATION Fault Monitoring 1 Short circuit does not occur until itis actuated The safety function is no longer available i e emergency stop button also ceases to be effective The fault is only detected when regular maintenance is performed on the machine Power ON K1 ON K2 ON Fault 2 The module cannot be switched on again after releasing emergency stop The module can only be switched on again once the relevant fault has been removed Power ON K1 ON K2 OFF 3 6 PHOENIX CONTACT 102597 01 en Wiring Examples 3 2 2 PSR ESM4 Application Example 2 PSR ESM4 Application Features Emergency stop monitoring Two channel 511 512 521 522 Up to safety category 4 EN 954 1 N O contacts 1 contact Cross circuit detection 511 512 521 522 Us 24 V DC AC Manual activation S33 S34 Monitored start Stop category 0 24 V DC AC 2 Gt W O GG 1 511 512 521 522 13 23 93 41 41 PSR ESM
40. 597 01 en Ordering Data Order No 29 81 56 7 29 81570 Order No 2981486 2981499 Order No 2981512 2981525 Order No 2981677 2981680 2963734 2964005 2981033 2981046 2963747 2963970 2981402 2981415 2981363 2981376 2981444 2981457 2981460 2981473 Order No 2890425 2981716 Order No 2699202 5148802 5106873 Pcs Pck Pcs Pck Pcs Pck Pcs Pck gt gt Pcs Pck 50 50 Pcs Pck 1 1 1 PHOENIX CONTACT B 3 SAFETY RELAY APPLICATION B 4 PHOENIX CONTACT 102597_01_en Appendices Section 1 Section 2 Section 3 102597 01 C 1 Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 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 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 3 1 Figure 3 2 List of Figures List of Figures C 1 2 Cross circuit detection the event of single faults 1 4 Cross circuit detection in the event of several faults 1 4 Structure of a two hand control 1 7 Emergency stop 1 10 Notifiable accidents at work since 1950
41. CONTACT 102597_01_en List of Tables 2 List of Tables Section 1 Table 1 1 Requirements according to EN 574 1 6 Section 2 Table 2 1 Typical examples of standards 2 9 Table 2 2 Interesting links on the Internet 20 2 11 Table 2 3 OSHA machinery and machine guarding standards 2 15 Table 2 4 ANSIB13 SIandards uu s xu u Ha 2 16 Table 2 5 Definitions and abbreviations 2 20 102597_01_en PHOENIX CONTACT C 5 SAFETY RELAY APPLICATION 6 PHOENIX CONTACT 102597_01_en Revision History D Revision History kika 05 2006 First publication of the application manual in English 102597_01_en PHOENIX CONTACT D 1 SAFETY RELAY APPLICATION D 2 PHOENIX CONTACT 102597_01_en
42. CT 102597_01_en Wiring Examples 3 8 6 PSR SSM Application Example 1 Downtime Monitoring Using PNP or 2 Wire Proximity Switches PSR SSM Application Features Downtime monitoring Two channel IN1 SEN1 IN2 SEN2 using two PNP or 2 wire proximity switches Up to safety category 3 EN 954 1 SIL 3 according to EN 61508 Safety category 4 is possible if a test is performed within 24 hours of machine downtime to detect the internal sensor errors 24 V DC 52 51 Ai INT 2 SENT SEN2 13 23 31 41 PSR SSM oz 102597 027 Figure 3 31 PSR SSM Application example 1 downtime monitoring using PNP or 2 wire proximity switches S1 S2 1 Contact tooth No contact gap 102597 01 en PHOENIX CONTACT 3 37 SAFETY RELAY APPLICATION 3 9 PSR SDC4 PSR URD4 PSR URM4 Emergency Stop Monitoring 3 9 1 PSR SDC4 Application Example 1 PSR SDC4 Application Features Emergency stop monitoring Two channel A2 S22 511 512 bridge S10 S11 Up to safety category 4 EN 954 1 2 N O contacts Us 24 V DC Cross circuit detection A2 S22 S11 S12 Manual activation S33 S34 Monitored start Stop category 0 424 V DC TBUS 1 1 13 23 PSR SDC4 7 2 14 24 102597 041 Figure 3 32 PSR SDC4 Application example 1 3 38 PHOENIX CONTACT 102597 01 en Wiring Examples 3 9 2 PSR SDC4 Application Example 2 PSR SDC4 Application Features Emergency
43. ENIX CONTACT PSR ESD Application Example 1 With Fault Monitoring Features Two channel 511 512 521 522 bridge 510 511 Y1 Y2 3 undelayed N O contacts 2 delayed N O contacts 1 N O contact Us 24 V DC Cross circuit detection 510 511 512 521 522 Manual activation 533 534 Monitored start Stop category 0 1 N gt gt oNN n 2 x 0 2 0 4 0 6 0 8 0 8 2 4 3 2 4 2 gt MH O O 2 3 oEN o 2 2 C2 6 4 12 8 19 2 25 38 gt gt NN MH a 2 T 50 100 150 200 250 300 CONTACT Q Power O K3 t O N 9 PSR ESD 102597 A020 PSR ESD Application example 1 102597_01_en Wiring Examples Fault Monitoring Fault 1 Short circuit 511 512 Power ON K1 ON K2 OFF Fault 2 Faulty wiring 533 534 or bridge Y 1 Y2 missing Power ON K1 OFF K2 OFF K3 t OFF KA t OFF Fault 3 Short circuit 521 522 Power ON K1 OFF K2 ON Fault 4 Cross circuit between the two emergency stop channels Conductive connection between the two emergency stop channels Power OFF K1 OFF K2 OFF K3 t OFF KA t OFF 102597 01 en PHOENIX CONTACT 3 29 SAFETY RELAY APPLICATION 3 7 2 PSR ESD Application
44. IA Professional Institute for Safety at Work 2 4 PHOENIX CONTACT 102597 01 en Safety Technology Organizational Causes Operating errors represent a major percentage of the causes of accidents There are numerous reasons for this In addition to the reasons previously mentioned which result in manipulation insufficient knowledge of the following points can lead to incorrect behavior Correct operation of the machine Imminent dangers during use Suitable safety equipment In addition existing technical defects on machines often result in the use of prohibited operating procedures In order to prevent accidents at work it must be determined on the basis of individual cases whether in addition to the technical requirements correct operating instructions and training are provided for each operation and that they are also understood and observed by employees Summary and Outlook Accidents at work involving metal machining and processing machines represent a high percentage of the total number of accidents It is therefore important to investigate their cause and determine their main aspects so that effective safety equipment can be used The number and severity of accidents highlight the importance accorded to machine safety and that intensive accident prevention work is still required 2 2 Strategies for Preventing Accidents at Work Aims of Safety Technology Prevention of accidents at work that may be caused as
45. IL data on request 24 230 V DC AC EMERGENCY STOP 2 1 510 511 512 521 522 13 23 33 41 13 123 133 PSR ESAM4 3X1 A2 533 534 535 14 24 34 42 OV Features Two channel 511 512 521 522 bridge 510 511 3 contacts 1 contact Cross circuit detection 511 512 521 522 Us 24 230 V DC AC Automatic activation S33 S35 Stop category 0 L 1 2 41 42 14 102597 039 Figure 3 11 PSR ESMA4 3X 1 Application example 2 102597_01_en PHOENIX CONTACT 3 15 SAFETY RELAY APPLICATION 3 3 6 PSR ESAM4 3X1 Application Example 3 PSR ESAMA 3X1 Application Features Emergency stop monitoring Single channel S11 S12 bridge 521 522 S10 S12 Up to safety category 2 EN 954 1 3 contacts 1 contact According to EN 61508 SIL 3 Us 24 230 V SIL data on request Manual activation S33 S34 Monitored start Stop category 0 24 230 V EMERGENCY 79 1 510 511 512 521 522 13 23 33 41 13 4123 433 141 io PSR ESAM4 3X1 Y 34 fa A2 S33 S34 S35 14 24 34 42 L dep 2 41 42 14 OV 1025974040 Figure 3 12 PSR ESMA4 3X 1 Application example 3 16 PHOENIX CONTACT 102597 01 en PSR THC4 24 V DC AC Wiring Examples 3 4 PSR THC4 Two Hand Controls 3 4 1 PSR THC4 Application Example 1 With Fault Monitoring Appl
46. SIL 3 according to EN 61508 Us 24 V DC Automatic activation bridge Y 1 Y2 Stop category 0 24 V DC gt 5 qe T Fault 2 1 Y1 Y2 PSR ESP4 A2 OV 102597A018 Figure 3 21 PSR ESP4 Application example 2 Fault Monitoring Fault 1 Recovery time not reached Remove fault through voltage reset Power at A1 A2 K1 ON K2 OFF Fault 2 Bridge 1 2 missing Power at A1 A2 K1 OFF K2 OFF 3 26 PHOENIX CONTACT 102597_01_en Wiring Examples 3 6 3 PSR ESP4 Application Example 3 PSR ESP4 Application Features Evaluation of a safety control system 2 contacts 1 contact Up to safety category 4 EN 954 1 Us 24 V DC SIL 3 according to EN 61508 Monitored contact extension Y 1 Y2 with fault prevention in the input circuit Stop category 0 Safe PLC OUT e g S7 F 24 V DC K3 YT Y2 PSR ESP4 A2 102597A019 Figure 3 22 PSR ESP4 Application example 3 102597 01 PHOENIX CONTACT 3 27 SAFETY RELAY APPLICATION 3 7 PSR ESD Emergency Stop With Delayed Contacts 3 7 1 PSR ESD 300 Application Emergency stop monitoring Up to safety category 3 4 EN 954 1 424 V DC Fault 2 Haus Yi Y2 510 Sii 12 521 S22 13 23 33 41 57 67 STOP qui STOP HA 2 I Fault 4 123 133 157 167 i i Yo4 4 PSR ESD A2 533 534 535 14 24 34 42 58 68 gt OV Figure 3 23 3 28 PHO
47. SR SPP 24DC ESD 5X1 1X2 2T5 PSR SPP 24DC ESD 5X1 1X2 T3 PSR SPP 24DC ESD 5X1 1X2 T4 PSR SPP 24DC ESD 5X1 1X2 T5 PSR SPP 24DC ESD 5X1 1X2 T6 PSR SPP 24DC ESD 5X1 1X2 T10 PSR SPP 24DC ESD 5X1 1X2 T15 PSR SPP 24DC ESD 5X1 1X2 T20 PSR SPP 24DC ESD 5X1 1X2 T30 Type PSR SCP 24DC RSM4 4x1 PSR SPP 24DC RSM4 AX1 With start button monitoring Order No 2981428 2981431 See table See table Order No 2981101 2981143 2981169 2981125 2981208 2981224 2981240 2981266 2981282 2981088 2981305 2981321 2981347 Order No 2981130 2981156 2981172 2981198 2981211 2981237 2981253 2981279 2981295 2981091 2981318 2981334 2981350 Order No 29 81 538 29 81 54 1 Pcs Pck 1 1 Delay Time 0 5s 1s 1 5s 25 2 55 38 45 55 65 105 155 205 30 5 Delay Time 0 5 18 1 5 25 2 55 38 45 55 65 105 155 205 30 5 Pcs Pck 1 1 102597 01 PSR SSM Description Activation Type Downtime monitoring Manual and PSR SCP 24DC SSM 2X1 24 two channel automatic control via two automatic PSR SPP 24DC SSM 2X1 standard initiators With start button monitoring PSR SDC Description Activation Type Light grid emergency stop and safety door Manual and PSR SCP 24UC SDC4 2X1 B monitoring automatic PSR SPP 24UC SDC4 2X1 B 24 V DC single and two channel with without cross circuit detection with interface for DIN rail connector With start button monitoring PSR
48. The safety related parts of control systems and or their safety equipment as well as their components must be designed built selected assembled and combined in accordance with the relevant standards so that they can withstand the following Expected operational stress e g reliability with regard to switching capacity and switching frequency Influence in the work process of materials used e g detergents in a washing machine A Other relevant external influences e g mechanical vibrations external fields power supply interrupts or malfunctions Note For parts that meet safety category B no special safety measures are used Safety category B is thus restricted mainly to the correct selection of the suitable parts for the construction of a control system i e Safety classes Protection types Safety equipment Conductor type and insulation Conductor colors Conductor cross sections Colors for control or signaling devices Utilization categories of drives Measures to prevent environmental influences Dimensioning of switching devices and drives The occurrence of a fault can lead to the loss of the safety functions PHOENIX CONTACT 2 23 SAFETY RELAY APPLICATION System behavior in the event of a fault 2 24 PHOENIX CONTACT Safety Category 1 Single Channel Control The requirements of category B must be met Proven components and proven safe
49. and 4 for safety related parts of control systems S Severity of injury Preferred categories for reference points S1 Slight normally reversible injury 52 Serious normally irreversible injury F Frequency and or exposure time Possible categories which can to the hazard require additional measures F1 Seldom to quite often and or the exposure time is short F2 Frequent to continuous and or the exposure time is long P Possibility of avoiding the Measures which can be over hazard dimensioned for relevant risk P1 Possibility under specific conditions P2 Scarcely possible 2 22 PHOENIX CONTACT 102597 01 en System behavior in event of a fault 102597 01 Safety Technology 2 3 5 2 Safety Categories The safety categories determine the required behavior of the safety related parts of a control system in respect of their resistance to faults on the basis of the step by step design procedure They are equally valid for electrical hydraulic pneumatic and mechanical control systems irrespective of the form of power When a safety function is performed by several safety related parts e g sensor link monitoring modules control devices in the load circuit these parts may belong to one category and or a combination of different categories In order to be able to make a better comparison safety categories 1 to 4 are explained below using the example of safety grid monitoring Safety Category B
50. annunggsrichtlinie 89 336 EWG EMV Richtlinie GS ET 20 Grunds tze f r die Pr fung und Zertifizierung von Sicherheitsschaltger ten 2001 04 DIN EN 60947 5 1 Steuerger te und Schaltelemente Elektromechanische Steuerger te 2000 08 Bemerkungen Die sicherheitsrelevanten Strompfade mit den Ausgangskontakten siehe Anlage erf llen hinsichtlich der sicherheitsrelevanten Funktion die Anforderungen der Kategorie 4 nach DIN EN 954 1 1997 03 Das gepr fte Baumuster stimmt mit den in 8 4 Absatz 1 des Ger te und Produktsicherheitsgesetzes genannten Anforderungen berein Das Baumuster entspricht somit auch den einschl gigen Bestimmungen der Richtlinie 98 37 EG Maschinen Der Bescheinigungsinhaber ist berechtigt das umseitig abgebildete GS Zeichen an den mit dem gepr ften Baumuster bereinstimmenden Produkten anzubringen Der Bescheinigungsinhaber hat dabei die umseitig aufgef hrten Bedingungen zu beachten Diese Bescheinigung einschlie lich der Berechtigung zur Anbringung des GS Zeichens wird sp testens ung ltig am 01 05 2007 Weiteres ber die G ltigkeit eine G ltigkeitsverl ngerung und andere Bedingungen regelt die Pr f und Zertifizierungsordnung vom April 2004 Leiter der Zertifi rungsstelle _ Postadresse Hausadresse Telefon 02 21 37 78 6301 2 ez Postfach 51 05 80 Gustav Heinemann Ufer 130 Telefax 02 21 37 78 6322 b 50941 K ln 50968 K ln PHOENIX CONTACT
51. bH amp Co Phoenix Contact GmbH amp Co Flachsmarktstr 8 28 Flachsmarktstr 8 28 32825 Blomberg 32825 Blomberg Deutschland Deutschland Produkt Zweihandschaltungen Zweihand Steuerungs Relais vom Typ nach EN 574 1996 Identifikation Sicherheits Relais Kombination Typ PSR SCP 24UC THC4 Typ PSR SPP 24UC THC4 Betriebsarten Zweihand Steuerung Schutz berwachung jeweils mit Gleichheits berwachung lt 0 5 sec Max Reaktionszeit 20 ms Ersetzt bisheriges Zertifikat BB 60006134 vom 09 10 2003 Die EG Baumusterbescheinigung bezieht sich auf das o g Produkt Es wird bescheinigt dass das Baumuster mit den grundlegenden Auforderungen der o g Richtlinie und den dazu eris Anderungsrichtlinien bereinstimmt Der Inhaber ist berechtigt diese Bescheinig n jc TER I seiner EG Konformit tserkl rung zu verwenden K ln den 05 11 2003 Dipl Ing F Schuh T V Rheinland Product Safety GmbH Am Grauen Stein D 51105 K ln Akkreditiert von der Zentralstelle der L nder f r Sicherheitstechnik ZLS Notifiziert unter der Nr 0197 bei der Kommission der Europ ischen Gemeinschaft Die CE Kennzeichnung darf bei Einhaltung aller zutreffenden EG Richtlinien angebracht werden 10 020 7 950 102597_01_en PHOENIX CONTACT 9 SAFETY RELAY APPLICATION 2 5 PSR ESP TUV Rheinland Group T V Industrie Service GmbH Automation Software und Informationstechnologie ZERTEIKAL
52. course of his her operational activities Occurs in connection with his her operational activities Forms the basis for a claim against statutory accident insurance All operational activities which are defined as being in the interests of the company are insured 45 000 40 000 35 000 MN 30 000 0 e LO e LO LO e LO LO e LO LO N N e 2 2 2 2 2 2 2 2 2 q Figure 2 1 Notifiable accidents at work since 1950 The number of accidents at work has fallen to a record low Even travel accidents and occupational diseases have decreased considerably in recent years as reported by the Hauptverband der gewerblichen Berufsgenossenschaften HVBG German Federation of Institutions for Statutory Accident Insurance and Prevention in Berlin Germany This decrease is due to the success of preventive measures However the rate of contribution rose slightly due to economic development and fewer people being employed In 2003 10 5 fewer cases of accidents at work were recorded than in the previous year In addition the risk of injury in the workplace also decreased considerably the accident rate fell by 4 The number of fatal injuries fell by 4 9 compared to the previous year PHOENIX CONTACT 2 1 SAFETY RELAY APPLICATION 2 2 PHOENIX CONTACT Every year around 15 of all the accidents at work which occur in the member companies of our occupational safety and
53. e 33 34 erf llen die Anforderun gen der Kategorie 4 nach DIN EN 954 1 03 97 a Das gepr fte Baumuster entspricht den einschl gigen Bestimmungen der Richtlinie 98 37 Maschinen Weiteres ber die G ltigkeit eine G ltigkeitsverl ngerung und andere Bedingungen regelt die Pr f und Zertifizierungsordnung vom Oktober 1997 Diese Bescheinigung wird sp testens ung ltig am Postadresse Tel 02 21 37 78 0 PZB10 Postfach 51 05 amp 0 Gustav Heinem fin Ufer 130 Fax 02 21 37 78 3 66 10 98 50941 K ln 50968 K ln 1 A 4 PHOENIX CONTACT 102597_01_en 102597 01 PZB03D 05 04 Approvals and Certificates A 2 2 PSR ESM4 Fachausschuss Elektrotechnik Pruf und Zertifizierungsstelle im BG PRUFZERT Hauptverband der gewerblichen Berufsgenossenschaften GS Prufbescheinigung Bescheinigungs Nummer Name und nschrift des PHOENIX CONTACT GmbH amp Co KG Bescheinigungsinhabers Flachsmarktstra e 8 Auftraggeber 32825 Blomberg Name und Anschrift des siehe Auftraggeber Herstellers Zeichen des Auftraggebers Zeichen der Pr f und Zertifizierungsstelle Ausstellungsdatum 23 520 25 05 155 318 Wid Ow 30 12 2005 Produktbezeichnung Not Aus Relais Typ PSR SCP 24UC ESM4 siehe Anlage PSR SPP 24UC ESM4 siehe Anlage Bestimmungsgem e Verwendung Pr fgrundlage 73 23 EWG Niedersp
54. eferred to as p factor Ability to handle errors with a common cause MTTFd Mean Time To Failure dangerous Time available to perform a safety function on demand time to failure MTBF Mean Time Between Failure Time available between two faults mean time between two failures Safe Failure Fraction Proportion of harmless failures All safe and dangerous faults that are detected Performance Level Benchmark for the probability of failure for executing risk reducing functions from PL a highest failure probability to PL e lowest failure probability PFD avg Average Probability of Failure on Demand Average nn of dangerous failure on demand of a safety function Probability of Failure on Demand Average probability of failure on demand of a function probability that a safety system does not perform its function on demand Probability of dangerous Failure per Hour Probability of a dangerous failure per hour Lambda Rate of failure Failure in the event of safe s and dangerous d faults Test Interval experiment test Interval between protective function tests 2 20 PHOENIX CONTACT 102597 01 en Safety Technology Risk Graph According to EN ISO 13849 1 The revision of EN 954 1 will become EN ISO 13849 and represents a practical bridge to the purely mathematical statistical approach of IEC 61508 A brief overview IEC 61508 light International standard Reliability and availability are taken into account 5 additional
55. eliably and precisely up to safety category 3 4 according to EN 954 1 102597 01 en Introduction 1 2 6 Stop Stop Categories According to DIN EN 60204 1 VDE 0113 1 Every machine must be equipped with a category 0 stop function Category 1 and or 2 stop functions must be provided when this is necessary for the safety and or functional requirements of the machine Category 0 and category 1 stops must be able to function independently of the operating mode and a category 0 stop must have priority In order to stop a machine three stop categories are defined in DIN EN 60204 1 VDE 0113 1 which describe the stop control sequence independently of an emergency situation Not permitted for emergency stop purposes Category 0 Stop Category 1 Stop Category 2 Stop Stopping by immediate removal of A controlled stop with power available A controlled stop with power left power to the machine drives 1 an to the machine drives to achieve the available to the machine drives uncontrolled stop stop and then removal of power when the stop is achieved 102597 01 en PHOENIX CONTACT 1 9 SAFETY APPLICATION Emergency stop Automatic disconnection of the power supply to an entire installation or part of an installation in the event of an emergency if there is a risk of electric shock or another risk of electrical origin the two definitions of emergency stop are often confused Emergency stop emergency opera
56. ese Bescheinigung wird sp testens ung ltig am 1 p Postadresse Hausadresse 402 2 06 0 PZB10 Postfach 51 05 80 Gustav Heinemann Ufer 130 37 78 3 66 10 98 50941 K ln 50968 K ln PHOENIX CONTACT 7 SAFETY RELAY APPLICATION TUV T V Rheinland Group T V Industrie Service GmbH Automation Software und Informationstechnologie IE RII 968 355 00 05 CERTIFICATE Pr fgegenstand Relais Sicherheitskombination Zertifikatsinhaber Phoenix Contact GmbH 8 Co Product tested Licence Holder Fjachsmarktstra e 8 D 32825 Blomberg Typbezeichnung PSR SCP 24 230UC Verwendungs Relais Sicherheitskombination f r designation ESAM4 3X1 1X2 zweck Not Aus and Schutzt ranwen Intended dungen PSR SPP 24 230UC application ESAMA 3X1 1X2 Pr fgrundlagen EN 954 1 1996 EN 60204 1 1998 Codes and standards forming EN 50178 1998 IEC 61508 Teile 1 7 the basis of testing EN 418 1992 Pr fungsergebnis Unter Beachtung der Hinweise in der Betriebsanleitung werden die Test results Anforderungen der Sicherheitskategorie 4 nach EN 954 1 und SIL 3 nach der Normenreihe IEC 61508 erf llt Besondere Bedingungen Nach 6 Monaten ist die Schutzeinrichtung zu bet tigen damit Specific requirements sichergestellt ist dass Fehler nicht unentdeckt bleiben und die Sicherheitsfunktion durch einen zweiten Fehler nicht au er Kraft gesetzt wird Ein Anteil von 15 des SIL 3
57. etectable by a simple test or indicated by the control system 102597 01 en Introduction to 102597 01 Safety Technology Standardization In the United States machine safety is governed by three main areas of competency Guidance from these areas must be used as the basis for a safe machine design However machine users designers may need to further investigate specific national state and local requirements These main competency areas are as follows 1 Occupational Safety and Health Administration OSHA 2 Industrial organizations that are referenced by OSHA as consensus standards organizations These organizations include American National Standards Institute ANSI National Fire Protection Association NFPA Robotics Industries Association RIA 3 Corporate developed regulations Note Companies corporations buying industrial machines will expect that the machine builders are following OSHA and consensus organizations standards However according to OSHA the ultimate responsibility to protect employees lies with the user Occupational Safety and Health Administration OSHA The hierarchy of machine safety standards starts at federal level with the Occupational Safety and Health Administration OSHA OSHA is an agency of the U S Department of Labor which extends to state level not all states OSHA standards and regulations have the ultimate legal priority Consensus
58. etween the two emergency stop channels Power OFF K1 OFF K2 OFF 102597 01 en Wiring Examples 3 1 2 PSR ESA4 Application Example 2 PSR ESA4 Application Features Emergency stop monitoring Two channel S11 S12 S21 S22 Up to safety category 4 EN 954 1 2 contacts 1 contact Cross circuit detection 511 512 521 522 Us 24 V DC AC Automatic activation bridge S33 S34 Stop category 0 24 V DC AC gt T Gt K2 ul to A1 11 12 521 522 13 23 31 PSR ESA4 Ns M 5 A2 S33 S34 14 24 32 102597 002 Figure 3 2 PSR ESAA Application example 2 102597_01_en PHOENIX CONTACT 3 3 SAFETY RELAY APPLICATION 3 1 3 PSR ESA4 Application Example 3 PSR ESA4 Application Features Emergency stop monitoring Single channel in circuit A1 bridge 511 512 521 522 Up to safety category 2 EN 954 1 2 contacts 1 contact Us 24 V DC AC Manual activation S33 S34 Stop category 0 24 V EMERGENCY STOP G 1 511 512 521 522 13 23 31 1 4 Vf 32 A2 533 534 14 24 32 OV 102597A003 Figure 3 3 PSR ESA4 Application example 3 3 4 PHOENIX CONTACT 102597_01_en Wiring Examples 3 2 PSR ESM4 Emergency Stop Applications With Start Button Monitoring 3 2 1 PSR ESM4 Application Example 1 With Fault Monitoring PSR ESM4 Application Features Emergency stop monitoring Single channel in circuit A1 bridge
59. ety today is affected by NFPA documents The mission statement is to reduce the worldwide burden of fire and other hazards on the quality of life by developing and advocating scientifically based consensus codes and standards research training and education The scope of NFPA 70 involves the installation of electric conductors and equipment The following installations are governed by NFPA 70 Public private floating and utility buildings or other structures Mobile homes and recreational vehicles Premises such as yards carnivals parking and other lots Industrial substations The provisions of NFPA 79 standards apply to the electrical electronic equipment apparatus or systems of industrial machines operating with a rated voltage of 600 V or less and commencing at the point of connection of the supply cable to the electrical equipment of the machine PHOENIX CONTACT 2 17 SAFETY RELAY APPLICATION 2 18 PHOENIX CONTACT With regard to safety the following NFPA 79 areas are of interest A Electric shock protection Closed loop control circuits and control functions Emergency stop devices Cabling practices Marking and safety marks 2 3 4 Functional Safety In order to achieve the 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 syste
60. g und Zertifizierung von Sicherheitsschaltger ten 2004 01 DIN EN ISO 13849 2 Sicherheitsbezogene Teile von Steuerungen Teil 2 Validierung 2003 12 DIN EN 60947 5 1 Steuerger te und Schaltelemente Elektromechanische VDE 0660 Teil 1 Steuerger te 2000 08 Bemerkungen Die sicherheitsrelevanten Strompfade mit den unverz gerten Ausgangskontakten 13 14 23 24 und 33 34 erf llen die Anforderungen der Kategorie 4 die r ckfallverz gerten Ausgangskontakte 57 58 und 67 68 erf llen die Anforderungen der Kategorie 3 nach DIN EN 954 1 1997 03 Das gepr fte Baumuster stimmt mit den in 4 Absatz 1 des Ger te und Produktsicherheitsgesetz genannten Anforderungen berein Das Baumuster entspricht somit auch den einschl gigen Bestimmungen der Richtlinie 98 37 EG Maschinen Der Bescheinigungsinhaber ist berechtigt das umseitig abgebildete GS Zeichen an den mit dem gepr ften Baumuster bereinstimmenden Produkten anzubringen Der Bescheinigungsinhaber hat dabei die umseitig aufgef hrten Bedingungen zu beachten Diese Bescheinigung einschlie lich der Berechtigung zur Anbringung des GS Zeichens wird sp testens ung ltig am 30 06 2009 Weiteres ber die G ltigkeit eine G ltigkeitsverl ngerung und andere Bedingungen regelt die Pr f und Zertifizierungsordnung vom April 2004 7 EN 5 ar E QQ So0 lt Yon x OR UO SUN Dipl Ing Steffi Stommel Leiter der Zertifizierungs
61. ication Features Two hand control 2 contacts 1 contact Up to safety category 4 EN 954 1 Us 24 V DC AC Synchronous activation monitoring lt 0 56 Cross circuit detection 511 514 512 521 524 522 According to 574 type IIIC Fault 1 Fault 4 Y2 511 S14 522 PSR THC4 A2 OV 102597_01_en 512 521 13 23 31 524 1 123 131 24 6 14 24 32 102597 010 Figure 3 13 PSR THC4A Application example 1 Fault Monitoring Fault 1 Short circuit S11 S12 S14 Power ON K1 OFF K2 ON Fault 2 No bridge between Y1 Y2 Power ON K1 OFF K2 OFF PHOENIX CONTACT 3 17 SAFETY RELAY APPLICATION Fault 3 Undervoltage at A1 A2 Power ON K1 OFF lights up only faintly K2 ON Fault 4 Short circuit 521 522 524 Power ON K1 ON K2 OFF Fault 5 Cross circuit between the two emergency stop channels Conductive connection between the two emergency stop channels Power OFF K1 OFF K2 OFF 3 4 2 PSR THC4 Application Example 2 PSR THC4 Application Features Monitoring of control guard according to 2 contacts 1 contact 1088 Up to safety category 4 EN 954 1 Us 24 V DC AC Synchronous activation monitoring 0 5 s According to EN 574 type IIIC 24 V DC AC Y1 Y2 S21 814 511 S12 13 28 3 S22 S24 u 113 123 PSR THC4 2 14 24 32 OV 102597A01 1 Figure 3 14 PSR THC4 Application example 2 3 18 PHOENIX CONTACT 10
62. ication example 3 PHOENIX CONTACT 3 23 SAFETY RELAY APPLICATION 3 5 4 PSR ESL4 Application Example 4 PSR ESL4 Application Features Light grid monitoring Two channel OSSD1 S12 OSSD2 S22 Up to safety category 4 EN 954 1 3 contacts 1 contact Cross circuit detection OSSD1 OSSD2 fault detected by light grid Us 24 V DC AC Automatic activation S33 S35 Monitored contact extension Stop category 0 24 V DC AC 11 S12 822 13 23 33 41 41 PSR ESLA ME A2 533 534 535 102597 016 Figure 3 19 PSR ESL4 Application example 4 3 24 PHOENIX CONTACT 102597 01 en Wiring Examples 3 6 PSR ESP4 Process Technology Applications 3 6 1 PSR ESP4 Application Example 1 PSR ESP4 Application Features Emergency stop monitoring Single channel in circuit A1 Up to safety category 2 EN 954 1 2 contacts 1 contact According to EN 61508 SIL 3 Us 24 V DC SIL data on request Monitored activation Y1 Y2 Monitored contact extension Y1 Y2 Stop category 0 24 V DC EMERGENCY in K3 Reset K4 A1 Y1 Y2 PSR ESP4 A2 102597A017 Figure 3 20 PSR ESP4 Application example 1 102597 01 PHOENIX CONTACT 3 25 SAFETY RELAY APPLICATION 3 6 2 PSR ESP4 Application Example 2 With Fault Monitoring PSR ESP4 Application Features Emergency stop monitoring Single channel in circuit A1 Up to safety category 2 EN 954 1 2 contacts 1 contact
63. ing to EN 61508 SIL 3 SIL data on request 24 230 V DC AC Fault 1 Fault 2 AH 7 JY Fault 5 ei AL M S10 S11 S12 S21 S22 13 23 33 4 EMERGENCY HER PSR ESAM4 3X1 51 A2 S33 S34 S35 14 24 34 42 Fault 3 Reset OV Features Two channel 511 512 521 522 bridge 510 511 3 contacts 1 contact Cross circuit detection 511 512 521 522 Us 24 230 V DC AC Manual activation S33 S34 Monitored start Stop category 0 8341533835 812811 811810 814512824 822 1 2 24 41 42 14 134 1025978038 Figure 3 10 PSR ESMAA 3X1 Application example 1 102597_01_en PHOENIX CONTACT 3 13 SAFETY RELAY APPLICATION 3 14 PHOENIX CONTACT Fault Monitoring Fault 1 Short circuit S11 S12 Power ON K1 ON K2 OFF Fault 2 Short circuit 521 522 Power ON K1 OFF K2 ON Fault 3 Restart not possible following initial emergency stop actuation Emergency stop safety function provided Power ON K1 OFF 2 Fault 4 No bridge or interrupt Power ON K1 OFF K2 OFF Fault 5 Cross circuit between the two emergency stop channels Conductive connection between the two emergency stop channels Power OFF K1 OFF K2 OFF 102597 01 Wiring Examples 3 9 5 PSR ESAM4 3X1 Application Example 2 PSR ESAMA 3X1 Application Emergency stop monitoring Up to safety category 4 EN 954 1 According to EN 61508 SIL 3 S
64. ion 10772 Berlin Germany Phone 49 30 26 010 Fax 49 30 26 01 12 60 Website http www2 din de EC directives laws and decrees Bundesanzeiger Verlagsgesellschaft mbH Federal Official Gazette Amsterdamer Stra e 192 50735 Cologne Germany Phone 49 221 97 66 80 Fax 49 221 97 66 82 88 Website http www bundesanzeiger de DIN standards ISO standards VDI directives Beuth Verlag GmbH Burggrafenstra e 6 10787 Berlin Germany Phone 49 30 26 01 0 Fax 49 30 26 01 12 60 Website http www2 beuth de VDE regulations IEC standards VDE Verlag GmbH Bismarckstr 33 10625 Berlin Germany Phone 49 30 34 80 01 0 Fax 49 30 34 17 09 3 Website http www vde verlag de Ger tesicherheitsgesetz Device Safety Law accident prevention regulations ZH 1 Schriften der Berufsgenossenschaften ZH 1 regulations of German occupational safety and liability associations Carl Heymanns Verlag Luxemburger Stra e 449 50939 Cologne Germany Phone 49 221 94 37 30 Fax 49 221 94 37 39 01 Website http www heymanns com 102597 01 Safety Technology 2 3 2 Interesting Links on the Internet The following table provides interesting links to topics covered in this manual The links were active at the time of going to print However as the information displayed and thus also the links change relatively quickly on the Internet it cannot be guaranteed that the links
65. lication example 1 3 20 PSR ESL4 Application example 2 3 22 PSR ESL4 Application example 3 23 PSR ESL4 Application example 4 3 24 PSR ESP4 Application example 1 3 25 PSR ESP4 Application example 2 3 26 PSR ESP4 Application example 3 27 PSR ESD Application example 1 3 28 PSR ESD Application example 2 3 30 PSR ESD Application example 3 31 PSR RSM Application example 1 most basic machine 3 32 PSR RSM Application example 2 basic machine with a Montord gt ee rm 3 33 PSR RSM Application example 3 machine tool with several drives and differentiated operating modes 3 34 PSR RSM Application example 4 speed monitoring using 2 wire proximity switches 3 35 PSR SSM Application example 5 basic machine with monitored drive and additional drive shaft monitoring 3 36 PSR SSM Application example 1 downti
66. m 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 faults Control of systematic faults Control of random faults or failures Functional safety is defined in IEC 61508 This standard is ratified in Europe has no assumed effect and is not listed in the machinery directive Structure of EN 61508 Part 1 General requirements Part 2 Hardware requirements Part 3 Software requirements Part 4 Definitions and abbreviations Part 5 Examples of methods for the determination of SILs Part 6 Guidelines on the application of Part 2 and Part 3 Part 7 Explanation of techniques methods and measures Validity Parts 1 to 4 are normative Parts 4 to 7 are informative However this distinction has no legal basis 102597_01_en 102597 01 Safety Technology Application of EN 61508 gt Actuator 35 15 50 102597A034 Figure 2 9 Functional safety of electrical electronic programmable electronic safety related systems E E PES IEC Safety related function DIN VDE Components Structure of EN 61508 Part 5 informative normative Methods for determining the Risk analysis required system Assignment of measures for risk reduction Specification of safety functions for E E PES Part 6 informative Guidelines for 2 and 3 Impleme
67. me monitoring using PNP or 2 wire proximity switches 3 37 PSR SDC4 Application example 1 3 38 PSR SDC4 Application example 2 3 39 PSR SDC4 Application example 3 40 PSR SDC4 Application example 4 3 41 PSR SDC4 Application example 5 3 42 102597 01 en 102597 01 Figure 3 37 Figure 3 38 Figure 3 39 Figure 3 40 Figure 3 41 Figure 3 42 Figure 3 43 Figure 3 44 List of Figures PSR SDC4 and PSR URMA AX1 extension module Application example O nu Wiring via T BUS DIN rail connector PSR SDCA and PSR URD3 extension module Application example 7 Wiring via T BUS DIN rail connector PSR ES 4 Application example 1 PSR ESA2 Application example 2 PSR ES 4 and PSR URM4 extension modules Application example Su nee EIE RE Ce S PSR ESAM4 PSR ESAA Application example 1 PHOENIX CONTACT 3 SAFETY RELAY APPLICATION C 4 PHOENIX
68. n about CE marking links to the most important European authorities and institutes http www vti bochum de Verlag Technik amp Information Information about various technology sectors e g occupational health and safety machinery with references for further reading http kan de Commission for Occupational Health and Safety and Standardization Information about occupational health and safety and standards links to websites with information about basic laws occupational health and safety standardization organizations etc in Germany Europe and around the world http www osha gov OSHA Statutory requirements and standards for safety in the workplace in North America 102597_01_en PHOENIX CONTACT 2 11 SAFETY RELAY APPLICATION 2 12 PHOENIX CONTACT 2 3 3 Standards in the USA Safe Machine Design Control Reliability is a design strategy that is used to ensure that a machine will remain safe when a failure is encountered Achieving Control Reliability is not as simple as implementing redundancy Monitoring must also be integrated into the safety function Clause 12 of the American National Standards Institute ANSI 11 19 2003 Complementary Equipment lists equipment that can be used in conjunction with safety guards to in effect design a control reliable system Here safety relays are defined Safety relays are used to provide the monitoring and additional functionality required to achieve Co
69. nks on the Internet 2 2 2 11 2 9 9 Standards the USA 2 12 2 3 4 Functional isse etu mes 2 18 2 3 5 Safety Categories According to DIN EN 954 1 2 22 3 1 PSR ESA4 Emergency Stop Applications Without Start Button Monitoring 3 1 3 1 1 PSR ESAA Application Example 1 With Fault Monitoring 3 1 3 1 2 PSR ESAA Application Example 2 3 3 3 1 3 PSR ESAA Application Example 3 4 PSR ESM4 Emergency Stop Applications With Start Button Monitoring 3 5 3 2 1 PSR ESMA Application Example 1 With Fault Monitoring 3 5 3 2 2 PSR ESMA Application Example 2 3 7 3 2 3 PSR ESMA Application Example 3 8 PSR ESAMA Emergency Stop Applications With Start Button Monitoring 3 9 3 3 1 PSR ESAMA Application Example 1 With Fault Monitoring 3 9 3 3 2 PSR ESAMA Application Example 2 3 11 3 33 PSR ESAMA Application Example 3 12 3 3 4 PSR ESAMA 3X1 Application Example 1 With Fault Monitoring 3 13 395 4 1 Application Example 2
70. ntation of E E PES Part 4 normative Hardware Rs requirements for software Definitions systems and requirements subsystems Part 7 Part 2 Part 3 informative normative normative Description of measures and technology Part 1 normative Installation startup Operation and maintenance Decommissioning 102597A035 Figure 2 10 Structure of EN 61508 The general safety related requirements and tests for plants and systems are defined in Part 1 PHOENIX CONTACT 2 19 SAFETY RELAY APPLICATION Definitions and Abbreviations Table 2 5 Definitions and abbreviations Safety Integrity Level The safety performance of an electrical or electronic control device is defined in IEC 61508 The standard defines four discrete levels SIL 1 to SIL 4 The higher the Safety Integrity Level of safety related systems the lower the probability that they do not perform the required safety functions Function Safety Management Document for the management of functional safety Failure Modes amp Effects Analysis Possible fault and effects analysis risk analysis Possible faults are considered at product level and their possible effects are evaluated E E PE S Electrical Electronic Programmable Electrical electronic and or programmable electronic Electronic Safety Related System system Diagnostic Coverage Capacity of the safety related part of a control system to detect faults Common Cause Failure Management Also r
71. ntrol Reliability Understanding the requirements of relevant standards is the key to designing an accepted safe and control reliable machine Vital information on Control Reliability can be found in ANSI B11 and the Occupational Safety and Health Administration OSHA 1910 standards ANSI B11 19 2003 defines the concept of Control Reliability as follows In Clause 3 14 of ANSI B11 19 2003 The capability of the machine control system the safeguarding other control components and related interfacing to achieve a safe state in the event of a failure within their safety related functions Clause 6 1 is also very important This clause states the actual requirements for the design strategy commonly called Control Reliability Also important to note is that in Annex C of ANSI B11 19 itis stated that the requirements of control reliability are not directly comparable to the safety categories of ISO 13849 1 EN 954 1 and exceed the safety requirements of category 2 With this understanding it is commonly accepted that a safety category 3 or 4 IEC installation must be implemented to achieve control reliability The OSHA 1910 217 defines Control Reliability as follows The control system shall be constructed so that a failure within the system does not prevent the normal stopping action from being applied to the press when required but does prevent initiation of a successive stroke until the failure is corrected The failure shall be d
72. ol With Several Drives and Differentiated Operating Modes PSR RSM Application Features Monitoring of several drives in aworking 4 contacts area Encoder sensors Us 24 V DC Connection via RJ45 Automatic start following overspeed bridge 533 535 Up to safety category 3 EN 954 1 Stop category O SIL 3 according to EN 61508 SIL data on request 424 V DC 1 12 5833834 835 5 24 V 24 V 1 2 PSR RSM LLI gt 2 ae gt At S11 512 521 22 13 23 33 4 41 13 123 133 PSR ESM4 f Operating 14 124 134 142 A2 S33 S34 14 24 34 42 switch Ai 12 833534535 gt 24 V 24 V 2 gt IN1 IN PSR RSM K4 102597 025 Figure 3 28 PSR RSM Application example 3 machine tool with several drives and differentiated operating modes SK Safety contact UK Monitoring contact 3 34 PHOENIX CONTACT 102597 01 en PSR RSM 424 V DC OV 102597_01_en Wiring Examples 3 8 4 PSR RSM Application Example 4 Speed Monitoring Using 2 Wire Proximity Switches Application Speed monitoring IN1 IN2 2 wire proximity switch Up to safety category 3 EN 954 1 SIL 3 according to EN 61508 SIL data on request Operating mode switch A1 12 13 533534535 13 23 3343 PSR RSM Overspeed Downtime Features 4 N O contacts Us 24 V DC Automatic activation bridge S33 S35 Stop categ
73. on the reprinted material must include a copyright notice in the following format Copyright O 2005 Underwriters Laboratories Inc 102597 01 PHOENIX CONTACT 3 SAFETY RELAY APPLICATION 2 1 PSR ESA4 Fachausschuss Elektrotechnik Pruf und Zertifizierungsstelle im BG PRUFZERT Hauptverband der gewerblichen Berufsgenossenschaften Baumusterpr fbescheinigung 02117 Name und Anschrift Phoenix Contact GmbH amp Co Bescheinigungs Nummer des Bescheinigungsinhabers Flachsmarktstra e 2 Auftraggeber 32825 Blomberg Name und Anschrift des Herstellers siehe Auftraggeber Zeichen des Auftraggebers Zeichen der Pr f und Zertifizierungsstelle Ausstellungsdatum 23 520 25 01 79 318 Wid Ow 15 04 2002 Produktbezeichnung Relais Sicherheitskombination Typ PSR SCP 24UC ESA4 2X1 1X2 PSR SCP 24UC ESA4 3X1 1X2 B Bestimmungsgem e Verwendung in UUU Pr fgrundlage 73 23 Niederspannungsrichtlinie 89 336 EWG EMV Richtlinie GS ET 20 Grunds tze f r die Pr fung und Zertifizierung von Relais Sicherheitskombinationen 03 99 DIN EN 60947 5 1 Steuerger te und Schaltelemente Elektromechanische Steuerger te 08 00 DIN EN 61000 4 6 St rfestgikeit gegen leitungsgef hrte St rgr en induziert durch hochfrequente Felder 12 01 Bemerkungen Die sicherheitsrelevanten Strompfade mit den Ausgangskontakten 13 14 und 23 24 bei PSR SCP 24UC ESA4 3X1 1X2 B zus tzlich die Kontakt
74. ory 0 EMERGENCY STOP Ai S11 512 21 22 13 23 33 4 113 123 133 21 PSR ESM4 pm UM 42 14 24 34 42 2 K4 N 102597 A026 Figure 3 29 PSR RSM Application example 4 speed monitoring using 2 wire proximity switches S1 S2 1 Contact tooth No contact gap PHOENIX CONTACT 3 35 SAFETY RELAY APPLICATION 3 8 5 PSR RSM Application Example 5 Basic Machine With Monitored Drive and Additional Drive Shaft Monitoring PSR SSM Application Features Evaluation of a safe speed 4 N O contacts Additional drive shaft monitoring Us 24 V DC IN1 IN2 Encoder sensors Automatic activation bridge 533 535 Connection via RJ45 Stop category O Up to safety category 4 EN 954 1 SIL 3 according to EN 61508 SIL data on request 424 V DC Encoder Shaft earwheel Proximity switch g 1 1 1 1 1 1 I I Operating mode Enabling P 2 switch EMERGENCY STOP A1 S11 512 521 S22 13 23 33 41 113 123 133 111 PSR ESMA indu A1 MI I3 12 11 533534535 24 V 24 V 533 534 24 34 42 5 IN1 2 PSR RSM AVE 8 K4 Y RJ45 A2 FO MO1MO2 1424 34 44 KA OV 102597A037 Figure 3 30 PSR SSM Application example 5 basic machine with monitored drive and additional drive shaft monitoring 3 36 PHOENIX CONTA
75. otective systems EN 999 Calculation of safety distances EN 954 1 Safety of machinery Safety related parts of control systems PHOENIX CONTACT 1 5 SAFETY RELAY APPLICATION 1 2 3 Two Hand Controls According to DIN 574 the simultaneity of two hand controls must be monitored to be lt 0 5 seconds The time is reliably checked and evaluated by corresponding category type modules Two hand controls are localized safety equipment The operator must keep his her hands on the control device during dangerous machine movements see example in Figure 1 4 on page 1 7 Table 1 1 Requirements according to EN 574 Requirements According to EN 574 Typel Type Il Type Ill A B 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 Synchronous actuation simultaneous actuation within 0 5 seconds Re initiation of an output signal only once both input signals are finished gt re initiation of the output signal is possible 1 6 PHOENIX CONTACT 102597_01_en 102597 01 Introduction Manual control 0 emergency stop button Control device Input command n PSR THC Synchronous actuation Triggering of Triggering of End of 1st input signal 2nd input signal input signals 1st hand 2nd hand Time t lt 0 5s S
76. part of Phoenix Contact GmbH amp Co KG to furnish information on alterations to products and or technical documentation Any other agreement shall only apply if confirmed in writing by Phoenix Contact GmbH amp Co KG Please note that the supplied documentation is product specific documentation only Although Phoenix Contact GmbH amp Co KG makes every effort to ensure that the information content is accurate up to date and state of the art technical inaccuracies and or printing errors in the information cannot be ruled out Phoenix Contact GmbH amp Co KG does not offer any guarantees as to the reliability accuracy or completeness of the information provided Phoenix Contact GmbH amp Co KG accepts no liability or responsibility for errors or omissions in the content of the technical documentation in particular data sheets installation instructions manuals etc As far as is permissible by applicable jurisdiction no guarantee or claim for liability for defects whatsoever shall be granted in conjunction with the information available in the technical documentation whether expressly mentioned or implied This information does not include any guarantees on quality does not describe any fair marketable quality and does not make any claims as to quality guarantees or guarantees on the suitability for a special purpose Phoenix Contact GmbH amp Co KG reserves the right to alter correct and or improve the info
77. particular to safety technology On the one hand machine and system builders are faced with the challenge of meeting applicable safety directives and on the other hand they want to keep the costs and effort required to a minimum Our products show that future oriented safety solutions do not necessarily have to be highly complex in their application in order to meet the most demanding safety requirements in machine and system production Phoenix Contact safety technology features easy integration and handling combined with a high level of quality PHOENIX CONTACT 1 1 SAFETY RELAY APPLICATION 1 2 Wide Range of Products in Slim Housing The safety relays from the Phoenix Contact INTERFACE range meet the highest requirements for monitoring emergency stop circuits safety door circuits and two handed controls Special modules are available for contact extension process technology SIL 3 safe time functions as well as light grid and speed monitoring functions All connection terminal blocks are pluggable and keyed 1 2 1 Emergency Stop Safety Door PSR safety relays provide up to eight enabling current paths and one signaling current path for monitoring emergency stop and safety door circuits Manually activated modules also check the function of the connected start button i e a malfunction is reliably detected Cable Lengths In many applications several sensors such as emergency stop switches are usually used
78. performance levels a e Probabilistic approach probability of a fault It includes the parameters DC Diagnostic Coverage MTTFd Mean Time To Failure dangerous and CCF Common Cause Failure A PDF value Probability of a Dangerous Failure per hour is obtained as a measurable result Certain ranges of PDF values then result in performance level a to e which is no longer directly comparable with the former categories Performance level Low risk Category SIL for each EN 954 1 IEC 61508 safety function S1 No special safety P1 requirements F1 2 1 2 P2 High risk Figure 2 11 Relationship between risk graph according to EN 954 1 and IEC 61508 MTTFd Mean Time To Failure dangerous time available to perform a safety function on demand CCF Common Cause Failure Management also known as factor Ability to 102597_01_en DC handle errors with a common cause Diagnostic Coverage capacity of the safety related part of a control system to detect faults PHOENIX CONTACT 2 21 SAFETY RELAY APPLICATION 2 3 5 Safety Categories According to DIN EN 954 1 2 3 5 1 Risk Graph According to DIN EN 954 1 The risk graph is only a selection tool for determining the safety category in cases where there have so far been no relevant C standards or where the standards do not list any safety category for the application in question Figure 2 12 Selection of category B 1 2 3
79. pplication Example 1 With Fault Monitoring 3 28 3 7 2 PSR ESD Application Example 2 3 30 3 7 3 PSR ESD Application Example 3 31 PSR RSM PSR SSM Speed and Downtime Monitoring 3 32 3 8 1 PSR RSM Application Example 1 Most Basic Machine 3 32 3 8 2 PSR RSM Application Example 2 Basic Machine With a Monitored Drive REEL I 3 33 3 8 3 PSR RSM Application Example 3 Machine Tool With Several Drives and Differentiated Operating Modes 3 34 3 8 4 PSR RSM Application Example 4 Speed Monitoring Using 2 Wire Proximity 3 35 3 8 5 PSR RSM Application Example 5 Basic Machine With Monitored Drive and Additional Drive Shaft Monitoring 3 36 3 8 6 PSR SSM Application Example 1 Downtime Monitoring Using PNP or 2 Wire Proximity Switches 3 37 PSR SDCA PSR URD4 PSR URM4 Emergency Stop 3 38 3 9 1 PSR SDC4 Application Example 1 3 38 3 9 2 PSR SDC4 Application Example 2 3 39 3 9 3 PSR SDC4 Application Example 3 40 3 9 4 PSR SDC4 Application Example 4
80. rding to the standard a mixture of SELV and is strictly prohibited Only switch 230 V AC at one of the two contacts if the adjacent contact carries the same potential 6 kV impulse voltage withstand level Reinforced insulation e g larger clearance between tracks is designed for a higher surge category than basic insulation Therefore SELV circuits U x 25 V or U lt 60 V DC and circuits with higher voltages can be mixed 1 2 8 Process Technology Phoenix Contact is setting new standards in safety technology the PSR safety relay modules are some of the first safety products to be approved for process technology according to SIL 3 IEC 61508 Conventional safety relay modules often have a very high inrush current which control systems interpret as a short circuit PSR ESP safety relays provide optimized switch on behavior and have two separate isolated redundant N O contacts as well as one N C contact with a design width of 22 5 mm that can switch up to 250 V AC 6 A They are used to safely electrically isolate the field application from the control system or to adjust the voltage or power The international standard IEC 61508 applies to electrical and electronic applications in particular in process technology such as chemical processing and mechanical engineering Along with safety related controllers or control systems compact safety relays are also an integral part of the safety chain PHOENIX CONTACT 1 11
81. refully followed could result in damage to hardware and software or personal injury The note symbol informs you of conditions that must strictly be observed to achieve error free operation It also gives you tips and advice on the efficient use of hardware and on software optimization to save you extra work The text symbol refers to detailed sources of information manuals data sheets literature etc on the subject matter product etc This text also provides helpful information for the orientation in the manual We Are Interested in Your Opinion We are constantly striving to improve the quality of our manuals Should you have any suggestions or recommendations for improvement of the contents and layout of our manuals please send us your comments PHOENIX CONTACT GmbH amp Co KG Documentation Services 32823 Blomberg Germany Phone 49 52 35 30 0 Fax 49 52 35 34 20 21 E mail tecdoc phoenixcontact com 102597 01 102597 01 SAFETY APPLICATION General Terms and Conditions of Use for Technical Documentation Phoenix Contact GmbH amp Co KG reserves the right to alter correct and or improve the technical documentation and the products described in the technical documentation at its own discretion and without giving any notice The provision of technical documentation in particular data sheets installation instructions manuals etc does not constitute any further duty on the
82. rmation and the products described in the information at its own discretion and without giving any notice PHOENIX CONTACT SAFETY RELAY APPLICATION PHOENIX CONTACT Statement of Legal Authority This manual including all illustrations contained herein is copyright protected Use of this manual by any third party is forbidden Reproduction translation or electronic and photographic archiving or alteration requires the express written consent of Phoenix Contact Violators are liable for damages Phoenix Contact reserves the right to make any technical changes that serve the purpose of technical progress Phoenix Contact reserves all rights in the case of patent award or listing of a registered design Third party products are always named without reference to patent rights The existence of such rights shall not be excluded CD ROM This manual is supplied with a CD ROM This CD ROM contains data sheets and package slips for PSR safety relays in electronic format Internet Up to date information on Phoenix Contact products can be found on the Internet at www phoenixcontact com Make sure you always use the latest documentation can be downloaded at www download phoenixcontact com A conversion table is available on the Internet at www download phoenixcontact com general 7000_en_00 pdf 102597_01_en Table of Contents 1 55
83. rotechnik Pr f und Zertifizierungsstelle im BG PR FZERT Hauptverband der gewerblichen Berufsgenossenschaften Baumusterpriifbescheinigung Name und Anschrift Phoenix Contact GmbH amp Co KG Bescheinigungs Nummer des Bescheinigungsinhabers Flachsmarktstra e 8 Auftraggeber 32825 Blomberg Name und Anschrift des Herstellers siehe Auftraggeber Zeichen des Auftraggebers Zeichen der Pr f und Zertifizierungsstelle Ausstellungsdatum 23 520 25 02 27 318 Gom Ow 14 10 2002 Produktbezeichnung NOT AUS Sicherheitsrelais und Schutzt rw chter Typ PSR SC P 24UC ESAM4 8x1 1 X2 Artikel Nr 29 63 91 2 Bestimmungsgem e Verwendung Pr fgrundlage mE 73 23 Niederspannungsriehtinie j 89 336 EWG EMWRl htinie 0 7 2 22 GS 20 Grunds tze f r die Pr fung ul d Zerfzierung von Relais Sicherheltskombinat 03 99 55022 A1 WA 10 00 EN 50082 2 St rfestigkeitIndustriebere Yo 10 01 Bemerkungen Der sicherheitarelsvanisn Strompfade mit den 13 14 bis 83 84 erf llen die ARGENT UR der Kategorie 4 nach DIN EN 954 1 03 97 Das gepr fte Baumuster entspricht den einschl gigen Bestimmungen der Richtlinie 98 37 EG Maschinen 31 12 2007 Weiteres ber die G ltigkeit eine G ltigkeitsverl ngerung und andere Bedingungen regelt die Pr f und Zertifizierungsordnung vom Oktober 1997 Di
84. s involving lathes and saws In the majority of cases the accidents occurred on old machines without CE marking The free exchange of machines in the European Economic Area demands the improved assignment of machine accidents to machine related characteristics As a result more detailed information about the manufacturer country of origin type year of manufacture CE marking EC declaration of conformity EC type examination etc is required 102597 01 en 102597 01 Safety Technology No information 3 Repairs conversion Other Machining process 3 3 Maintenance work S 39 11 Troubleshooting 22 Tool change setup work 19 Figure 2 2 Activity performed by the injured party at the time of the accident No information 14 No 11 Yes 75 Figure 2 3 Incorrect operation of the machine PHOENIX CONTACT 2 3 UM SAFETY RELAY APPLICATION No information 18 Other cause Technical defect 43 39 Figure 2 4 Cause of accident Technical defect Causes of Accidents at Work There are often various causes for accidents at work For example the bypassing or manipulation of safety equipment can result from the following Unsuitable safety equipment which leads to manipulation or bypassing e g due to incorrect safety concept Poor visibility Faulty ergonomic design Complex operation of the machine Convenience or inexperience of the operator Source BG
85. standards Standard Type Typical Examples EN 1050 1996 11 Safety of machinery Principles for risk assessment Type Basic safety standards EN ISO 12100 1 2003 11 Safety of machinery Basic concepts general principles for design Pr EN 204 1026 Type B1 EN 349 096506 EN 418 199240 EN 842 190609 EN 955 1997 10 EN ISO 13849 1 2004 05 Safety related parts of control systems General principles for design intended as a replacement for EN 954 1 EN ISO 13849 2 2003 08 Safety related parts of control systems Validation prEN ISO 13850 2005 01 Emergency stop equipment intended as a replacement for EN 418 EN 60204 11 2000 11 Electrical equipment of machines EN 61496 1 2004 05 Electrosensitive protective equipment EN 61508 2001 12 Functional safety management EN 201 1997 02 Injection molding machines Productsafety EN 692 1996 06 Mechanical presses Type C Group safety standards standards EN 693 2001 01 Hydraulic presses EN 775 1992 10 Industrial robots T This table contains only a few examples and is not complete 102597 01 en PHOENIX CONTACT 2 9 SAFETY RELAY APPLICATION Sources of Reference for Technical Regulations in Germany 2 10 PHOENIX CONTACT 2 3 1 Useful Addresses for Information About Standards and Regulations For everything about standards regulations and directives DIN Deutsches Institut f r Normung e V German Institute for Standardizat
86. stelle de 91 vH Postadresse Hausadresse Telefon 02 21 37 78 6301 2 030 amp A Postfach 51 05 80 Gustav Heinemann Ufer 130 Telefax 02 21 37 78 6322 05 04 LI 50941 K ln 50968 K ln 102597 01 PHOENIX CONTACT 11 SAFETY RELAY APPLICATION A 12 PHOENIX CONTACT 102597_01_en Ordering Data PSR ES 4 Description Emergency stop and safety door monitoring 24 V single and two channel 2 enabling current paths with cross circuit detection Emergency stop and safety door monitoring 24 single and two channel 3 enabling current paths with cross circuit detection Emergency stop and safety door monitoring 24 V AC DC single channel 4 enabling current paths Process technology emergency stop and safety door monitoring 24 V DC single channel 2 enabling current paths PSR ESAM4 Description Emergency stop and safety door monitoring 24 V AC DC single and two channel 8 enabling current paths with without cross circuit detection Emergency stop and safety door monitoring PSR safety relays are available in two connection versions 24 V AC DC 230 V AC DC single and two channel 3 enabling current paths with without cross circuit detection PSR THC Description Two hand controls and safety door monitoring synchronous activation monitoring lt 0 5 s 24 V AC DC two channel 2 enabling current paths
87. still work Table 2 2 Interesting links on the Internet http www2 din de DIN Deutsches Institut f r Normung e V German Institute for Standardization http www cenorm be European Committee for Standardization CEN Direct link http www newapproach org Overview of the latest applicable standards and regulations http www normapme com German European Office of Crafts Trades and Small and Medium Sized Enterprises normapme de htm for Standardization Information about standards and an overview of standards for various sectors http www stmwvt bayern de Bayrisches Staatsministerium f r Wirtschaft Verkehr und Technologie The Bavarian Ministry of Economic Affairs Transport and Technology Law and law formation in EU Brief information about EU directives http gps sozialnetz de Product and device safety http www lfas bayern de Bayrisches Landesamt f r Arbeitsschutz Arbeitsmedizin und Sicherheitstechnik The Bavarian Authority for Occupational Health and Occupational Medicine and Safety Technology http europa eu int Information about the European Union http www dke de DKE The German organization responsible for the elaboration of standards and safety specifications covering the area of electrical engineering electronic and information technologies Information about standards links to website addresses of national and international organizations http www ce richtlinien de VDI news Informatio
88. stop monitoring Two channel A2 S22 511 512 bridge 510 511 Up to safety category 4 EN 954 1 2 N O contacts Us 24 V DC Cross circuit detection A2 S22 S11 S12 Automatic activation bridge Y1 S33 S35 Stop category 0 24 V DC ie IBUS wx 1 Yi 13 23 PSR SDC4 572 ve I 5 TBUS 2 LU LLI gt 102597 042 Figure 3 33 PSR SDC4 Application example 2 102597_01_en PHOENIX CONTACT 3 39 SAFETY RELAY APPLICATION 3 9 3 PSR SDC4 Application Example 3 PSR SDC4 Application Safety door monitoring 1 N O contact 1 N C contact Up to safety category 3 EN 954 1 24 V DC TBUS dp A1 Yi PSR SDC4 A2 S22 TBUS gt gC 0 123 Features Two channel 511 512 511 513 bridge 510 511 2 522 2 N O contacts Us 24 V DC Manual activation S33 S34 Monitored start Stop category 0 102597A043 Figure 3 34 PSR SDC4 Application example 3 3 40 PHOENIX CONTACT 102597_01_en PSR SDC4 424 V DC IBUS 102597_01_ Wiring Examples 3 9 4 PSR SDC4 Application Example 4 Application Features Emergency stop monitoring Single channel S11 S12 bridge 510 512 A1 S22 Up to safety category 2 EN 954 1 2 N O contacts Us 24 V DC Manual activation S33 S34 Monitored start Monitored contact extension Stop category 0 K3 K4 Reset 13 23 PSR
89. szweck The test report no 968 EL 200 01 04 dated 2004 09 08 is an integral part of this certificate This certificate is valid only for products which are identical with the product tested It becomes invalid at any change of the codes and standards forming the basis of testing for the intended application T V Industrie Service GmbH Automation Software und Informationstechnologie Am Grauen Stein 51105 K ln Postfach 91 09 51 51101 K ln Date Company seal Signature 2004 09 08 Gesch ftsfeld ASI A 10 PHOENIX CONTACT 102597_01_en Approvals and Certificates A 2 6 PSR ESD Fachausschuss Elektrotechnik Pr f und Zertifizierungsstelle im BG PRUFZERT Hauptverband der gewerblichen Berufsgenossenschaften GS Pr fbescheinigung Bescheinigungs Nummer Name und Anschrift des Phoenix Contact GmbH amp Co KG Bescheinigungsinhabers Flachsmarktstra e 8 Auftraggeber 32825 Blomberg Name und Anschrift des siehe Auftraggeber Herstellers Zeichen des Auftraggebers Zeichen der Pr f und Zertifizierungsstelle Ausstellungsdatum 23 520 25 04 105 318 Sto Ow 29 11 2004 Produktbezeichnung Not Aus Sicherheitsrelais und Schutzt rw chter Typ PSR SCP 24 DC ESD 5x1 1x2 300 Art Nr 298 1428 PSR SPP 24 DC ESD 5x1 1x2 300 Art Nr 298 1431 Bestimmungsgem e Verwendung Pr fgrundlage 73 23 EWG Niederspannungsrichtlinie 89 336 EWG EMV Richtlinie GS ET 20 Grunds tze f r die Pr fun
90. tegory 3 and category 4 a first fault must never lead to danger This makes it necessary to provide redundancy in the control structure In a redundant circuit e g safety grid monitoring with two limit switches according to the wiring example below it is possible that cross circuits unintentional incorrect connection between two redundant circuits may not be detected because the limit switches are always actuated or enabled simultaneously by the grid Movable guard Open Safety circuits Closed 51 I I TUO Positively actuated NMRA 9 ER Rod We ttt tt 22 3 2222722 51 Not positively actuated 4 Figure 1 2 Cross circuit detection in the event of single faults This type of single fault cross circuit a alone does not directly lead to a dangerous situation but cannot be tolerated in category 3 see Figure 1 2 Movable guard Open Safety circuits Closed 51 I I Positively actuated 1 4 4 51 Notpositively actuated KIC Figure 1 3 Cross circuit detection in the event of several faults 1 4 PHOENIX CONTACT 102597 01 Some application examples Relevant standards 102597 01 Introduction If another fault b then occurs the safety equipment ceases to be effective This means that the circuit no longer responds to the opening and closing of the safety grid In safety category 4 this fault accumulation following a
91. the operating environment Selecting suitable materials for the construction of the machine Isolation of conductive parts to prevent contact Protection against hydraulic and compressed air lines or hoses that may burst 2 6 PHOENIX CONTACT 102597 01 en Safety Technology Provision of diverse redundancy in control systems to ensure single fault tolerance as a minimum Defining the limits of the machine or system physical and in terms of time Identifying and evaluating the hazards with suitable checklist if necessary New hazards detected Hazard analysis Can the hazard be avoided Risk reduction by design Has the risk been reduced Is safety ensured Is the use of safety equipment possible Use of safety equipment Yes Is safety ensured No Information for use Special notes in the operating instructions or on plates Yes Is safety ensured Protection objective achieved Figure 2 6 Strategy diagram 102597 01 en PHOENIX CONTACT 2 7 SAFETY RELAY APPLICATION 2 3 Standards and Directives European Standards Legal requirements The single European market opened up in 1993 was established under the Single European Act and is an area without internal borders Within this area the free movement of goods persons services and capital is ensured under the Act Currently 25 countries belong to the European Economic
92. tion intended to stop a process or movement that would become according to ISO 13850 hazardous stop EN 60204 1 Annex D The emergency stop function is triggered by a single operator operation This function must be available and operational at all times according to ISO 13849 1 EN 954 1 In this case the operating mode is not taken into consideration 102597A048 Figure 1 5 Emergency stop 1 10 PHOENIX CONTACT 102597_01_en Basic insulation between circuits Reinforced insulation between the circuits SIL IEC 61 508 102597_01_en Introduction 1 2 7 Safe Isolation Depending on the version the modules have safe isolation between the input and output and between the contacts Applications with 230 V low voltage can be connected reliably and safely Isolation Between Input and Output PSR modules 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 Due to the internal structure and the insulation properties between the input and the contacts in Phoenix Contact PSR modules 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 4 kV impulse voltage withstand level Acco
93. tori r sz sa aa 54 0 z 2 K2 EN 1 510 511 512 521 522 13 23 33 43 53 63 12 91 113 123 133 43 153 163 173 183 91 PSR ESAM4 Sa 4 Yos O A2 S33 S34 S35 14 24 34 44 54 64 74 84 92 5211522 2 83 63 64 13 14 23 24 jea 73 74 OV 102597A008 Figure 3 8 PSR ESMAA Application example 2 102597_01_en PHOENIX CONTACT 3 11 SAFETY RELAY APPLICATION 3 3 3 PSR ESAM4 Application Example PSR ESAM4 Application Features Emergency stop monitoring Single channel S11 S12 bridge S10 S12 521 522 Up to safety category 2 954 1 8 N O contacts 1 N C contact Us 24 V DC AC Manual activation 533 534 Monitored start Stop category 0 24 V DC AC gt 2 GY Sizes sse st ss 53 510154454432 92 44 54 gt 0 lt 0 x 0 1 510 511 512 521 522 13 23 33 43 53 63 73 83 91 123 133 143 153 I I 91 PSR ESAM4 O A2 S33 S34 S35 14 24 34 44 54 64 74 84 92 T2 1 5211522 2 83 63 64 13 14 23 24 jsa 73 74 102597A009 Figure 3 9 PSR ESMAA Application example 3 3 12 PHOENIX CONTACT 102597 01 en Wiring Examples 3 3 4 PSR ESAM4 3X1 Application Example 1 With Fault Monitoring PSR ESAMA 3X1 Application Emergency stop monitoring Up to safety category 4 EN 954 1 Accord
94. ty principles must be used The occurrence of a fault can lead to the loss of the safety functions but the probability of the fault occurring is lower than in category B Movable guard Open Closed Positively actuated Figure 2 13 Safety category 1 102597_01_en System behavior in event of a fault Function of the circuit for safety category 2 102597_01_en Safety Technology Safety Category 2 Single Channel Control and Testing The requirements of category B and the use of proven safety principles must be met The safety function must be tested at suitable intervals by the machine control system Testing of the safety function whether initiated manually or automatically must generate a starting point for the initiation of suitable control measures if a fault is present If it is not possible to achieve a safe shutdown the output must provide for warning of the hazard The occurrence of a fault can lead to the loss of the safety function between the test intervals The loss of the safety function is detected by the test Movable guard 202 K2 VI K2 AW Closed Positively 9 9 3 actuated mJ E t lt s s z un FE C LL
95. ult monitoring is provided after the relevant application example 3 1 PSR ESA4 Emergency Stop Applications Without Start Button Monitoring 3 1 1 PSR ESA4 Application Example 1 With Fault Monitoring PSR ESA4 Application Features Emergency stop monitoring Two channel 511 512 521 522 Up to safety category 4 954 1 2 contacts 1 contact Cross circuit detection S11 S12 521 522 Us 24 V DC AC Manual activation 533 534 Stop category O 24 V DC AC Fault 1 Fault 2 A1 511 S12 521 S22 13 423 33 PSR ESA4 N A2 533 534 14 24 34 gt dp Fault 3 OV 102597A001 Figure 3 1 PSR ESA4 Application example 1 102597_01_en PHOENIX CONTACT 3 1 SAFETY RELAY APPLICATION 3 2 PHOENIX CONTACT Fault Monitoring Fault 1 If an emergency stop button contact does not open is bypassed the fault remains undetected until it is actuated The safety function is no longer available for single channel circuit both channels must be connected or bridged Power ON K1 OFF K2 ON Fault 2 As for fault 1 Power ON K1 ON K2 OFF Fault 3 No fault detection on initial start After releasing the emergency stop as for automatic start Reset button without function Power ON K1 ON K2 ON Fault 4 Recovery time not reached Remove fault through voltage reset Power ON K1 OFF K2 ON Fault 5 Cross circuit between the two emergency stop channels Conductive connection b
96. y 4 954 1 x N O contacts x N C contacts Us 24 V Automatic activation 533 534 3 48 PHOENIX CONTACT 102597 01 en Wiring Examples Machine 1 Mast achine 1 Master _ 7 s 4 K3 X1 8 X1 6 Reset K4 Bo B4 A zi m i B 535 534 533 A2 184 4174 164 154 144 134 4124 114 l Yes Yon LA des i oe PSR ESAM4 91 83 73 63 53 43 33 23 19 s S11 S10 Hi gt gt a X17X15 o Ola L2 L1 WEE HILL 24 V DC AC Machine 2 Slave HHHHIHHHH 5 u 5 p gt Ai 511 512 S21 S22 M x 113 423 31 PSR ESA4 a T A2 533 534 14 24 32 102597A031 Figure 3 44 PSR ESAMA PSR ESA4 Application example 1 102597_01_en PHOENIX CONTACT 3 49 SAFETY RELAY APPLICATION 3 50 PHOENIX CONTACT 102597_01_en Approvals and Certificates Approvals and Certificates 1 Approvals Order No Type CE BG T V CUL Fuel EN 954 1 IEC 61508 Technology SIL 3 EN 50156 1 VDE 0116 2963718 07 PSR SCP 240 5 4 2 1 1 2 2963705 00 PSR SPP 240 5 4 2 1 1 2 2963750 02 PSR SCP 240 5 4 2 1 1 2 2963938 00 PSR SPP 24UC ESA4 2X1 1X2 2963776 02 PSR SCP 24UC ESM4 3X1 1X2 B 2963925 00 PSR SPP 24UC ESM4 3X1 1X2 B 2963763 02 PSR SCP 24UC ESA4 3X1 1X2 B 2963941 00 PSR SPP 24UC ESA4 3X1 1X2 B 2963912 02 PSR SCP 24UC ESAM4 8X1 1X2 2963996 00 PSR SPP 24UC ESAM4 8X1 1X2 2981114 00 PSR SCP 24 230UC ESAM4 3X1 1X2 2981127 00 PSR
97. ynchronous Time period for actuation simultaneous actuation 102597A032 Figure 1 4 Structure of a two hand control PHOENIX CONTACT 1 7 SAFETY RELAY APPLICATION 1 8 PHOENIX CONTACT 1 2 4 Contact Extension Positively Driven Contacts more contacts are required than are available as a standard For these applications positively driven contact extension modules are used They can be connected as modules as required Positively Driven Standard EN 50205 makes a distinction between two groups of relays with positively driven contacts Application type A Relay with positively driven set of contacts Application type B Relay with positively driven set of contacts and other not positively driven contacts as well as a contact set with PDT contacts The definition positively driven was first established in 1972 in the professional association safety regulation ZH1 457 Control systems for power driven presses in metal processing with the wording Positively driven is when the contacts are mechanically connected to one another in such a way that the N C and N O contact can never be closed at the same time It must be guaranteed for the full period of service life even when destroyed that the contact spacings are at least 0 5 mm 1 2 5 Safe Time Function Using appropriate devices applications that require time delayed contacts e g locked protective covers or dynamic processes are switched r

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