User Manual UM EN SAFETY RELAY APPLICATION Handbook
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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 05/2006 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 PHOENIX CONTACT UM EN SAFETY RELAY APPLICATION 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 carefully 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 & Co. KG Documentation Services 32823 Blomberg Germany Phone Fax E-mail PHOENIX CONTACT +49 - 52 35 - 30 0 +49 - 52 35 - 34 20 21 tecdoc@phoenixcontact.com 102597_01_en UM EN SAFETY RELAY APPLICATION General Terms and Conditions of Use for Technical Documentation Phoenix Contact GmbH & 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 part of Phoenix Contact GmbH & Co. KG to furnish information on alterations to products and/or technical documentation. Any other agreement shall only apply if expressly confirmed in writing by Phoenix Contact GmbH & Co. KG. Please note that the supplied documentation is product-specific documentation only. Although Phoenix Contact GmbH & 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 & Co. KG does not offer any guarantees as to the reliability, accuracy or completeness of the information provided. Phoenix Contact GmbH & 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 & Co. KG reserves the right to alter, correct, and/or improve the information and the products described in the information at its own discretion and without giving any notice. 102597_01_en PHOENIX CONTACT UM EN SAFETY RELAY APPLICATION 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. It 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 PHOENIX CONTACT 102597_01_en Table of Contents 1 2 3 Introduction..............................................................................................................................1-1 1.1 Phoenix Contact – The Innovative Company ..................................................... 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 Grid (Light Curtain) .................................................................... 1-5 1.2.3 Two-Hand Controls ............................................................................. 1-6 1.2.4 Contact Extension/Positively Driven Contacts .................................... 1-8 1.2.5 Safe Time Function ............................................................................ 1-8 1.2.6 Stop .................................................................................................... 1-9 1.2.7 Safe Isolation .................................................................................... 1-11 1.2.8 Process Technology .........................................................................1-11 1.2.9 Speed and Downtime Monitoring .....................................................1-12 1.2.10 Connection Terminal Blocks ............................................................. 1-12 1.3 Documentation .................................................................................................1-12 Safety Technology...................................................................................................................2-1 2.1 Accidents at Work .............................................................................................. 2-1 2.2 Strategies for Preventing Accidents at Work...................................................... 2-5 2.3 Standards and Directives ................................................................................... 2-8 2.3.1 Useful Addresses for Information About Standards and Regulations .......................................................................................2-10 2.3.2 Interesting Links on the Internet .......................................................2-11 2.3.3 Standards in the USA (OSHA) .........................................................2-12 2.3.4 Functional Safety .............................................................................. 2-18 2.3.5 Safety Categories According to DIN EN 954-1 ................................. 2-22 Wiring Examples......................................................................................................................3-1 102597_01_en 3.1 PSR-ESA4: Emergency Stop Applications Without Start Button Monitoring...... 3-1 3.1.1 PSR-ESA4: Application Example 1 With Fault Monitoring ................. 3-1 3.1.2 PSR-ESA4: Application Example 2 .................................................... 3-3 3.1.3 PSR-ESA4: Application Example 3 .................................................... 3-4 3.2 PSR-ESM4: Emergency Stop Applications With Start Button Monitoring .......... 3-5 3.2.1 PSR-ESM4: Application Example 1 With Fault Monitoring ................. 3-5 3.2.2 PSR-ESM4: Application Example 2 .................................................... 3-7 3.2.3 PSR-ESM4: Application Example 3 .................................................... 3-8 3.3 PSR-ESAM4: Emergency Stop Applications With Start Button Monitoring........ 3-9 3.3.1 PSR-ESAM4: Application Example 1 With Fault Monitoring .............. 3-9 3.3.2 PSR-ESAM4: Application Example 2 ...............................................3-11 3.3.3 PSR-ESAM4: Application Example 3 ...............................................3-12 3.3.4 PSR-ESAM4/3X1: Application Example 1 With Fault Monitoring ..... 3-13 3.3.5 PSR-ESAM4/3X1: Application Example 2 ........................................3-15 3.3.6 PSR-ESAM4/3X1: Application Example 3 ........................................3-16 3.4 PSR-THC4: Two-Hand Controls ......................................................................3-17 3.4.1 PSR-THC4: Application Example 1 With Fault Monitoring ...............3-17 PHOENIX CONTACT i UM EN SAFETY RELAY APPLICATION 3.4.2 3.4.3 ii PHOENIX CONTACT PSR-THC4: Application Example 2 .................................................. 3-18 PSR-THC4: Application Example 3 .................................................. 3-19 3.5 PSR-ESL4: Light Grid Applications..................................................................3-20 3.5.1 PSR-ESL4: Application Example 1 With Fault Monitoring ................ 3-20 3.5.2 PSR-ESL4: Application Example 2 ...................................................3-22 3.5.3 PSR-ESL4: Application Example 3 ...................................................3-23 3.5.4 PSR-ESL4: Application Example 4 ...................................................3-24 3.6 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 .................................................. 3-27 3.7 PSR-ESD: Emergency Stop With Delayed Contacts ....................................... 3-28 3.7.1 PSR-ESD: Application 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 ....................................................3-31 3.8 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) ...............................................................................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 Switches) ...............................................................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 3.9 PSR-SDC4, PSR-URD4, PSR-URM4: Emergency Stop Monitoring.............................................................................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 .................................................. 3-40 3.9.4 PSR-SDC4: Application Example 4 .................................................. 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 ......................................................................3-44 3.10 PSR-ES...4: Connection of Several Safety Relays ..........................................3-45 3.10.1 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: Application Example 3 ......................................................................3-47 3.11 PSR-ESAM4, PSR-ESA4: Machines in Integrated Systems............................ 3-48 3.11.1 PSR-ESAM4, PSR-ESA4: Application Example 1 ...........................3-48 102597_01_en Table of Contents A Approvals and Certificates...................................................................................................... A-1 A1 Approvals ......................................................................................................... A-1 A2 Certificates ....................................................................................................... A-3 A 2.1 PSR-ESA4 ......................................................................................... A-4 A 2.2 PSR-ESM4 ........................................................................................ A-5 A 2.3 PSR-ESAM4 ...................................................................................... A-7 A 2.4 PSR-THC ........................................................................................... A-9 A 2.5 PSR-ESP ......................................................................................... A-10 A 2.6 PSR-ESD ......................................................................................... A-11 B Ordering Data ......................................................................................................................... B-1 C Appendices............................................................................................................................. C-1 D C1 List of Figures................................................................................................... C-1 C2 List of Tables.................................................................................................... C-5 Revision History...................................................................................................................... D-1 102597_01_en PHOENIX CONTACT iii UM EN SAFETY RELAY APPLICATION iv PHOENIX CONTACT 102597_01_en Introduction 1 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 the Phoenix Elektrizitätsgesellschaft H. Knümann & 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 & 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 the best solutions are often the simplest. This applies in 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. 102597_01_en PHOENIX CONTACT 1-1 UM EN 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 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. EMERGENCY STOP +24 V DC/AC 11 21 12 22 A1 S34 S33 S11 R2 Power K1 K2 -K2 A1 S11 S12 S21 S22 PSR-ESA4 A2 S33 S34 13 31 13 23 31 14 24 32 14 S35 23 24 PSR-ESA4 R1 S12 S21 S22 A2 32 31 13 14 32 23 24 0V 102597A036 Figure 1-1 1-2 PHOENIX CONTACT Cable lengths 102597_01_en Introduction Using the example of an emergency stop application with the PSR-ESA4 (see Figure 1-1), the following calculations can be made: Assumed values: Cable: A = 1.5 mm2 Specific conductivity for Cu: κ = 56 m/(Ω * mm2) (at 20°C) Technical data for the safety relay: Input data: Maximum voltage drop for S11-S12 and S21-S22: 2 V DC, approximately (corresponds to 22 Ω = RL, approximately) RL = R1 + R2 RL = 22 Ω Calculated value: l = RL * A * κ l = 22 Ω * 1.5 mm2 * 56 m/Ω * mm2 l = 1848 m Where: l Permissible cable length RL Cable resistance A Cable cross section κ (= 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. 102597_01_en PHOENIX CONTACT 1-3 UM EN SAFETY RELAY APPLICATION Cross-Circuit Detection In both category 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 1 S1 Closed Positively actuated K1 K1 K2 K2 2 3 S1 a Not positively actuated K1 Figure 1-2 4 K2 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 1 Closed S1 b Positively actuated K1 K1 K2 K2 2 3 S1 a Not positively actuated K1 Figure 1-3 1-4 PHOENIX CONTACT 4 K2 Cross-circuit detection in the event of several faults 102597_01_en 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 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). 1.2.2 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 a 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. Some application examples – – – – – – 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) Relevant standards EN 61496-1, EN 61496-2, IEC 61496-1, IEC 61496-2: Requirements for electrosensitive protective systems EN 999: Calculation of safety distances EN 954-1: Safety of machinery - Safety-related parts of control systems 102597_01_en PHOENIX CONTACT 1-5 UM EN SAFETY RELAY APPLICATION 1.2.3 Two-Hand Controls According to DIN 574, the simultaneity of two-hand controls must be monitored to be < 0.5 seconds. The time is reliably checked and evaluated by corresponding category type IIIC 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 Type I Type II Type III A B C Use of both hands (simultaneous actuation) Relationship between input signals and output signals (only both input signals -> output signal) Prevention of accidental operation Prevention of defeat Re-initiation of an output signal (only once both input signals are finished -> re-initiation of the output signal is possible) Synchronous actuation (simultaneous actuation within 0.5 seconds) Safety category 1 application, EN 954-1 Safety category 3 application, EN 954-1 Safety category 4 application, EN 954-1 1-6 PHOENIX CONTACT X X X X X 102597_01_en Introduction Manual control e.g., emergency stop button Control device Input command PSR-THC Synchronous actuation Triggering of 1st input signal Triggering of 2nd input signal End of input signals 1st hand 2nd hand Time t £ 0.5 s Synchronous actuation Time period for simultaneous actuation 102597A032 Figure 1-4 102597_01_en Structure of a two-hand control PHOENIX CONTACT 1-7 UM EN SAFETY RELAY APPLICATION 1.2.4 Contact Extension/Positively Driven Contacts Often 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 reliably and precisely up to safety category 3/4 according to EN 954-1. 1-8 PHOENIX CONTACT 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: STOP STOP S2 K2 S2 S1 K1 S1 STOP K1 S1 S2 Brake Brake M M Not permitted for emergency stop purposes Category 0 Stop Category 1 Stop Category 2 Stop Stopping by immediate removal of power to the machine drives (i.e., an uncontrolled stop). A controlled stop with power available to the machine drives to achieve the stop and then removal of power when the stop is achieved. A controlled stop with power left available to the machine drives. 102597_01_en PHOENIX CONTACT M 1-9 UM EN SAFETY RELAY 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 (according to ISO 13850, EN 60204-1, Annex D) An emergency operation intended to stop a process or a movement that would become hazardous (stop). The emergency stop function is triggered by a single operator operation. This function must be available and operational at all times according to ISO 13849-1 (EN 954-1). In this case, the operating mode is not taken into consideration. Risk of Electric shock Movement Shutdown with emergency stop Stop with emergency stop 102597A048 Figure 1-5 1-10 PHOENIX CONTACT Emergency stop 102597_01_en Introduction 1.2.7 I O 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. Basic insulation between circuits (4 kV impulse voltage withstand level) According to the standard, a mixture of SELV and PELV is strictly prohibited. Only switch 230 V AC at one of the two contacts if the adjacent contact carries the same potential. Reinforced insulation between the circuits (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 ≤ 25 V AC or U ≤ 60 V DC and circuits with higher voltages can be mixed. 1.2.8 SIL IEC 61 508 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. 102597_01_en PHOENIX CONTACT 1-11 UM EN SAFETY RELAY APPLICATION 1.2.9 n=0 n 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: – Can be 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 1-12 PHOENIX CONTACT 102597_01_en Safety Technology 2 Safety Technology 2.1 Accident at work Accidents at Work An accident at work is understood to be a personal injury to an employee that: – Occurs during the 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 30,000 25,000 20,000 15,000 10,000 5000 Figure 2-1 2000 1995 1990 1985 1980 1975 1970 1965 1960 1955 1950 0 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. 102597_01_en PHOENIX CONTACT 2-1 UM EN SAFETY RELAY APPLICATION Every year around 15% of all the accidents at work, which occur in the member companies of our occupational safety and 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 accidents 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. 2-2 PHOENIX CONTACT 102597_01_en Safety Technology No information Repairs/conversion Maintenance work 3% Other Machining process 3% 3% 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 102597_01_en Incorrect operation of the machine PHOENIX CONTACT 2-3 UM EN SAFETY RELAY APPLICATION No information 18% Figure 2-4 Other cause Technical defect 43% 39% 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: – An incorrect safety concept – Poor visibility – Faulty ergonomic design – Complex operation of the machine – Convenience or inexperience of the operator (Source: BGIA (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 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_en PHOENIX CONTACT 2-5 UM EN SAFETY RELAY APPLICATION Safety equipment For safeguarding The danger zone Guard The source of danger Localized safety equipment Deterring/ impeding device Trip device Two-hand control devices Finger barrier Optical data links Access button Hand barrier Light curtains Operator barrier Switch plates Switch mats Trapping safety equipment Switch cords Control strips Enclosing guard Cover Fencing off Guards 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 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) Yes New hazards detected? No Hazard analysis Can the hazard be avoided? Yes Risk reduction by design No Has the risk been reduced? No Yes No Is the use of safety equipment possible? Is safety ensured? Yes Yes Use of safety equipment Yes No Is safety ensured? No No Information for use (Special notes in the operating instructions or on plates) Yes Is safety ensured? Protection objective achieved Figure 2-6 102597_01_en Strategy diagram PHOENIX CONTACT 2-7 UM EN 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 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 National legislation S SF N EC directive EU member states EST EU candidate countries LV LT DK IRL GB NL PL D B LUX National legislation F CH CZ SK A H SLO HR RO BiH SCG I P National legislation BG ALMK E GR TR CY Figure 2-7 2-8 PHOENIX CONTACT 102597A033 European Economic Area (EEA) 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 standards Standard Type Designation Type A Basic safety standards Type B1 Type B2 Group safety standards Typical Examples EN 1050 (1996-11) Safety of machinery - Principles for risk assessment EN ISO 12100-1 (2003-11) Safety of machinery - Basic concepts, general principles for design EN 294 (1992-06) Safety distances EN 349 (1993-04) Minimum distances EN 418 (1992-10) Emergency stop equipment EN 574 (1996-11) Two-hand control devices EN 842 (1996-06) Visual danger signals EN 953 (1997-10) Guards EN 954-1 (1996-12) Safety-related parts of control systems EN 1037 (1995-12) Power supply/reduction EN 1088 (1995-12) Interlocking devices associated with guards 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) Type C 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 Product safety EN 692 (1996-06) standards EN 693 (2001-01) EN 775 (1992-10) Mechanical presses Hydraulic presses Industrial robots This table contains only a few examples and is not complete. 102597_01_en PHOENIX CONTACT 2-9 UM EN SAFETY RELAY APPLICATION 2.3.1 Sources of Reference for Technical Regulations in Germany Useful Addresses for Information About Standards and Regulations For everything about standards, regulations, and directives DIN Deutsches Institut für Normung e. V. (German Institute for Standardization) 10772 Berlin, Germany Phone: Fax: Website: +49 - 30 - 26 01 0 +49 - 30 - 26 01 12 60 http://www2.din.de EC directives, laws, and decrees Bundesanzeiger Verlagsgesellschaft mbH (Federal Official Gazette) Amsterdamer Straße 192 50735 Cologne, Germany Phone: Fax: Website: +49 - 221 - 97 66 80 +49 - 221 - 97 66 82 88 http://www.bundesanzeiger.de DIN standards, ISO standards, VDI directives Beuth Verlag GmbH Burggrafenstraße 6 10787 Berlin, Germany Phone: Fax: Website: +49 - 30 - 26 01 0 +49 - 30 - 26 01 12 60 http://www2.beuth.de VDE regulations, IEC standards VDE-Verlag GmbH Bismarckstr. 33 10625 Berlin, Germany Phone: Fax: Website: +49 - 30 - 34 80 01 0 +49 - 30 - 34 17 09 3 http://www.vde-verlag.de Gerätesicherheitsgesetz (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 Straße 449 50939 Cologne, Germany Phone: Fax: Website: 2-10 PHOENIX CONTACT +49 - 221 - 94 37 30 +49 - 221 - 94 37 39 01 http://www.heymanns.com 102597_01_en 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 still work. Table 2-2 Interesting links on the Internet Link Holder of Web Page/Content http://www2.din.de DIN: Deutsches Institut für Normung e.V. (German Institute for Standardization) http://www.cenorm.be Direct link: http://www.newapproach.org European Committee for Standardization (CEN) http://www.normapme.com/German/ normapme-de.htm European Office of Crafts, Trades and Small and Medium-Sized Enterprises for Standardization Information about standards and an overview of standards for various sectors http://www.stmwvt.bayern.de Bayrisches Staatsministerium für Wirtschaft, Verkehr und Technologie (The Bavarian Ministry of Economic Affairs, Transport, and Technology) Law and law formation in the EU Brief information about EU directives http://gps.sozialnetz.de/ Product and device safety http://www.lfas.bayern.de Bayrisches Landesamt für 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 Information about CE marking, links to the most important European authorities and institutes http://www.vti-bochum.de Verlag Technik & 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 Overview of the latest applicable standards and regulations PHOENIX CONTACT 2-11 UM EN SAFETY RELAY APPLICATION 2.3.3 Standards in the USA (OSHA) 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) B11.19-2003, 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 Control 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 it is 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 detectable by a simple test, or indicated by the control system." 2-12 PHOENIX CONTACT 102597_01_en 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) Introduction to the 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 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 (OSHA) 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 102597_01_en PHOENIX CONTACT 2-13 UM EN SAFETY RELAY APPLICATION OSHA 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 ANSI NFPA Occupational Safety and Health Administration (OSHA) RIA Other Figure 2-8 2-14 PHOENIX CONTACT Relationship between OSHA and consensus standards 102597_01_en Safety Technology OSHA machine safety standards OSHA's machine guarding safety standards, including those from the Code of Federal Regulations, Title 29, OSHA 1910, Subpart O (Machinery and Machine Guarding), are listed in Table 2-3. Table 2-3 OSHA machinery and machine guarding standards OSHA Standard Designation 1910.212 General requirements for all machines 1910.213 Woodworking machinery requirements 1910.214 Cooperage machinery 1910.215 Abrasive wheel machinery 1910.216 Mills and calendars in the rubber and plastics industries 1910.217 Mechanical power presses 1910.218 Forging machines 1910.219 Mechanical power-transmission apparatus 3067 Concepts & Techniques of Machine Safeguarding Important note: Standards from other organizations which are incorporated by reference have the same force and effect as the OSHA 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. 102597_01_en PHOENIX CONTACT 2-15 UM EN SAFETY RELAY APPLICATION ANSI B11-19-2003 Performance Criteria for Safeguarding The B11.19 standard provides performance requirements for the design, construction, installation, operation, and maintenance of safeguards when applied to machine tools. 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 2-16 PHOENIX CONTACT ANSI B11 standards ANSI Standard Designation B11.1-2001 Mechanical Power Presses B11.2-1995 Hydraulic Power Presses B11.3-2002 Power Press Brakes B11.4-2003 Shears B11.5-1988 Iron Workers B11.6-2001 Lathes B11.7-1995 Cold Headers and Cold Formers B11.8-2001 Manual Milling, Drilling and Boring B11.9-1975 Grinding B11.10-2003 Metal Sawing B11.11-2001 Gear and Spline Cutting B11.12-1996 Roll Forming and Roll Bending B11.13-1992 Automatic Screw/Bar and Chucking Machine B11.14-1996 Coil Slitting B11.15-2001 Pipe, Tube and Shape Bending B11.17-1996 Horizontal Hydraulic Extrusion Presses B11.18-1997 Coil Processing Systems B11.19-2003 Performance Criteria for Safeguarding B11.20-1991 Manufacturing Systems/Cells B11.21-1997 Machine Tools Using Lasers B11.22-2002 Numerically Controlled Turning B11.23-2002 Machining Centers B11.24-2002 Transfer B11.TR3-2000 Risk Assessment and Risk Reduction 102597_01_en Safety Technology Other areas covered by ANSI standards 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 society 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. 102597_01_en PHOENIX CONTACT 2-17 UM EN SAFETY RELAY APPLICATION With regard to safety, the following NFPA 79 areas are of interest: – 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 system to remain in the safe state or enter a safe state. The requirements for achieving functional safety are based on the following objectives: – Avoidance of systematic 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 – – – – – – – – 2-18 PHOENIX CONTACT 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 Safety Technology Application of EN 61508 Sensor E/E/PES 35% Actuator 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) Part 1 (normative) – Risk analysis – Assignment of measures for risk reduction – Specification of safety functions for E/E/PES Methods for determining the required system Part 6 (informative) Implementation of E/E/PES Guidelines for Part 2 and Part 3 Part 4 (normative) Hardware requirements for systems and subsystems Software requirements Part 2 (normative) Part 3 (normative) Definitions Part 7 (informative) 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. 102597_01_en PHOENIX CONTACT 2-19 UM EN SAFETY RELAY APPLICATION Definitions and Abbreviations Table 2-5 Definitions and abbreviations Abbreviation Term Description SIL 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. FSM Function Safety Management Document for the management of functional safety FMEA Failure Modes & 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 Electronic (Safety-Related System) Electrical, electronic and/or programmable electronic (system) DC Diagnostic Coverage Capacity of the safety-related part of a control system to detect faults CCF Common Cause Failure Management Also referred to as β 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) SFF Safe Failure Fraction Proportion of harmless failures. All safe and dangerous faults that are detected PL 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 probability of dangerous failure on demand of a safety function PFD 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 PFH 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 TI 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 "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 for each safety function Low risk Category (EN 954-1) SIL (IEC 61508) No special safety requirements High risk Figure 2-11 102597_01_en 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 β factor. Ability to handle errors with a common cause. DC Diagnostic Coverage - capacity of the safety-related part of a control system to detect faults. PHOENIX CONTACT 2-21 UM EN 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. B S1 F1 S2 F2 1 2 3 4 P1 P2 P1 P2 Figure 2-12 S Selection of category B, 1, 2, 3, and 4 for safety-related parts of control systems Severity of injury S1 Slight (normally reversible) injury Preferred categories for reference points S2 Serious (normally irreversible) injury F Frequency and/or exposure time to the hazard Possible categories which can 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 hazard Measures which can be over dimensioned for the relevant risk P1 Possibility under specific conditions P2 Scarcely possible 2-22 PHOENIX CONTACT 102597_01_en 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 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) – 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 System behavior in the event of a fault 102597_01_en The occurrence of a fault can lead to the loss of the safety functions. PHOENIX CONTACT 2-23 UM EN SAFETY RELAY APPLICATION Safety Category 1 (Single-Channel Control) The requirements of category B must be met. Proven components and proven safety principles must be used. System behavior in the event of a fault 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 1 Closed S1 Positively actuated 2 K1 K1 Figure 2-13 2-24 PHOENIX CONTACT Safety category 1 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 a warning of the hazard. System behavior in the event of a fault – 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 F02 Open Closed Danger H1 OFF 5 K1 K1 Positively actuated K3 K2 K1 S1 6 Π V1 K01 K2 AW 1 3 2 4 F01 S01 ON S02 Warning OFF S2 K01 K1 K01 F02 M 3~ K2 K3 K01 AW = Disconnect wiping relay Figure 2-14 Function of the circuit for safety category 2 Dangerous drive = Safety circuit Safety category 2 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 in. 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. 102597_01_en PHOENIX CONTACT 2-25 UM EN 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: – A 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 event of a fault – – – When the single fault occurs, the safety function is always performed. Some but not all faults are detected. An accumulation of undetected faults can lead to the loss of the safety function. Movable guard Open 1 Safety circuits Closed S1 Positively actuated K1 K1 K2 K2 2 3 S1 Not positively actuated Figure 2-15 2-26 PHOENIX CONTACT 4 K1 K2 Control signals at PLC input via optocoupler Safety category 3 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: – A single fault in any of these parts does not lead to the loss of the safety function – The 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 event of a fault – – When faults occur, the safety function is always performed. The faults will be detected in time to prevent the loss of the safety function. Movable guard 1 Open K2 START Safety circuits S3 Closed S1 2 K3 5 K2 K1 K1 K2 K2 K3 K3 Positively actuated K3 S2 Not positively actuated Figure 2-16 102597_01_en K1 K2 K1 3 K1 K3 4 K3 Safety category 4 PHOENIX CONTACT 2-27 UM EN 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 fault 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 (S11-S12, S21-S22) Up to safety category 4, EN 954-1 2 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Manual activation (S33-S34) Stop category 0 +24 V DC/AC Fault 2 Fault 1 EMERGENCY STOP 11 21 4 12 3 A1 S34 S33 S11 22 S12 S21 S22 A2 Fault 5 Power K1 K2 -K1 S11 S12 A1 S21 S22 PSR-ESA4 Reset 23 13 23 14 24 14 S33 S34 A2 13 24 33 PSR-ESA4 2 1 33 34 34 31 13 14 32 23 24 Fault 3 0V 102597A001 Figure 3-1 102597_01_en PSR-ESA4: Application example 1 PHOENIX CONTACT 3-1 UM EN SAFETY RELAY APPLICATION Fault Monitoring – – – – – 3-2 PHOENIX CONTACT Fault 1: If an emergency stop button contact does not open or 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 between the two emergency stop channels. Power OFF K1 OFF K2 OFF 102597_01_en Wiring Examples 3.1.2 PSR-ESA4 PSR-ESA4: Application Example 2 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22) Up to safety category 4, EN 954-1 2 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Automatic activation (bridge S33-S34) Stop category 0 EMERGENCY STOP +24 V DC/AC A1 Power K1 K2 S11 S12 S21 S22 PSR-ESA4 A2 13 31 13 23 31 14 24 32 14 S33 S34 23 24 PSR-ESA4 -K2 A1 S34 S33 S11 S12 S21 S22 A2 32 31 13 14 32 23 24 0V 102597A002 Figure 3-2 102597_01_en PSR-ESA4: Application example 2 PHOENIX CONTACT 3-3 UM EN SAFETY RELAY APPLICATION 3.1.3 PSR-ESA4 PSR-ESA4: Application Example 3 Application Features Emergency stop monitoring Single-channel (in circuit A1, bridge S11-S12, S21-S22) Up to safety category 2, EN 954-1 2 N/O contacts, 1 N/C contact US = 24 V DC/AC Manual activation (S33-S34) Stop category 0 +24 V DC/AC EMERGENCY STOP A1 S34 S33 S11 Power K1 K2 -K2 S11 S12 A1 S21 S22 PSR-ESA4 A2 23 31 13 23 31 14 24 32 14 24 32 31 13 14 32 23 24 Reset S33 S34 13 PSR-ESA4 S12 S21 S22 A2 0V 102597A003 Figure 3-3 3-4 PHOENIX CONTACT PSR-ESA4: Application example 3 102597_01_en Wiring Examples 3.2 3.2.1 PSR-ESM4 PSR-ESM4: Emergency Stop Applications With Start Button Monitoring PSR-ESM4: Application Example 1 With Fault Monitoring Application Features Emergency stop monitoring Single-channel (in circuit A1, bridge S11-S12, S21-S22) Up to safety category 2, EN 954-1 3 N/O contacts, 1 N/C contact US = 24 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 EMERGENCY STOP +24 V DC/AC Fault 1 A1 S34 S33 S11 -K2 A1 S11 S12 S21 S22 13 PSR-ESM4 14 14 S33 S34 Reset A2 13 23 23 24 24 33 33 34 34 41 41 Power K1 K2 PSR-ESM4 S12 S21 S22 A2 42 42 41 33 13 14 42 34 23 24 Fault 2 0V 102597A004 Figure 3-4 102597_01_en PSR-ESM4: Application example 1 PHOENIX CONTACT 3-5 UM EN SAFETY RELAY APPLICATION Fault Monitoring – – 3-6 PHOENIX CONTACT Fault 1: Short circuit does not occur until it is actuated. The safety function is no longer available, i.e., the 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 the emergency stop. The module can only be switched on again once the relevant fault has been removed. Power ON K1 ON K2 OFF 102597_01_en Wiring Examples 3.2.2 PSR-ESM4 PSR-ESM4: Application Example 2 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 EMERGENCY STOP +24 V DC/AC A1 Power K1 K2 S11 S12 S21 S22 PSR-ESM4 23 33 13 23 33 14 24 34 14 S33 S34 24 34 41 41 42 42 41 33 13 14 42 34 23 24 Reset A2 13 PSR-ESM4 -K1 A1 S34 S33 S11 S12 S21 S22 A2 0V 102597A005 Figure 3-5 102597_01_en PSR-ESM4: Application example 2 PHOENIX CONTACT 3-7 UM EN SAFETY RELAY APPLICATION 3.2.3 PSR-ESM4 PSR-ESM4: Application Example 3 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Manual activation (S33-S34) Monitored start Monitored contact extension Stop category 0 EMERGENCY STOP +24 V DC/AC A1 L S11 S12 S21 S22 PSR-ESM4 Reset 33 23 33 14 24 34 K1 ext K2 ext 23 13 14 S33 S34 A2 13 24 34 41 41 Power K1 K2 PSR-ESM4 -K1 A1 S34 S33 S11 S12 S21 S22 A2 42 42 41 33 13 14 42 34 23 24 K2 K1 N 0V 102597A006 Figure 3-6 3-8 PHOENIX CONTACT PSR-ESM4: Application example 3 102597_01_en Wiring Examples 3.3 PSR-ESAM4: Emergency Stop Applications With Start Button Monitoring 3.3.1 PSR-ESAM4 PSR-ESAM4: Application Example 1 With Fault Monitoring Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22, bridge S10-S11) Up to safety category 4, EN 954-1 8 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 +24 V DC/AC Fault 2 11 21 12 22 4 3 S12 S34 S33 S35 91 33 43 53 S10 S11 S11 S12 92 34 44 54 A1 S21 S22 A2 83 63 64 13 14 84 73 74 Fault 5 2 Fault 4 -K1 S21 S22 PSR-ESAM4 S33 S34 S35 Reset A2 Power K1 K2 1 S10 S11 S12 A1 PSR-ESAM4 EMERGENCY STOP Fault 1 13 23 33 43 53 63 73 83 91 13 23 33 43 53 63 73 83 91 14 24 34 44 54 64 74 84 92 14 24 34 44 54 64 74 84 92 23 24 Fault 3 0V 102597A007 Figure 3-7 102597_01_en PSR-ESMA4: Application example 1 PHOENIX CONTACT 3-9 UM EN SAFETY RELAY APPLICATION Fault Monitoring – – – – – 3-10 PHOENIX CONTACT Fault 1: Short circuit S11-S12 Power ON K1 ON K2 OFF Fault 2: Short circuit S21-S22 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 K2 ON 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_en Wiring Examples 3.3.2 PSR-ESAM4 PSR-ESAM4: Application Example 2 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22, bridge S10-S11) Up to safety category 4, EN 954-1 8 N/O contacts, 1 N/C contact Cross-circuit detection (S11-S12; S21-S22) US = 24 V DC/AC Automatic activation (bridge S33-S35) Stop category 0 S12 S34 S33 S35 91 33 43 53 S10 S11 S11 S12 92 34 44 54 A1 S21 S22 A2 83 63 64 13 14 84 73 74 PSR-ESAM4 EMERGENCY STOP +24 V DC/AC Power K1 K2 -K2 A1 S10 S11 S12 S21 S22 PSR-ESAM4 A2 S33 S34 S35 13 23 33 43 53 63 73 83 13 23 33 43 53 63 73 83 14 24 34 44 54 64 74 84 14 24 34 44 54 64 74 84 91 91 92 92 23 24 0V 102597A008 Figure 3-8 102597_01_en PSR-ESMA4: Application example 2 PHOENIX CONTACT 3-11 UM EN SAFETY RELAY APPLICATION 3.3.3 PSR-ESAM4 PSR-ESAM4: Application Example 3 Application Features Emergency stop monitoring Single-channel (S11-S12, bridge S10-S12, S21-S22) Up to safety category 2, EN 954-1 8 N/O contacts, 1 N/C contact US = 24 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 S12 S34 S33 S35 91 33 43 53 S10 S11 S11 S12 92 34 44 54 A1 S21 S22 A2 83 63 64 13 14 84 73 74 PSR-ESAM4 EMERGENCY STOP +24 V DC/AC Power K1 K2 -K2 S10 S11 S12 A1 S21 S22 PSR-ESAM4 23 33 43 53 63 73 83 13 23 33 43 53 63 73 83 14 24 34 44 54 64 74 84 14 S33 S34 S35 24 34 44 54 64 74 84 91 91 92 92 23 24 Reset A2 13 0V 102597A009 Figure 3-9 3-12 PHOENIX CONTACT PSR-ESMA4: Application example 3 102597_01_en Wiring Examples 3.3.4 PSR-ESAM4/3X1 PSR-ESAM4/3X1: Application Example 1 With Fault Monitoring Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22, bridge S10-S11) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C contact According to EN 61508 SIL 3 (SIL data on request) Cross-circuit detection (S11-S12; S21-S22) US = 24 ... 230 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 Fault 1 11 21 4 12 3 S12 S21 S22 PSR-ESAM4/3X1 S33 S34 S35 A2 A1 A1 S34 S33 S35 S12 S11 S11 S10 S10 S12 S21 S22 Fault 5 1 S10 S11 A1 22 2 Fault 4 -K1 Fault 2 13 23 33 41 13 23 33 41 14 24 34 42 14 24 34 PSR-ESAM4/3X1 EMERGENCY STOP +24...230 V DC/AC 42 41 Reset Power K1 K2 42 13 23 24 14 33 34 Fault 3 0V 102597B038 Figure 3-10 102597_01_en PSR-ESMA4/3X1: Application example 1 PHOENIX CONTACT 3-13 UM EN SAFETY RELAY APPLICATION Fault Monitoring – – – – – 3-14 PHOENIX CONTACT Fault 1: Short circuit S11-S12 Power ON K1 ON K2 OFF Fault 2: Short circuit S21-S22 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 K2 ON 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_en Wiring Examples 3.3.5 PSR-ESAM4/3X1 PSR-ESAM4/3X1: Application Example 2 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22, bridge S10-S11) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C contact According to EN 61508 SIL 3 (SIL data on request) Cross-circuit detection (S11-S12; S21-S22) US = 24 ... 230 V DC/AC Automatic activation (S33-S35) Stop category 0 -K2 A1 S10 S11 S12 S21 S22 PSR-ESAM4/3X1 A2 S33 S34 S35 13 23 33 41 13 23 33 41 14 24 34 42 14 24 34 A1 A1 S34 S33 S35 S12 S11 S11 S10 S10 S12 S21 S22 PSR-ESAM4/3X1 EMERGENCY STOP +24...230 V DC/AC Power K1 K2 42 41 42 13 23 24 14 33 34 0V 102597A039 Figure 3-11 102597_01_en PSR-ESMA4/3X1: Application example 2 PHOENIX CONTACT 3-15 UM EN SAFETY RELAY APPLICATION 3.3.6 PSR-ESAM4/3X1 PSR-ESAM4/3X1: Application Example 3 Application Features Emergency stop monitoring Single-channel (S11-S12, bridge S21-S22, S10-S12) Up to safety category 2, EN 954-1 3 N/O contacts, 1 N/C contact According to EN 61508 SIL 3 (SIL data on request) US = 24 ... 230 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 -K2 S10 S11 S12 A1 S21 S22 13 PSR-ESAM4/3X1 S33 S34 S35 A2 23 33 41 13 23 33 41 14 24 34 42 14 24 34 A1 A1 S34 S33 S35 S12 S11 S11 S10 S10 S12 S21 S22 PSR-ESAM4/3X1 EMERGENCY STOP +24...230 V DC/AC Power K1 K2 42 42 13 23 24 14 33 34 Reset 41 0V 102597A040 Figure 3-12 3-16 PHOENIX CONTACT PSR-ESMA4/3X1: Application example 3 102597_01_en Wiring Examples 3.4 PSR-THC4: Two-Hand Controls 3.4.1 PSR-THC4 PSR-THC4: Application Example 1 With Fault Monitoring Application Features Two-hand control 2 N/O contacts, 1 N/C contact Up to safety category 4, EN 954-1 US = 24 V DC/AC Synchronous activation monitoring < 0.5 s Cross-circuit detection (S11-S14-S12; S21-S24-S22) According to EN 574 type IIIC +24 V DC/AC Fault 1 Fault 4 11 13 S1 13 11 S2 14 12 14 4 12 3 1 Fault 2 S11 S14 S12 Y1 Y2 S11 S14 S22 S12 S24 S14 S12 S22 S24 S21 S24 S22 -K1 A1 A1 Y2 S11 S21 Y2 13 S21 PSR-THC4 A2 23 31 13 23 31 14 24 32 14 24 32 Power K1 K2 A2 PSR-THC4 Fault 5 2 31 13 14 32 23 24 0V 102597A010 Figure 3-13 PSR-THC4: Application example 1 Fault Monitoring – – 102597_01_en 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 UM EN SAFETY RELAY APPLICATION – – – Fault 3: Undervoltage at A1-A2 Power ON K1 OFF/lights up only faintly K2 ON Fault 4: Short circuit S21, S22, S24 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 PSR-THC4: Application Example 2 Application Features Monitoring of control guard according to EN 1088 2 N/O contacts, 1 N/C contact 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 A1 Y2 S11 S21 -K2 A1 Y1 Y2 S21 S14 S22 S11 S12 S24 PSR-THC4 A2 13 23 31 13 23 31 14 24 32 14 24 32 S12 S24 Power K1 K2 A2 PSR-THC4 S14 S22 Y2 31 13 14 32 23 24 0V 102597A011 Figure 3-14 3-18 PHOENIX CONTACT PSR-THC4: Application example 2 102597_01_en Wiring Examples 3.4.3 PSR-THC4 PSR-THC4: Application Example 3 Application Features Two-hand control 2 N/O contacts, 1 N/C contact Up to safety category 4, EN 954-1 US = 24 V DC/AC Synchronous activation monitoring < 0.5 s Monitored contact extension (Y1-Y2) According to EN 574 type IIIC +24 V DC/AC 13 11 S1 13 11 S2 14 14 12 12 K1 ext A1 Y2 S11 S21 S14 S22 Y2 L L -K2 A1 Y1 Y2 S11 S14 S22 S12 S24 S21 PSR-THC4 A2 S12 S24 A2 S21 S24 S22 23 13 31 13 23 31 14 24 32 24 14 32 Power K1 K2 PSR-THC4 K2 ext S11 S14 S12 31 13 14 32 23 24 K2 ext K1 ext 0V N 102597A012 Figure 3-15 102597_01_en PSR-THC4: Application example 3 PHOENIX CONTACT 3-19 UM EN SAFETY RELAY APPLICATION 3.5 PSR-ESL4: Light Grid Applications 3.5.1 PSR-ESL4 PSR-ESL4: Application Example 1 With Fault Monitoring Application Features Light grid monitoring Two-channel (OSSD1-S12, OSSD2-S22) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C 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 +24 V DC/AC Light grid A1 S34 S33 S35 S11 S12 S22 A2 1 OSSD1 -K1 A1 S11 S12 S22 PSR-ESL4 S33 S34 S35 13 23 33 13 23 33 14 24 34 14 24 34 41 41 42 42 41 33 13 14 42 34 23 24 Reset A2 Power K1 K2 OSSD2 PSR-ESL4 Fault 1 0V 102597A013 Figure 3-16 3-20 PHOENIX CONTACT PSR-ESL4: Application example 1 102597_01_en Wiring Examples Fault Monitoring – – – 102597_01_en 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 properly. OSSD1-S12, OSSD2-S22. S11 not connected. Power ON K1 OFF K2 OFF Fault 3: During operation (all LEDs lit up), K1 and K2 OFF. Restart not possible. Undervoltage at A1-A2. Power ON K1 OFF/lights up only faintly K2 ON PHOENIX CONTACT 3-21 UM EN SAFETY RELAY APPLICATION 3.5.2 PSR-ESL4 PSR-ESL4: Application Example 2 Application Features Emergency stop monitoring Two-channel (S11-S12, S11-S22) Up to safety category 3, EN 954-1 3 N/O contacts, 1 N/C contact US = 24 V DC/AC Manual activation (S33-S34) Monitored start Monitored contact extension (S33-S34) Stop category 0 EMERGENCY STOP +24 V DC/AC A1 S11 S12 PSR-ESL4 S33 S34 Reset A2 L L S22 S35 13 23 33 13 23 33 14 24 34 14 24 34 41 41 42 Power K1 K2 PSR-ESL4 -K1 A1 S34 S33 S35 S11 S12 S22 A2 42 K4 41 33 13 14 42 34 23 24 K3 K3 K4 0V 102597A014 Figure 3-17 3-22 PHOENIX CONTACT PSR-ESL4: Application example 2 102597_01_en Wiring Examples 3.5.3 PSR-ESL4 PSR-ESL4: Application Example 3 Application Features Emergency stop monitoring Single-channel (S11-S12, bridge S12-S22) Up to safety category 2, EN 954-1 3 N/O contacts, 1 N/C contact US = 24 V DC/AC Manual activation (S33-S34) Monitored start Stop category 0 EMERGENCY STOP +24 V DC/AC A1 Power K1 K2 S11 S12 S22 PSR-ESL4 S33 S34 S35 23 33 13 23 33 14 24 34 14 24 34 41 41 42 42 41 33 13 14 42 34 23 24 Reset A2 13 PSR-ESL4 -K1 A1 S34 S33 S35 S11 S12 S22 A2 0V 102597A015 Figure 3-18 102597_01_en PSR-ESL4: Application example 3 PHOENIX CONTACT 3-23 UM EN SAFETY RELAY APPLICATION 3.5.4 PSR-ESL4 PSR-ESL4: Application Example 4 Application Features Light grid monitoring Two-channel (OSSD1-S12, OSSD2-S22) Up to safety category 4, EN 954-1 3 N/O contacts, 1 N/C 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 Light grid A1 S34 S33 S35 OSSD1 OSSD2 -K1 A1 S11 S12 13 S22 PSR-ESL4 A2 S33 S34 S35 23 33 13 23 33 14 24 34 14 K4 K3 Power K1 K2 L L 24 34 41 PSR-ESL4 S11 S12 S22 A2 41 42 42 41 33 13 14 42 34 23 24 K3 K4 0V 102597A016 Figure 3-19 3-24 PHOENIX CONTACT PSR-ESL4: Application example 4 102597_01_en Wiring Examples 3.6 PSR-ESP4: Process Technology Applications 3.6.1 PSR-ESP4 PSR-ESP4: Application Example 1 Application Features Emergency stop monitoring Single-channel (in circuit A1) Up to safety category 2, EN 954-1 2 N/O contacts, 1 N/C contact According to EN 61508 SIL 3 (SIL data on request) US = 24 V DC Monitored activation (Y1-Y2) Monitored contact extension (Y1-Y2) Stop category 0 Reset K3 A1 K4 L Y1 Y2 A2 L K1 K2 -K2 A1 Y1 13 Y2 PSR-ESP4 23 31 13 23 31 14 24 32 14 A2 24 PSR-ESP4 EMERGENCY STOP +24 V DC 32 31 13 14 32 23 24 K3 K4 N 0V 102597A017 Figure 3-20 102597_01_en PSR-ESP4: Application example 1 PHOENIX CONTACT 3-25 UM EN SAFETY RELAY APPLICATION 3.6.2 PSR-ESP4 PSR-ESP4: Application Example 2 With Fault Monitoring Application Features Emergency stop monitoring Single-channel (in circuit A1) Up to safety category 2, EN 954-1 2 N/O contacts, 1 N/C contact SIL 3 according to EN 61508 US = 24 V DC Automatic activation (bridge Y1-Y2) Stop category 0 EMERGENCY STOP +24 V DC Y1 Y2 A2 Fault 2 K1 K2 -K2 A1 Y1 13 Y2 PSR-ESP4 31 23 31 14 24 32 14 A2 23 13 24 32 PSR-ESP4 A1 31 13 14 32 23 24 0V 102597A018 Figure 3-21 PSR-ESP4: Application example 2 Fault Monitoring – – 3-26 PHOENIX CONTACT Fault 1: Recovery time not reached. Remove fault through voltage reset. Power at A1-A2 K1 ON K2 OFF Fault 2: Bridge Y1-Y2 missing. Power at A1-A2 K1 OFF K2 OFF 102597_01_en Wiring Examples 3.6.3 PSR-ESP4 PSR-ESP4: Application Example 3 Application Features Evaluation of a safety control system 2 N/O contacts, 1 N/C contact Up to safety category 4, EN 954-1 US = 24 V DC SIL 3 according to EN 61508 (with fault prevention in the input circuit) Monitored contact extension (Y1-Y2) Stop category 0 Safe PLC OUT, e.g., S7...F 24 V DC A1 K4 L -K2 A1 Y1 PSR-ESP4 31 13 23 31 14 24 32 24 14 A2 K1 K2 23 13 Y2 Y1 Y2 A2 32 PSR-ESP4 K3 31 13 14 32 23 24 K3 K4 N 0V 102597A019 Figure 3-22 102597_01_en PSR-ESP4: Application example 3 PHOENIX CONTACT 3-27 UM EN SAFETY RELAY APPLICATION 3.7 PSR-ESD: Emergency Stop With Delayed Contacts 3.7.1 PSR-ESD/300 PSR-ESD: Application Example 1 With Fault Monitoring Application Features Emergency stop monitoring Two-channel (S11-S12 and S21-S22, bridge S10-S11, Y1-Y2) Up to safety category 3/4, EN 954-1 3 undelayed N/O contacts, 2 delayed N/O contacts, 1 N/O contact US = 24 V DC Cross-circuit detection (S10-S11-S12, S21-S22) Manual activation (S33-S34) Monitored start Stop category 0/1 +24 V DC 12 6 3 4 5 1 2 3 4 5 6 0.2 0.4 0.6 0.8 1 1.2 0.8 1.6 2.4 3.2 4 4.2 6.4 12.8 19.2 25 32 38 100 200 250 ON OFF EMERGENCY STOP A B A B A B A B ON OFF 4 3 Fault 2 S10 PSR-ESD S11 3 4 5 A S22 13 23 33 ON 13 23 33 OFF 14 24 34 B S33 S34 S35 14 50 OFF 24 34 41 41 42 42 57 57 67 58 68 58 150 300 67 68 S12 S34 S33 S35 A1 S21 S22 A2 S10 S11 S11 S12 Y1 Y2 Power K1 K2 Reset A2 S12 S21 12 6 ON PSR-ESD Y2 OFF Fault 3 Fault 1 Y1 Fault 4 1 -K1 A1 ON 2 K3(t) K4(t) 57 67 41 13 23 24 58 68 42 14 33 34 0V 102597A020 Figure 3-23 3-28 PHOENIX CONTACT PSR-ESD: Application example 1 102597_01_en Wiring Examples Fault Monitoring – – – – 102597_01_en Fault 1: Short circuit S11-S12 Power ON K1 ON K2 OFF Fault 2: Faulty wiring S33-S34 or bridge Y1-Y2 missing. Power ON K1 OFF K2 OFF K3(t) OFF K4(t) OFF Fault 3: Short circuit S21-S22 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 K4(t) OFF PHOENIX CONTACT 3-29 UM EN SAFETY RELAY APPLICATION 3.7.2 PSR-ESD/300 PSR-ESD: Application Example 2 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 positive-opening switches and installing cable in separate cable sheaths US = 24 V DC Manual activation (S33-S34) Monitored start Stop category 0/1 +24 V DC 12 6 3 4 5 1 2 3 4 5 6 0.2 0.4 0.6 0.8 1 1.2 0.8 1.6 2.4 3.2 4 4.2 6.4 12.8 19.2 25 32 38 100 200 250 ON OFF EMERGENCY STOP A B A B A B A B ON OFF ON OFF ON Y1 Y2 S10 S11 PSR-ESD 6 S33 S34 S35 S21 A 23 33 ON 13 23 33 OFF 14 24 34 B S22 14 24 34 41 41 42 42 57 67 58 68 58 300 67 57 68 S12 S34 S33 S35 A1 S21 S22 A2 S10 S11 S11 S12 Y1 Y2 Power K1 K2 Reset A2 3 4 5 13 S12 12 150 PSR-ESD A1 50 OFF -K1 K3(t) K4(t) 57 67 41 13 23 24 58 68 42 14 33 34 0V 102597A021 Figure 3-24 3-30 PHOENIX CONTACT PSR-ESD: Application example 2 102597_01_en Wiring Examples 3.7.3 PSR-ESD/300 PSR-ESD: Application Example 3 Application Features Limit switch monitoring Two-channel with semiconductor output (OUT1 at S10, OUT2 at S12, bridge Y1-Y2, S21-S22) Up to safety category 4, EN 954-1 (depending on limit switch) 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 +24 V DC 12 6 Semiconductor output 3 4 5 1 2 3 4 5 6 0.2 0.4 0.6 0.8 1 1.2 0.8 1.6 2.4 3.2 4 4.2 6.4 12.8 19.2 25 32 38 100 200 250 ON GND +24 V DC OFF A B A B A B A B ON OUT1 OFF OUT2 ON OFF ON Y1 Y2 S10 S11 PSR-ESD 6 S33 S34 S35 S21 A B S22 23 33 ON 13 23 33 OFF 14 24 34 14 24 34 41 41 42 42 57 57 58 58 300 67 67 68 68 S12 S34 S33 S35 A1 S21 S22 A2 S10 S11 S11 S12 Y1 Y2 Power K1 K2 Reset A2 3 4 5 13 S12 12 150 PSR-ESD A1 50 OFF -K1 K3(t) K4(t) 57 67 41 13 23 24 58 68 42 14 33 34 0V 102597A022 Figure 3-25 102597_01_en PSR-ESD: Application example 3 PHOENIX CONTACT 3-31 UM EN SAFETY RELAY APPLICATION 3.8 PSR-RSM, PSR-SSM: Speed and Downtime Monitoring 3.8.1 PSR-RSM PSR-RSM: Application Example 1 (Most Basic Machine) Application Features Evaluation of a safe speed 4 N/O contacts Encoder sensors US = 24 V DC Connection via RJ45 Automatic activation (bridge S33-S35) Up to safety category 3, EN 954-1 Stop category 0 SIL 3 according to EN 61508 (SIL data on request) +24 V DC SK ÜK EMERGENCY STOP Release 33 43 S11 S12 S21 S22 A1 Downtime 13 23 Overspeed A1 MI I3 I2 I1 S33 S34 S35 +24 V +24 V IN1 IN2 PSR-RSM L 13 23 13 PSR-ESM4 23 14 S33 S34 A2 L 24 14 24 33 33 34 34 41 41 42 42 RJ45 FO MO1 MO2 14 24 34 44 Reset A2 Servo K3 K4 K4 K3 K4 K3 M N 0V 102597A023 Figure 3-26 PSR-RSM: Application example 1 (most basic machine) SK = Safety contact ÜK = Monitoring contact 3-32 PHOENIX CONTACT 102597_01_en Wiring Examples 3.8.2 PSR-RSM PSR-RSM: Application Example 2 (Basic Machine With a Monitored Drive) Application Features Downtime monitoring 4 N/O contacts Monitoring of parameterized speeds I3, I2 US = 24 V DC Encoder sensors Automatic activation (bridge S33-S35) Connection via RJ45 Stop category 0 Up to safety category 3, EN 954-1 SIL 3 according to EN 61508 (SIL data on request) +24 V DC Release SK ÜK Enabling switch EMERGENCY STOP Operating mode switch OM 14 24 Downtime 33 43 A1 S11 S12 S21 S22 Servo 13 23 23 33 33 41 41 14 24 34 42 14 24 34 42 S33 S34 34 44 L 13 PSR-ESM4 A2 Reset RJ45 FO MO1 MO2 A2 13 23 Overspeed A1 MI I3 I2 I1 S33 S34 S35 +24 V +24 V IN1 IN2 PSR-RSM L K3 K4 K4 K3 K4 K3 M N 0V 102597A024 Figure 3-27 PSR-RSM: Application example 2 (basic machine with a monitored drive) SK = Safety contact ÜK = Monitoring contact 102597_01_en PHOENIX CONTACT 3-33 UM EN SAFETY RELAY APPLICATION 3.8.3 PSR-RSM PSR-RSM: Application Example 3 (Machine Tool With Several Drives and Differentiated Operating Modes) Application Features Monitoring of several drives in a working area 4 N/O contacts Encoder sensors US = 24 V DC Connection via RJ45 Automatic start following overspeed (bridge S33-S35) Up to safety category 3, EN 954-1 Stop category 0 SIL 3 according to EN 61508 (SIL data on request) RJ45 FO MO1 MO2 A2 13 23 14 24 33 43 Downtime A1 MI I3 I2 I1 S33 S34 S35 +24 V +24 V IN1 IN2 PSR-RSM Overspeed Enabling switch SK ÜK 34 44 Servo EMERGENCY STOP Release +24 V DC A1 OM Servo S11 S12 S21 S22 RJ45 FO MO1 MO2 A2 14 24 33 43 23 13 23 14 K3 K4 33 41 41 K4 K3 K4 34 44 N 0V 33 24 34 42 24 34 42 14 S33 S34 Reset 13 23 Downtime A1 MI I3 I2 I1 S33 S34 S35 +24 V +24 V IN1 IN2 PSR-RSM L 13 PSR-ESM4 A2 Overspeed Operating mode switch L K3 M M 102597A025 Figure 3-28 PSR-RSM: Application example 3 (machine tool with several drives and differentiated operating modes) SK = Safety contact ÜK = Monitoring contact 3-34 PHOENIX CONTACT 102597_01_en Wiring Examples 3.8.4 PSR-RSM PSR-RSM: Application Example 4 (Speed Monitoring Using 2-Wire Proximity Switches) Application Features Speed monitoring IN1, IN2 4 N/O contacts 2-wire proximity switch US = 24 V DC Up to safety category 3, EN 954-1 Automatic activation (bridge S33-S35) SIL 3 according to EN 61508 (SIL data on request) Stop category 0 EMERGENCY STOP +24 V DC Operating mode switch S2 1 L L S1 14 24 34 44 A1 S11 S12 S21 S22 13 23 13 PSR-ESM4 A2 33 23 33 41 41 24 34 42 24 34 42 14 14 S33 S34 Reset RJ45 FO MO1 MO2 A2 33 43 Downtime A1 MI I1 I2 I3 S33 S34 S35 13 23 +24 V +24 V IN1 IN2 PSR-RSM Overspeed 0 K3 K3 K4 K4 N K4 K3 M 0V 102597A026 Figure 3-29 PSR-RSM: Application example 4 (speed monitoring using 2-wire proximity switches) S1, S2: 1 = Contact (tooth) 0 = No contact (gap) 102597_01_en PHOENIX CONTACT 3-35 UM EN SAFETY RELAY APPLICATION 3.8.5 PSR-SSM PSR-RSM: Application Example 5 (Basic Machine With Monitored Drive and Additional Drive Shaft Monitoring) Application Features Evaluation of a safe speed 4 N/O contacts Additional drive shaft monitoring (IN1, IN2) US = 24 V DC Encoder sensors Automatic activation (bridge S33-S35) Connection via RJ45 Stop category 0 Up to safety category 4, EN 954-1 SIL 3 according to EN 61508 (SIL data on request) +24 V DC Encoder Drive Shaft Gearwheel Proximity switch EMERGENCY STOP Operating mode switch OM Start RJ45 FO MO1 MO2 A2 13 23 33 43 14 24 34 44 L S11 S12 S21 S22 L 13 23 13 PSR-ESM4 A2 Downtime Overspeed A1 MI I3 I2 I1 S33 S34 S35 +24 V +24 V IN1 IN2 PSR-RSM A1 23 K3 K4 K4 N 41 41 K3 M 102597A037 Figure 3-30 3-36 33 K4 K3 Servo 0V 33 14 24 34 42 14 24 34 42 S33 S34 Reset Enabling switch Release SK ÜK PHOENIX CONTACT PSR-SSM: Application example 5 (basic machine with monitored drive and additional drive shaft monitoring) 102597_01_en Wiring Examples 3.8.6 PSR-SSM PSR-SSM: Application Example 1 (Downtime Monitoring Using PNP or 2-Wire Proximity Switches) 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 S2 1 0 S1 A1 IN1 IN2 +SEN1 +SEN2 13 23 31 41 PSR-SSM A2 FO MO 14 24 32 42 0V 102597A027 Figure 3-31 PSR-SSM: Application example 1 (downtime monitoring using PNP or 2-wire proximity switches) S1, S2: 1 = Contact (tooth) 0 = No contact (gap) 102597_01_en PHOENIX CONTACT 3-37 UM EN SAFETY RELAY APPLICATION 3.9 PSR-SDC4, PSR-URD4, PSR-URM4: Emergency Stop Monitoring 3.9.1 PSR-SDC4 PSR-SDC4: Application Example 1 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 US = 24 V DC Cross-circuit detection (A2-S22, S11-S12) Manual activation (S33-S34) Monitored start Stop category 0 +24 V DC ... TBUS ... Reset A1 Y30 S22 A2 Power IN1 IN2 -K2 Y1 A1 S33 S34 13 S35 PSR-SDC4 S22 ... TBUS ... S10 S11 S12 S13 23 14 24 14 24 K1 K2 S34 S33 S35 Y1 13 14 EMERGENCY STOP A2 23 13 PSR-SDC4 S11 S10 S12 S13 23 24 0V 102597A041 Figure 3-32 3-38 PHOENIX CONTACT PSR-SDC4: Application example 1 102597_01_en Wiring Examples 3.9.2 PSR-SDC4 PSR-SDC4: Application Example 2 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 US = 24 V DC Cross-circuit detection (A2-S22, S11-S12) Automatic activation (bridge Y1-S33-S35) Stop category 0 +24 V DC ... TBUS ... A1 Y30 S22 A2 Power IN1 IN2 -K2 Y1 A1 S33 S34 13 S35 PSR-SDC4 S22 ... TBUS ... S11 S12 S13 23 14 24 14 24 K1 K2 S34 S33 S35 Y1 13 14 EMERGENCY STOP A2 S10 23 13 PSR-SDC4 S11 S10 S12 S13 23 24 0V 102597A042 Figure 3-33 102597_01_en PSR-SDC4: Application example 2 PHOENIX CONTACT 3-39 UM EN SAFETY RELAY APPLICATION 3.9.3 PSR-SDC4 PSR-SDC4: Application Example 3 Application Features Safety door monitoring (1 N/O contact, 1 N/C contact) Two-channel (S11-S12, S11-S13 bridge S10-S11, A2-S22) Up to safety category 3, EN 954-1 2 N/O contacts US = 24 V DC Manual activation (S33-S34) Monitored start Stop category 0 +24 V DC ... TBUS ... Reset A1 Y30 S22 A2 Power IN1 IN2 -K2 A1 Y1 S33 13 S35 S34 PSR-SDC4 S22 S10 S11 S12 S13 23 14 24 14 24 Safety door A2 23 13 ... TBUS ... K1 K2 PSR-SDC4 S11 S10 S12 S13 S34 S33 S35 Y1 13 14 23 24 0V 102597A043 Figure 3-34 3-40 PHOENIX CONTACT PSR-SDC4: Application example 3 102597_01_en Wiring Examples 3.9.4 PSR-SDC4 PSR-SDC4: Application Example 4 Application Features Emergency stop monitoring Single-channel (S11-S12, bridge S10-S12, 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 +24 V DC K3 Reset K4 A1 Y30 S22 A2 S11 S10 S12 S13 -K2 A1 Y1 S33 S34 13 S35 PSR-SDC4 ... TBUS ... S22 S10 EMERGENCY STOP A2 S11 S12 S13 23 13 23 14 24 14 Power IN1 IN2 K1 K2 PSR-SDC4 ... TBUS ... 24 S34 S33 S35 Y1 K3 13 14 23 24 K4 N 0V 102597A044 Figure 3-35 102597_01_en PSR-SDC4: Application example 4 PHOENIX CONTACT 3-41 UM EN SAFETY RELAY APPLICATION 3.9.5 PSR-SDC4 PSR-SDC4: Application Example 5 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 ... TBUS ... -K2 A1 Y1 S33 S34 13 S35 PSR-SDC4 A2 S22 S10 ... TBUS ... S11 OSSD1 S12 S13 23 13 23 14 24 14 24 OSSD2 Light grid 0V 102597A045 Figure 3-36 3-42 PHOENIX CONTACT PSR-SDC4: Application example 5 102597_01_en Wiring Examples 3.9.6 PSR-SDC4 PSR-SDC4 and PSR-URM4/4X1 Extension Module: Application Example 6 Application Features Emergency stop monitoring Two-channel (A2-S22, S11-S12, bridge S10-S11) Up to safety category 4, EN 954-1 5 N/O contacts, 1 N/C contact US = 24 V DC Cross-circuit detection (A2-S22 and S11-S12) Manual activation (S33-S34) Monitored start Stop category 0 +24 V DC Reset ... TBUS ... -K2 Y1 A1 S33 13 S35 S34 PSR-SDC4 S22 ... TBUS ... S10 S11 S12 S13 13 23 14 24 14 24 A1 K1/K2 11 12 23 33 43 53 61 24 34 44 54 62 PSR-URM4/4X1 A2 EMERGENCY STOP A2 23 0V 102597A046 PSR-SDC4 and PSR-URM4/4X1 extension module: Application example 6 A1 A2 PSR-SDC... K1/K2 S33 Y1 Figure 3-38 102597_01_en 11 12 23 33 43 53 61 A1 A1 A1 K1/ K2 A2 A2 PSR-URM4_B K1/ K1/K2 K2 11 12 Y1 A2 Y1 24 34 44 54 62 PSR-TBUS-TP 2981716 Figure 3-37 Y1 Wiring via T-BUS DIN rail connector PHOENIX CONTACT 3-43 UM EN SAFETY RELAY APPLICATION 3.9.7 PSR-SDC4 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 (undelayed contacts) 2 N/O contacts Delayed contacts: 4 N/O contacts, 1 N/C contact Up to safety category 3, EN 954-1 (delayed contacts) US = 24 V DC Cross-circuit detection (A2-S22 and S11-S12) Manual activation (S33-S34) Monitored start Stop category 1 +24 V DC Reset ... TBUS ... -K2 Y1 A1 S33 S34 13 S35 PSR-SDC4 S22 ... TBUS ... S10 S11 S12 S13 23 14 24 14 16 37 47 57 65 28 38 48 58 66 PSR-URD3 A2 24 27 EMERGENCY STOP A2 A1 K1/K2 15 23 13 0V 102597A047 PSR-SDC... A1 A1 A2 A2 K1/K2 S33 Y1 Figure 3-40 3-44 PHOENIX CONTACT PSR-SDC4 and PSR-URD3 extension module: Application example 7 K1/ 15 16 27 37 47 57 65 K2 A1 K1/K2 PSR-URD3 ) 15 A2 K1/ K2 16 Y1A2 Y1 Y1 ) 28 38 48 58 66 PSR-TBUS-TP 2981716 Figure 3-39 Wiring via T-BUS DIN rail connector 102597_01_en Wiring Examples 3.10 PSR-ES...4: Connection of Several Safety Relays 3.10.1 PSR-ES...4 PSR-ES...4: Application Example 1 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22) Up to safety category 4, EN 954-1 x N/O contacts, x N/C 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 +24 V DC/AC A1 EMERGENCY STOP -K1 EMERGENCY STOP Reset -K2 S11 S12 S21 S22 S33 S34 PSR-ESM4 PSR-ESA4 13 33 13 23 33 14 24 34 14 A2 23 24 34 A1 S11 S12 S21 S22 S33 S34 PSR-ESM4 PSR-ESA4 A2 13 23 13 23 14 24 14 24 33 33 34 34 0V 102597A028 Figure 3-41 102597_01_en PSR-ES...4: Application example 1 PHOENIX CONTACT 3-45 UM EN SAFETY RELAY APPLICATION 3.10.2 PSR-ESA2 PSR-ESA2: Application Example 2 Application Features Emergency stop monitoring Single-channel (S11-S12) 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 STOP EMERGENCY STOP Reset -K1 -K2 A1 S11 S12 S33 S34 13 PSR-ESA2 A2 23 33 43 51 13 23 33 43 51 14 24 34 43 52 14 24 34 44 52 A1 S11 S12 PSR-ESA2 A2 S33 S34 13 33 23 13 23 14 24 14 24 33 34 34 0V 102597A029 Figure 3-42 3-46 PHOENIX CONTACT PSR-ESA2: Application example 2 102597_01_en Wiring Examples 3.10.3 PSR-ES...4/PSR-URM4 PSR-ES...4 and PSR-URM4 Extension Module: Application Example 3 Application Features Emergency stop monitoring Two-channel (S11-S12, S21-S22) Up to safety category 4, EN 954-1 x N/O contacts, x N/C contacts US = 24 V DC/AC Cross-circuit detection (S11-S12 and S21-S22) Manual activation without start button monitoring for PSR-ESA (S33-S34) Manual activation with start button monitoring for PSR-ESM (S33-S34) Contact extension by PSR-URM4 Feedback circuit for monitoring contact extension EMERGENCY STOP +24 V DC/AC 11 21 12 22 -K1 -K2 S11 S12 S21 A1 S22 PSR-ESA4 PSR-ESM4 S33 S34 23 31 13 23 31 14 24 32 14 24 32 A1 PSR-URM4 A2 A2 A12 11 23 33 43 53 63 71 11 23 33 43 53 63 71 12 24 34 44 54 64 72 12 24 34 44 54 64 72 Reset A2 13 0V 102597A030 Figure 3-43 102597_01_en PSR-ES...4 and PSR-URM4 extension modules: Application example 3 PHOENIX CONTACT 3-47 UM EN SAFETY RELAY APPLICATION 3.11 3.11.1 PSR-ESAM4/PSR-ESA4 PSR-ESAM4, PSR-ESA4: Machines in Integrated Systems PSR-ESAM4, PSR-ESA4: Application Example 1 Application of Machine 1 Features of Machine 1 Emergency stop monitoring Two-channel (S11-S12, S21-S22, 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 (S33-S34) Monitored contact extension PSR-ESAM4/PSR-ESA4 Application of Machine 2 Features of Machine 2 Emergency stop monitoring Two-channel via machine 1 (S11-S12, S21-S22) Up to safety category 4, EN 954-1 x N/O contacts, x N/C contacts US = 24 V DC/AC Automatic activation (S33-S34) 3-48 PHOENIX CONTACT 102597_01_en Wiring Examples 0V Machine 1 (Master) K4 K3 K3 X1.8 X1.6 Reset K4 92 84 74 54 64 44 24 34 S35 14 92 84 74 64 54 44 34 24 14 91 83 73 63 53 43 33 23 13 83 73 63 53 33 43 23 13 S22 L2 L1 .6 .7 A2 PSR-ESAM4 X1.7 X1.5 X1 .5 S33 S21 S12 S11 S10 A1 EMERGENCY STOP 91 S34 .8 .4 .3 .2 .1 +24 V DC/AC +24 V DC/AC Machine 2 (Slave) X2 .5 .7 .8 .4 .3 .2 13 23 .1 EMERGENCY STOP .6 S11 A1 PSR-ESA4 A2 S33 S34 S12 S21 S22 31 13 23 31 14 24 32 14 24 32 0V 102597A031 Figure 3-44 102597_01_en PSR-ESAM4, PSR-ESA4: Application example 1 PHOENIX CONTACT 3-49 UM EN SAFETY RELAY APPLICATION 3-50 PHOENIX CONTACT 102597_01_en Approvals and Certificates A Approvals and Certificates A1 Order No. Type 2963718-07 2963705-00 Approvals CE BG TÜV CUL Fuel EN 954-1 Technology (EN 50156-1/ VDE 0116) PSR-SCP- 24UC/ESM4/2X1/1X2 • • • PSR-SPP- 24UC/ESM4/2X1/1X2 • • • • 2963750-02 PSR-SCP- 24UC/ESA4/2X1/1X2 • • • • 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-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- 24DC/ESP4/2X1/1X2 • 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_en IEC 61508, SIL 3 PHOENIX CONTACT A-1 UM EN SAFETY RELAY APPLICATION Order No. Type CE BG 2981428-02 2981431-02 PSR-SCP- 24DC/ESD/5X1/1X2/300 • • • • PSR-SPP- 24DC/ESD/5X1/1X2/300 • • • • 2981101-00 PSR-SCP- 24DC/ESD/5X1/1X2/0T5 • • • • 2981130-00 PSR-SPP- 24DC/ESD/5X1/1X2/0T5 • • • • 2981143-00 PSR-SCP- 24DC/ESD/5X1/1X2/T1 • • • • 2981156-00 PSR-SPP- 24DC/ESD/5X1/1X2/T1 • • • • 2981169-00 PSR-SCP- 24DC/ESD/5X1/1X2/1T5 • • • • 2981172-00 PSR-SPP- 24DC/ESD/5X1/1X2/1T5 • • • • 2981125-00 PSR-SCP- 24DC/ESD/5X1/1X2/T2 • • • • 2981198-00 PSR-SPP- 24DC/ESD/5X1/1X2/T2 • • • • 2981208-00 PSR-SCP- 24DC/ESD/5X1/1X2/2T5 • • • • 2981211-00 PSR-SPP- 24DC/ESD/5X1/1X2/2T5 • • • • 2981224-00 PSR-SCP- 24DC/ESD/5X1/1X2/T3 • • • • 2981237-00 PSR-SPP- 24DC/ESD/5X1/1X2/T3 • • • • 2981240-00 PSR-SCP- 24DC/ESD/5X1/1X2/T4 • • • • 2981253-00 PSR-SPP- 24DC/ESD/5X1/1X2/T4 • • • • 2981266-00 PSR-SCP- 24DC/ESD/5X1/1X2/T5 • • • • 2981279-00 PSR-SPP- 24DC/ESD/5X1/1X2/T5 • • • • 2981282-00 PSR-SCP- 24DC/ESD/5X1/1X2/T6 • • • • 2981295-00 PSR-SPP- 24DC/ESD/5X1/1X2/T6 • • • • 2981088-01 PSR-SCP- 24DC/ESD/5X1/1X2/T10 • • • • 2981091-03 PSR-SPP- 24DC/ESD/5X1/1X2/T10 • • • • 2981305-00 PSR-SCP- 24DC/ESD/5X1/1X2/T15 • • • • 2981318-00 PSR-SPP- 24DC/ESD/5X1/1X2/T15 • • • • 2981321-00 PSR-SCP- 24DC/ESD/5X1/1X2/T20 • • • • 2981334-00 PSR-SPP- 24DC/ESD/5X1/1X2/T20 • • • • 2981347-00 PSR-SCP- 24DC/ESD/5X1/1X2/T30 • • • • 2981350-00 PSR-SPP- 24DC/ESD/5X1/1X2/T30 • • • • 2963538-00 PSR-SCP- 24DC/RSM/4X1 • • • • • 2963541-00 PSR-SPP- 24DC/RSM/4X1 • • • • • 2963567-00 PSR-SCP- 24DC/SSM/2X1 • • • • • 2963570-00 PSR-SPP- 24DC/SSM/2X1 • • • • • A-2 PHOENIX CONTACT TÜV CUL Fuel EN 954-1 Technology (EN 50156-1/ VDE 0116) IEC 61508, SIL 3 102597_01_en Approvals and Certificates A2 Certificates 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 E140324 PHOENIX CONTACT GMBH & CO KG FLACHSMARKTSTRASSE 8 32825 BLOMBERG, GERMANY Controllers Types IL, PB, 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-..P120UC, followed by alpha numeric characters; Types PSR-SCP24UC/ESL4/3X1/1X2/B and PSRSPP24UC/ESL4/3X1/1X2/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 UL Listed and Classified Products Notice of Disclaimer UL Recognized Components Questions? Previous Page Products Certified 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 nonmisleading 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 addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2005 Underwriters Laboratories Inc.®" 102597_01_en PHOENIX CONTACT A-3 UM EN SAFETY RELAY APPLICATION A 2.1 A-4 PHOENIX CONTACT PSR-ESA4 102597_01_en Approvals and Certificates A 2.2 102597_01_en PSR-ESM4 PHOENIX CONTACT A-5 UM EN SAFETY RELAY APPLICATION A-6 PHOENIX CONTACT 102597_01_en Approvals and Certificates A 2.3 102597_01_en PSR-ESAM4 PHOENIX CONTACT A-7 UM EN SAFETY RELAY APPLICATION A-8 PHOENIX CONTACT 102597_01_en Approvals and Certificates A 2.4 102597_01_en PSR-THC PHOENIX CONTACT A-9 UM EN SAFETY RELAY APPLICATION A 2.5 A-10 PHOENIX CONTACT PSR-ESP 102597_01_en Approvals and Certificates A 2.6 102597_01_en PSR-ESD PHOENIX CONTACT A-11 UM EN SAFETY RELAY APPLICATION A-12 PHOENIX CONTACT 102597_01_en Ordering Data B Ordering Data PSR safety relays are available in two connection versions: – With screw connection (PSR-SC...-...) – With spring-cage connection (PSR-SP...-...) PSR-ES...4 Description Activation Type Order No. Pcs./Pck. Manual* PSR-SCP- 24UC/ESM4/2X1/1X2 PSR-SPP- 24UC/ESM4/2X1/1X2 2963718 2963705 1 1 PSR-SCP- 24UC/ESA4/2X1/1X2 PSR-SPP- 24UC/ESA4/2X1/1X2 2963750 2963938 1 1 PSR-SCP- 24UC/ESM4/3X1/1X2/B PSR-SPP- 24UC/ESM4/3X1/1X2/B 2963776 2963925 1 1 3 enabling current paths, with cross-circuit detection Manual and automatic PSR-SCP- 24UC/ESA4/3X1/1X2/B PSR-SPP- 24UC/ESA4/3X1/1X2/B 2963763 2963941 1 1 Emergency stop and safety door monitoring, Manual and automatic PSR-SCP- 24UC/ESA2/4X1/1X2/B PSR-SPP- 24UC/ESA2/4X1/1X2/B 2963802 2963954 1 1 Manual and automatic PSR-SCP- 24DC/ESP4/2X1/1X2 PSR-SPP- 24DC/ESP4/2X1/1X2 2981020 2981017 1 1 Emergency stop and safety door monitoring, 24 V AC/DC, single and two-channel, 2 enabling current paths, with cross-circuit detection Manual and automatic Emergency stop and safety door monitoring, 24 V AC/DC, single and two-channel, 24 V AC/DC, single-channel, 4 enabling current paths Process technology, emergency stop and safety door monitoring, Manual* 24 V DC, single-channel, 2 enabling current paths PSR-ESAM4 Description Activation Type Order No. Pcs./Pck. Emergency stop and safety door monitoring, 24 V AC/DC, single and two-channel, 8 enabling current paths, with/without cross-circuit detection Manual* and automatic PSR-SCP- 24UC/ESAM4/8X1/1X2 PSR-SPP- 24UC/ESAM4/8X1/1X2 2963912 2963996 1 1 Emergency stop and safety door monitoring, 24 V AC/DC ... 230 V AC/DC, single and two-channel, 3 enabling current paths, with/without cross-circuit detection Manual* and automatic PSR-SCP- 24-230UC/ESAM4/3X1/1X2 PSR-SPP- 24-230UC/ESAM4/3X1/1X2 2981114 2981127 1 1 Activation Type Order No. Pcs./Pck. Automatic PSR-SCP- 24UC/THC4/2X1/1X2 PSR-SPP- 24UC/THC4/2X1/1X2 2963721 2963983 Activation Type Order No. Pcs./Pck. Manual* and automatic PSR-SCP- 24UC/ESL4/3X1/1X2/B PSR-SPP- 24UC/ESL4/3X1/1X2/B 2981059 2981062 PSR-THC Description Two-hand controls and safety door monitoring, synchronous activation monitoring < 0.5 s, 24 V AC/DC, two-channel, 2 enabling current paths, 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 1 1 1 1 With start button monitoring PHOENIX CONTACT B-1 UM EN SAFETY RELAY APPLICATION PSR-ESD Description Type Order No. Pcs./Pck. Emergency stop and safety door monitoring, Manual* and with delayed and undelayed contacts, automatic 24 V DC, single and two-channel, adjustable from 200 ms to 300 s, with/without cross-circuit detection PSR-SCP- 24DC/ESD/5X1/1X2/300 PSR-SPP- 24DC/ESD/5X1/1X2/300 2981428 2981431 1 1 Manual* and automatic PSR-SCP- 24DC/ESD/5X1/1X2/T... PSR-SPP- 24DC/ESD/5X1/1X2/T... See table See table 1 1 Emergency stop and safety door monitoring, with delayed and undelayed contacts, 24 V DC, single and two-channel, with/without cross-circuit detection, with fixed times 0.5 s; 1 s ... 30 s (see table) Activation * PSR-RSM Description Speed and downtime monitoring, 24 V DC, two-channel, automatic control via cable adapter or two initiators PSR-ESD-T Order Versions Type Screw Connection Order No. Delay Time PSR-SCP- 24DC/ESD/5X1/1X2/0T5 2981101 0.5 s PSR-SCP- 24DC/ESD/5X1/1X2/T1 2981143 1s PSR-SCP- 24DC/ESD/5X1/1X2/1T5 2981169 1.5 s PSR-SCP- 24DC/ESD/5X1/1X2/T2 2981125 2s PSR-SCP- 24DC/ESD/5X1/1X2/2T5 2981208 2.5 s PSR-SCP- 24DC/ESD/5X1/1X2/T3 2981224 3s PSR-SCP- 24DC/ESD/5X1/1X2/T4 2981240 4s PSR-SCP- 24DC/ESD/5X1/1X2/T5 2981266 5s PSR-SCP- 24DC/ESD/5X1/1X2/T6 2981282 6s PSR-SCP- 24DC/ESD/5X1/1X2/T10 2981088 10 s PSR-SCP- 24DC/ESD/5X1/1X2/T15 2981305 15 s PSR-SCP- 24DC/ESD/5X1/1X2/T20 2981321 20 s PSR-SCP- 24DC/ESD/5X1/1X2/T30 2981347 30 s Type Spring-Cage Connection Order No. Delay Time PSR-SPP- 24DC/ESD/5X1/1X2/0T5 2981130 0.5 s PSR-SPP- 24DC/ESD/5X1/1X2/T1 2981156 1s PSR-SPP- 24DC/ESD/5X1/1X2/1T5 2981172 1.5 s PSR-SPP- 24DC/ESD/5X1/1X2/T2 2981198 2s PSR-SPP- 24DC/ESD/5X1/1X2/2T5 2981211 2.5 s PSR-SPP- 24DC/ESD/5X1/1X2/T3 2981237 3s PSR-SPP- 24DC/ESD/5X1/1X2/T4 2981253 4s PSR-SPP- 24DC/ESD/5X1/1X2/T5 2981279 5s PSR-SPP- 24DC/ESD/5X1/1X2/T6 2981295 6s PSR-SPP- 24DC/ESD/5X1/1X2/T10 2981091 10 s PSR-SPP- 24DC/ESD/5X1/1X2/T15 2981318 15 s PSR-SPP- 24DC/ESD/5X1/1X2/T20 2981334 20 s PSR-SPP- 24DC/ESD/5X1/1X2/T30 2981350 30 s Activation Type Order No. Pcs./Pck. Manual* and automatic PSR-SCP- 24DC/RSM4/4X1 PSR-SPP- 24DC/RSM4/4X1 29 81 53 8 29 81 54 1 * B-2 PHOENIX CONTACT With start button monitoring 1 1 With start button monitoring 102597_01_en Ordering Data PSR-SSM Description Downtime monitoring, 24 V DC, two-channel, automatic control via two standard initiators Activation Type Order No. Pcs./Pck. Manual* and automatic PSR-SCP- 24DC/SSM/2X1 PSR-SPP- 24DC/SSM/2X1 29 81 56 7 29 81 57 0 * PSR-SDC Description Light grid, emergency stop, and safety door monitoring, 24 V DC, single and two-channel, with/without cross-circuit detection, with interface for DIN rail connector 1 1 With start button monitoring Activation Type Order No. Pcs./Pck. Manual* and automatic PSR-SCP- 24UC/SDC4/2X1/B PSR-SPP- 24UC/SDC4/2X1/B 2981486 2981499 * 1 1 With start button monitoring PSR-URD Description Extension module with off-delay contacts, with single-channel control, 24 V DC, with interface for DIN rail connector PSR-URM Description Type Order No. Pcs./Pck. PSR-SCP- 24DC/URD3/4X1/2X2 PSR-SPP- 24DC/URD3/4X1/2X2 2981512 2981525 1 1 Type Order No. Pcs./Pck. Extension module, with single-channel control, 24 V DC, with interface for DIN rail connector PSR-SCP- 24DC/URM4/4X1/2X2/B PSR-SPP- 24DC/URM4/4X1/2X2/B 2981677 2981680 1 1 Extension module, with single or two-channel control, 24 V AC/DC PSR-SCP- 24UC/URM4/5X1/2X2 PSR-SPP- 24UC/URM4/5X1/2X2 2963734 2964005 1 1 Extension module, with single-channel control, 24 V AC/DC PSR-SCP- 24UC/URM4/5X1/2X2/B PSR-SPP- 24UC/URM4/5X1/2X2/B 2981033 2981046 1 1 24 V AC/DC PSR-SCP- 24UC/URM/5X1/2X2 PSR-SPP- 24UC/URM/5X1/2X2 2963747 2963970 1 1 120 V AC/DC PSR-SCP-120UC/URM/5X1/2X2 PSR-SPP-120UC/URM/5X1/2X2 2981402 2981415 1 1 24 V AC/DC PSR-SCF- 24UC/URM/2X21 2981363 1 120 V AC/DC PSR-SCF-120UC/URM/2X21 2981376 1 24 V AC/DC PSR-SCF- 24UC/URM/4X1/2X2 PSR-SPF- 24UC/URM/4X1/2X2 2981444 2981457 1 1 120 V AC/DC PSR-SCF-120UC/URM/4X1/2X2 PSR-SPF-120UC/URM/4X1/2X2 2981460 2981473 1 1 Universal safety relay, with positively driven contacts, Universal safety relay, with positively driven contacts Universal safety relay, with positively driven contacts Accessories Description Type Order No. Pcs./Pck. DIN rail connector, yellow, for PSR applications PSR-TBUS 2890425 50 Terminating connector PSR-TBUS-TP 2981716 50 Documentation Description Type Order No. Pcs./Pck. "Introduction to Safety Technology" user manual SAFETY INTRO UM E 2699202 1 Safety technology basics INF EN DE PSR/IL SAFE 5148802 1 Overview of the Phoenix Contact safety relay range FLY EN DE SAFETY RELAY 5106873 1 102597_01_en PHOENIX CONTACT B-3 UM EN SAFETY RELAY APPLICATION B-4 PHOENIX CONTACT 102597_01_en List of Figures C Appendices C1 List of Figures Section 1 Figure 1-1: Cable lengths .................................................................................... 1-2 Figure 1-2: Cross-circuit detection in the event of single faults ........................... 1-4 Figure 1-3: Cross-circuit detection in the event of several faults ......................... 1-4 Figure 1-4: Structure of a two-hand control ......................................................... 1-7 Figure 1-5: Emergency stop .............................................................................. 1-10 Figure 2-1: Notifiable accidents at work since 1950 ............................................ 2-1 Figure 2-2: Activity performed by the injured party at the time of the accident .... 2-3 Figure 2-3: Incorrect operation of the machine .................................................... 2-3 Figure 2-4: Cause of accident: Technical defect ................................................. 2-4 Figure 2-5: Safety equipment .............................................................................. 2-6 Figure 2-6: Strategy diagram ............................................................................... 2-7 Figure 2-7: European Economic Area (EEA) ....................................................... 2-8 Figure 2-8: Relationship between OSHA and consensus standards .................2-14 Figure 2-9: Functional safety of electrical/electronic/programmable electronic safety-related systems (E/E/PES) ...................................2-19 Figure 2-10: Structure of EN 61508 .....................................................................2-19 Figure 2-11: Relationship between risk graph according to EN 954-1 and IEC 61508 .......................................................................................2-21 Figure 2-12: Selection of category B, 1, 2, 3, and 4 for safety-related parts of control systems ...............................................................................2-22 Figure 2-13: Safety category 1 ............................................................................2-24 Figure 2-14: Safety category 2 ............................................................................2-25 Figure 2-15: Safety category 3 ............................................................................2-26 Figure 2-16: Safety category 4 ............................................................................2-27 Figure 3-1: PSR-ESA4: Application example 1 ................................................... 3-1 Figure 3-2: PSR-ESA4: Application example 2 ................................................... 3-3 Section 2 Section 3 102597_01_en PHOENIX CONTACT C-1 UM EN SAFETY RELAY APPLICATION C-2 PHOENIX CONTACT Figure 3-3: PSR-ESA4: Application example 3 ................................................... 3-4 Figure 3-4: PSR-ESM4: Application example 1 ................................................... 3-5 Figure 3-5: PSR-ESM4: Application example 2 ................................................... 3-7 Figure 3-6: PSR-ESM4: Application example 3 ................................................... 3-8 Figure 3-7: PSR-ESMA4: Application example 1 ................................................ 3-9 Figure 3-8: PSR-ESMA4: Application example 2 ..............................................3-11 Figure 3-9: PSR-ESMA4: Application example 3 ..............................................3-12 Figure 3-10: PSR-ESMA4/3X1: Application example 1 ....................................... 3-13 Figure 3-11: PSR-ESMA4/3X1: Application example 2 ....................................... 3-15 Figure 3-12: PSR-ESMA4/3X1: Application example 3 ....................................... 3-16 Figure 3-13: PSR-THC4: Application example 1 .................................................3-17 Figure 3-14: PSR-THC4: Application example 2 .................................................3-18 Figure 3-15: PSR-THC4: Application example 3 .................................................3-19 Figure 3-16: PSR-ESL4: Application example 1 .................................................. 3-20 Figure 3-17: PSR-ESL4: Application example 2 .................................................. 3-22 Figure 3-18: PSR-ESL4: Application example 3 .................................................. 3-23 Figure 3-19: PSR-ESL4: Application example 4 .................................................. 3-24 Figure 3-20: PSR-ESP4: Application example 1 .................................................3-25 Figure 3-21: PSR-ESP4: Application example 2 .................................................3-26 Figure 3-22: PSR-ESP4: Application example 3 .................................................3-27 Figure 3-23: PSR-ESD: Application example 1 ...................................................3-28 Figure 3-24: PSR-ESD: Application example 2 ...................................................3-30 Figure 3-25: PSR-ESD: Application example 3 ...................................................3-31 Figure 3-26: PSR-RSM: Application example 1 (most basic machine) ...............3-32 Figure 3-27: PSR-RSM: Application example 2 (basic machine with a monitored drive) .............................................................................. 3-33 Figure 3-28: PSR-RSM: Application example 3 (machine tool with several drives and differentiated operating modes) ........................3-34 Figure 3-29: PSR-RSM: Application example 4 (speed monitoring using 2-wire proximity switches) ...............................................................3-35 Figure 3-30: PSR-SSM: Application example 5 (basic machine with monitored drive and additional drive shaft monitoring) ....................3-36 Figure 3-31: PSR-SSM: Application example 1 (downtime monitoring using PNP or 2-wire proximity switches) .........................................3-37 Figure 3-32: PSR-SDC4: Application example 1 .................................................3-38 Figure 3-33: PSR-SDC4: Application example 2 .................................................3-39 Figure 3-34: PSR-SDC4: Application example 3 .................................................3-40 Figure 3-35: PSR-SDC4: Application example 4 .................................................3-41 Figure 3-36: PSR-SDC4: Application example 5 .................................................3-42 102597_01_en List of Figures 102597_01_en Figure 3-37: PSR-SDC4 and PSR-URM4/4X1 extension module: Application example 6 .....................................................................3-43 Figure 3-38: Wiring via T-BUS DIN rail connector ...............................................3-43 Figure 3-39: PSR-SDC4 and PSR-URD3 extension module: Application example 7 .....................................................................3-44 Figure 3-40: Wiring via T-BUS DIN rail connector ...............................................3-44 Figure 3-41: PSR-ES...4: Application example 1 .................................................3-45 Figure 3-42: PSR-ESA2: Application example 2 .................................................3-46 Figure 3-43: PSR-ES...4 and PSR-URM4 extension modules: Application example 3 .....................................................................3-47 Figure 3-44: PSR-ESAM4, PSR-ESA4: Application example 1 ...........................3-49 PHOENIX CONTACT C-3 UM EN SAFETY RELAY APPLICATION C-4 PHOENIX CONTACT 102597_01_en List of Tables C2 List of Tables Section 1 Table 1-1: Requirements according to EN 574 ................................................... 1-6 Table 2-1: Typical examples of standards........................................................... 2-9 Table 2-2: Interesting links on the Internet ........................................................ 2-11 Table 2-3: OSHA machinery and machine guarding standards ........................2-15 Table 2-4: ANSI B11 standards.........................................................................2-16 Table 2-5: Definitions and abbreviations ...........................................................2-20 Section 2 102597_01_en PHOENIX CONTACT C-5 UM EN SAFETY RELAY APPLICATION C-6 PHOENIX CONTACT 102597_01_en Revision History D Revision History Version Date 01 05/2006 102597_01_en Contents First publication of the application manual in English. PHOENIX CONTACT D-1 UM EN SAFETY RELAY APPLICATION D-2 PHOENIX CONTACT 102597_01_en
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