Operating instructions Safety Relay
Contents
1. ipf electronic gmbh Kalver Str 27 D 58515 L denscheid Operating instructions Safety Relay Original operating instructions for the safety relay for safety light curtains AO000299 Table of contents Important Notes Safety Regulations Designated Use Main Features Practical Notes Safety Notes Connection Terminals Function Diagram Block Diagram Indicators Setting Technical Data input circuit output Technical Data General Data Safety related data Characteristics Dimensions Application examples Troubleshooting Maintenance and repairs Labeling and connections EC Declaration of Conformity fon 49 0 2351 9365 0 fax 49 0 2351 9365 19 www ipf electronic com info ipf electronic com 2 2 4 4 5 5 5 5 6 7 7 8 8 9 10 10 11 12 Subject to alteration Version July 2011 5 Operating instructions Safety relay Before installing operating or maintaining this device these instructions must be care fully read and understood A Danger Dangerous voltage Electric shock will result in death or serious injury Disconnect all power supplies before servicing equipment Caution Safe operation of the device is only guaranteed when using cert2. Line fault detection on On button The line fault detection is only active when 512 and 522 are switched simultaneously If the ON button is closed before S12 S22 is connected to voltage also when line fault across On button the ouput contacts will not close A line fault across the On button which occurred after activation of the relay will be detected with the next activation and the output contacts will not close The gold plated contacts of the AO000299 mean that this module is also suitable for switching small loads of 1mVA 7VA 1mW 7W in the range 0 1 60V 1 300mA The contacts also permit the maximum switching current However since the gold plating will be burnt off at this current level the device is no longer suitable for switchin small loads after this The terminal S21 permits the operation of the device in IT systems with insulation monitor ing serves as a reference point for testing the control voltage and is used to connect the E stop loop when cross fault monitoring is selected D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to alteration 5 Operating instructions Safety relay To operate light curtains with symmetric outputs both channels switching the selector switch 51 has to be in position without To operate light curtains with asymmetric ouputs
3. 1 channel switches one channel the selector switch S1 has to be in position with The channel switching must be connected to S22 channel switching tom 12 A Safety Notes ATTENTION If a line fault occurs after the voltage has been connected to S12 S22 the unit will be activated because this line fault is similar to the normal On function ATTENTION Switch S1 must not be set while device is under supply volt age Switch S2 is used to select automatic or manual restart Additionally for the function automatic restart terminals S33 and S34 have to be bridged Con nect the device according to application examples The ipf safety light curtains have a switching function between automatic and manual start If the function manual start is used at the safety light curtain the function automatic restart has to be chosen on the relay 0000299 Connection Terminals Terminal designation signal designation A1 Supply Voltage 2 Supply Voltage 512 522 533 534 Control Inputs 11 21 Control Ouputs 13 14 23 24 33 34 Forcibly guided NO contacts for release circuit 41 42 Forcibly guided NC contact indicator output D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to Alteration Operating instructions a Function
4. 2 S2 manual S1 511 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to alteration D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 Operating instructions Safety relay Troubleshooting LED does not Power supply not connected Switch on the power supply light up LED K1 lights up Safety relay K1 is welded Replace the device but K2 remains off A 1 channel switch off oc Switch channel off on S22 curred on 512 LED K2 lights up Safety relay K2 is welded Replace the device but K1 remains off A 1 channel switch off oc Switch channel off on 512 curred on 522 Device cannot be acti Manual Start Mode vated Line fault on start button Disconnect power supply and remove fault Automatic Start Mode 533 534 bridged Connect S33 with S34 A safety relay is welded Replace the device Incorrect setting of switch S1 Control switch S1 und bring it in the correct position Maintenance and repairs device contains no parts that require maintenance Incase of failure do not open the device but send it to the manufacturer for repair D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to Alteration Operating in
5. 4 contactrows 5 S 4x5 A 100A device mounted without distance heated by devices with same load max current at 55 C over 4 contactrows 1A 2 qp 2 2 2 ah ho a E Current in contactrows Dimensions in mm ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to Alteration D 58515 L denscheid fax 449 0 2351 9365 19 info ipf electronic com Version July 2011 Operating instructions Safety Relay Application examples Single channel connection of light curtains with self test according to EN 61 496 1 Note Refer to Setting Switches in Position 51 without 52 manual light curtain 2 channel connection of light curtains with self test accord ing to EN 61 496 1 Cross fault detection the light curtain _0550 _ 05502_ _ _ _ _ _ I Note Refer to Setting light curtain Switches in Positions 51 With symmetric outputs on light curtains switch 51 in position without With asymmetric outputs on light curtains switch 1 in n position with 1 52 manual L2 Contact reinforcement and contact extension by external contactors Note Refer to Setting Switches in Positions 51 With symmetric outputs on light curtains switch 51 in position without With asymmetric outputs on light curtains switch 1 in position with ote tt tener em 5
6. Adequate fuse protection must be provided on all output contacts with capacitive and inductive loads e he safety function must be triggered at least once a month D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to Alteration Operating instructions e C a Designated use The AO000299 is used for safe interruption of a safety circuit It can be used to protect people and machines in applications with light curtains When used in accordance with its intended purpose and following these operating instruc tions this device presents no known residual risks Nonobservance may lead to personal injuries and damages to property Safety Relay Main featarues e According to Performance Level PL e and Category 4 to EN ISO 13849 1 2008 SIL Claimed Level SIL CL 3 to IEC EN 62061 Safety Integrity Level SIL 3 to IEC EN 61508 Category 4 to EN 954 1 e For light curtains with symmetric or asymmetric outputs adjustment with switch S1 e Output 3S3xno 1xnc the nc contact can only be used for monitoring e Single and 2 channel operation e ine fault detection on On button monitored start e Manual restart or automatic restart switch S2 e LED indicator for channel 1 and 2 and power e ED Anzeigen f r Kanal 1 2 und Netz e Fixed screw terminals Practical Notes
7. Diagram Block Diagram 511 Safety Relay button on light curtain output K2 521 14 24 34 42 Indicators LED Power on when supply connected LED K1 K2 on when relay K1 and K2 energized Setting To set the switches 51 52 please remove the cover of the 0000299 in assistance of a screwdriver etc see illustration The Drawing shows setting at the state of delivery Disconnect the unit before setting of S1 D 58515 Ludenscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to alteration Operating instructions Safety relay Technical Data Input Circuit Nominal Voltage Un Voltage Range Nominal consumption Min Off time Contro voltage on 511 at Un Control current over 512 S22 Min voltage on 512 522 When relay activated Short circuit protection Overvoltage protection Output Contacts Operate delay typ at Un Manual start Automatic start Releas delay typ at Un Disconnecting the supply Disconnecting 512 522 Nominal output voltage Switching of low loads contact 5um Au Thermal Current lin Switching capacity to AC 15 NO contacts NC contacts toDC 13 NO contacts NC contacts to DC13 SchlieBer Electrical contact life to 5A 230V cos 1 Permissible oper
8. Hesse quality management representative L denscheid 12 07 2011 This declaration confirms the conformity of the mentioned directives but does not comprise any guarantee of the product characteristics The safety directives of the product documentation are to be considered ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to Alteration D 58515 Ludenscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011
9. ating frequency Short circuit strength max fuse rating line circuit breaker 24V DC 0 90 1 1 Un approx 1 7W 250ms 22 5V DC typ 35mA at Un 21V DC internal PTC internal VDR 3 NO 1 NC The NC contacts 41 42 con only be used for monitoring 20ms 350ms 20ms 15ms max 250V AC DC see limit curve for arc free operation gt 100mV 21mA max 8A per contact see current limit curve 3A 230V AC IEC EN 60 947 5 1 2A 230V AC IEC EN 60 947 5 1 24V DC IEC EN 60 947 5 1 0 5A 110V DC IEC EN 60 947 5 1 24V DC IEC EN 60 947 5 1 8A 24AV DO gt 25 10 1 5 x10 switching cycles max 1200 operating cycles h ON 0 4s OFF 9 6s 10A gL IEC EN 60 947 5 1 B 6A Kalver Str 27 D 58515 L denscheid fon 449 0 2351 9365 0 fax 49 0 2351 9365 19 Subject to Alteration Version July 2011 www ipf electronic com info ipf electronic com ipf electronic gmbh 2 C d General Data Operating mode Temperature range operation storage Altitude Contact material Clearance and creepage distances Rated impulse Voltage Pollution Degrie EMC Electrostatic discharge ESD HF irradiation Fast Transients Surge Voltages between wires for power supply between wire and ground Interference suppression Degree of Protection Housing Terminals Housing Material Vibration resistance Climate resistance Terminal designation Wire fixing Mounti
10. ified compo nents Important Notes The product hereby described was developed to perform safety functions as a part of a whole installation or machine A complete safety system normally includes sensors eva luation units signals and logical modules for safe disconnections The manufacturer of the installation or machine is responsible for ensuring proper functioning of the whole system ipf cannot guarantee all the specifications of an installation or machine that was not de signed by ipf The total concept of the control system into which the device is integrated must be validated by the user ipf also takes over no liability for recommendations which are given or implied in the following description The following description implies no modi fication of the general ipf terms of delivery warranty or liability claims Safety Regulations e This device must be installed and operated by staff who are familiar with these instruc tions and with the current regulations for safety at work and accident prevention e Pay attention to applicable local regulations especially regarding safety measures e The shock protection on the connected elements and the cable insulation must be de signed for the highest voltage applied to the device e Opening the device or implementing unauthorized changes voids any warranty e he unit should be panel mounted in an enclosure rated at IP 54 or superior Dust and dampness may lead to malfunction e
11. ng Weight Safety related Data EN ISO 13849 1 Category PL MTTFa DCavg dop Nop teycle 62061 61508 SIL CL SIL HFT SFF PFHp ipf electronic gmbh Kalver Str 27 D 58515 L denscheid Operating instructions Safety Relay Continuous operation 15 55 C 25 85 C 2000m AgSnO or similar 4kV 2 Basis insulation IEC 60 664 1 8kV air IEC EN 61 000 4 2 10V m IEC EN 61 000 4 3 2kV IEC EN 61 000 4 4 0 5kV IEC EN 61 000 4 5 2kV IEC EN 61 000 4 5 Limit value class B EN 55 011 40 20 Thermoplastic with VO behaviour according to UL Subject 94 Amplitude 0 35mm frequency 10 55Hz IEC EN 60068 2 6 15 055 04 IEC EN 60068 1 50 005 Plus Minus terminal screwsM3 5 Box terminals with wire protection DIN rail IEC EN 60 715 220g 4 584 5a year 99 0 220d a days year 12h d hours day 3600s cycle 1 h 3 IEC EN 62061 3 IEC EN 61508 99 99 7 2 66 10 fon 49 0 2351 9365 0 www ipf electronic com Subject to alteration fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 Operating instructions Safety relay Characteristics Arc limit curve under resistive load Total current limit curve Switching voltage U VDC switching current A sale breaking no continuous arcing device mounted on distance with air circulation max 1 switching cycle s max current at 55 over
12. structions Safety Relay Labeling and connections K2 JEMEN EN 4 1 42 4 PZ 1 0 8 Nm 7 LB IN A 8mm 1x0 5 4 mm 1 x AWG 20 to 12 2X0 5 2 5 mm 2 x AWG 20 to 14 A 8mm 1x0 5 2 5 mm 1 x AWG 20 to 14 2 0 5 1 5mm 2 X AWG 20 to 16 A 8mm 1x0 5 4mm 1 x AWG 20 to 12 2 0 5 2 5mm 2 X AWG 20 to 14 ipf electronic gmbh Kalver Str 27 fon 49 0 2351 9365 0 www ipf electronic com Subject to alteration D 58515 L denscheid fax 49 0 2351 9365 19 info ipf electronic com Version July 2011 Operating instructions Safety relay EC Declaration of Conformity The ipf electronic gmbh Kalver Str 27 D 58515 Ludenscheid declares hereby that the following product product description safety switching device for electro sensitive protective devices type designation AO000299 conforms to the following European Standards EMC Directive 2004 108 EG Machinery directive 2006 42 EG Basis of testing EN ISO 13849 1 2008 AC 2009 EN 62061 2005 EN 60947 5 1 2004 A1 2009 EN 60204 1 2006 A1 2009 in extracts EN ISO 13850 2008 EN 50178 1997 The product has been validated by the following testing institutes TUV Rheinland Industrie Service GmbH AlboinstraBe 56 D 12103 Berlin Name of the documentation representative J rg Hesse Adress of the documentation representative see adress of the manufacturer signature J
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