User Manual UM EN SAFETY RELAY APPLICATION Handbook

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Order No.:
INTERFACE
Application Manual
for PSR Safety Relays
2888712
User Manual
UM EN SAFETY RELAY APPLICATION
Designation:
Revision:
Order No.:
This user manual is valid for:
05/2006
INTERFACE
102597_01_en PHOENIX CONTACT
Application Manual for PSR Safety Relays
UM EN SAFETY RELAY APPLICATION
01
2888712
All PSR safety relays from Phoenix Contact
User Manual
UM EN SAFETY RELAY APPLICATION
PHOENIX CONTACT 102597_01_en
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 +49 - 52 35 - 30 0
Fax +49 - 52 35 - 34 20 21
E-mail tecdoc@phoenixcontact.com
UM EN SAFETY RELAY APPLICATION
102597_01_en PHOENIX CONTACT
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.
UM EN SAFETY RELAY APPLICATION
PHOENIX CONTACT 102597_01_en
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
102597_01_en PHOENIX CONTACT i
Table of Contents
1 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
2 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
3 Wiring Examples......................................................................................................................3-1
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
UM EN SAFETY RELAY APPLICATION
ii PHOENIX CONTACT 102597_01_en
3.4.2 PSR-THC4: Application Example 2 ..................................................3-18
3.4.3 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
Table of Contents
102597_01_en PHOENIX CONTACT iii
A Approvals and Certificates...................................................................................................... A-1
A 1 Approvals ......................................................................................................... A-1
A 2 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
C 1 List of Figures................................................................................................... C-1
C 2 List of Tables.................................................................................................... C-5
D Revision History...................................................................................................................... D-1
UM EN SAFETY RELAY APPLICATION
iv PHOENIX CONTACT 102597_01_en
Introduction
102597_01_en PHOENIX CONTACT 1-1
1Introduction
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.
UM EN SAFETY RELAY APPLICATION
1-2 PHOENIX CONTACT 102597_01_en
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.
Figure 1-1 Cable lengths
Make sure that the specified cable lengths are not exceeded, so as to ensure error-free
operation of the safety requirement.
0V
PSR-ESA4
A1
23
14
13 23 31
13 31
14 24 32
24 32
S11 S12 S21 S22
A2
-K2
S33 S34
+24 V DC/AC
102597A036
EMERGENCY
STOP
PSR-ESA4
Power
K1
K2
31 13 14
32 23 24
A1 S34 S33 S11
S12 S21 S22 A2
S35
R1R2
11 21
12 22
Introduction
102597_01_en PHOENIX CONTACT 1-3
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:
This refers to the forward and return line for both channels (S11-S12 and S21-S22).
lPermissible cable length
RLCable resistance
A Cable cross section
κ(= Kappa) conductivity
Cu Copper
The cable length for S33-S34 must be taken into consideration here, since the
application operates with automatic start.
UM EN SAFETY RELAY APPLICATION
1-4 PHOENIX CONTACT 102597_01_en
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.
Figure 1-2 Cross-circuit detection in the event of single faults
This type of single fault (cross circuit a) alone does not directly lead to a dangerous
situation, but cannot be tolerated in category 3 (see Figure 1-2).
Figure 1-3 Cross-circuit detection in the event of several faults
S1
1
2
K1 K2
S1
K1
K2
K1
K2
3
4
a
Positively
actuated
Closed
Movable guard
Not positively
actuated
Safety circuits
Open
S1
1
2
K1 K2
S1
K1
K2
K1
K2
3
4
a
b
Positively
actuated
Closed
Movable guard
Not positively
actuated
Safety circuits
Open
Introduction
102597_01_en PHOENIX CONTACT 1-5
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
UM EN SAFETY RELAY APPLICATION
1-6 PHOENIX CONTACT 102597_01_en
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
ABC
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 XX
Safety category 3 application, EN 954-1 XX
Safety category 4 application, EN 954-1 X
Introduction
102597_01_en PHOENIX CONTACT 1-7
Figure 1-4 Structure of a two-hand control
1st hand
2nd hand
Triggering of
1st input signal
Triggering of
2nd input signal
End of
input signals
Synchronous
actuation
Synchronous actuation
Time period for
simultaneous actuation
t 0.5 s£
Input command
Control device
Manual control
e.g., emergency stop button
PSR-THC
102597A032
Time
UM EN SAFETY RELAY APPLICATION
1-8 PHOENIX CONTACT 102597_01_en
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.
Introduction
102597_01_en PHOENIX CONTACT 1-9
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:
M
K1
S2
S1
STOP
M
K1
K2
S2
S1
STOP
Brake
M
S2
S1
STOP
Brake
Not permitted for
emergency stop
purposes
Category 0 Stop
Stopping by immediate removal of
power to the machine drives (i.e., an
uncontrolled stop).
Category 1 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.
Category 2 Stop
A controlled stop with power left
available to the machine drives.
UM EN SAFETY RELAY APPLICATION
1-10 PHOENIX CONTACT 102597_01_en
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).
Figure 1-5 Emergency 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.
102597A048
Shutdown with
emergency stop Stop with emergency stop
Electric shock Movement
Risk of
Introduction
102597_01_en PHOENIX CONTACT 1-11
1.2.7 Safe Isolation
Depending on the version, the modules have safe isolation between the input and output,
and between the contacts. Applications with 230 V low voltage can be connected reliably
and safely.
Isolation Between Input and Output
PSR modules provide safe isolation, reinforced insulation, and 6 kV between the input
circuit and the enabling current paths. In EN 50178, safe isolation is required if SELV and
PELV are switched together or led directly next to one another in a device. Due to the
internal structure and the insulation properties between the input and the contacts in
Phoenix Contact PSR modules, 230 V AC, for example, can be switched without any
limitations. Depending on the type, the output contacts (13-14, 23-24, etc.) are isolated
from one another using basic insulation or reinforced insulation.
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 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.
I
O
IEC 61 508
SIL
UM EN SAFETY RELAY APPLICATION
1-12 PHOENIX CONTACT 102597_01_en
1.2.9 Speed and Downtime Monitoring
Monitoring modules for detecting downtimes and speeds in setup mode and in special
operating modes with safety doors open on machines and systems.
Advantages:
– 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
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
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.
n = 0 n
Safety Technology
102597_01_en PHOENIX CONTACT 2-1
2 Safety Technology
2.1 Accidents at Work
Accident 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.
Figure 2-1 Notifiable accidents at work since 1950
The number of accidents at work has fallen to a record low. Even travel accidents and
occupational diseases have decreased considerably in recent years, as reported by the
Hauptverband der gewerblichen Berufsgenossenschaften (HVBG, German Federation of
Institutions for Statutory Accident Insurance and Prevention) in Berlin, Germany. This
decrease is due to the success of preventive measures. However, the rate of contribution
rose slightly due to economic development and fewer people being employed.
In 2003, 10.5% fewer cases of accidents at work were recorded than in the previous year.
In addition, the risk of injury in the workplace also decreased considerably; the accident
rate fell by 4%. The number of fatal injuries fell by 4.9% compared to the previous year.
45,000
40,000
30,000
25,000
20,000
15,000
10,000
5000
0
35,000
1950
1955
1960
1965
1970
1975
1980
1985
1990
1995
2000
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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.
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Figure 2-2 Activity performed by the injured party at the time of the accident
Figure 2-3 Incorrect operation of the machine
Machining process
39%
Tool change/
setup work
19%
Troubleshooting
22%
Maintenance work
11%
Repairs/conversion
3%
No in
f
ormation
3% Other
3%
Yes
75%
No
11%
No information
14%
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Figure 2-4 Cause of accident: Technical defect
Causes of Accidents at Work
There are often various causes for accidents at work. For example, the bypassing or
manipulation of safety equipment can result from the following:
– Unsuitable safety equipment, which leads to manipulation or bypassing, e.g., due to:
– 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))
Technical defect
39%
Other cause
43%
No information
18%
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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)
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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
Safety equipment
The danger zone The source of danger
Guard Localized
safety
equipment
Deterring/
impeding
device
Trip device
Trapping
safety
equipment
Two-hand
control
devices
Finger
barrier
Hand
barrier
Operator
barrier
Optical data
links
Light
curtains
Switch plates
Switch mats
Switch cords
Control strips
Access
button
Enclosing guard
Cover
Fencing off
Guards
For safeguarding
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– Provision of diverse redundancy in control systems to ensure single-fault tolerance as
a minimum
Figure 2-6 Strategy diagram
Defining the limits of
the machine or system
(physical and in terms
of time)
Hazard analysis
Can the hazard
be avoided?
Protection objective
achieved
Identifying and evaluating
the hazards
(with suitable checklist, if
necessary)
Is the use
of safety equipment
possible?
New
hazards
detected?
Risk reduction
by design
Use of
safety equipment
Information for use
(Special notes in the operating
instructions or on plates)
Has the risk been
reduced?
Is safety ensured?
No
No
Yes
Yes
No
Yes
No
Is safety ensured?
Is safety ensured?
Yes
Yes
No
No
Yes
No
Yes
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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.
Figure 2-7 European Economic Area (EEA)
102597A033
DPL
N
SSF
F
E
TR
GR
IRL GB
I
P
DK
EST
LV
LT
BG
RO
H
SK
CZ
A
CH
NL
B
AL
BiH
LUX
SLO
MK
HR
SCG
CY
National legislation
National legislation
National legislation
National legislation
EC directive EU member states
EU candidate countries
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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 Typical Examples
Type A Basic safety
standards
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
Type B1 EN 294 (1992-06) Safety distances
EN 349 (1993-04) Minimum distances
Type B2 Group safety
standards
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)
EN 60204-11 (2000-11) Electrical equipment of machines
EN 61496-1 (2004-05) Electrosensitive protective equipment
EN 61508 (2001-12) Functional safety management
Type C Product safety
standards
EN 201 (1997-02) Injection molding machines
EN 692 (1996-06) Mechanical presses
EN 693 (2001-01) Hydraulic presses
EN 775 (1992-10) Industrial robots
This table contains only a few examples and is not complete.
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2.3.1 Useful Addresses for Information About Standards and
Regulations
Sources of Reference for
Technical Regulations in
Germany For everything about standards, regulations, and directives
DIN Deutsches Institut für Normung e. V. (German Institute for Standardization)
10772 Berlin, Germany
EC directives, laws, and decrees
Bundesanzeiger Verlagsgesellschaft mbH (Federal Official Gazette)
Amsterdamer Straße 192
50735 Cologne, Germany
DIN standards, ISO standards, VDI directives
Beuth Verlag GmbH
Burggrafenstraße 6
10787 Berlin, Germany
VDE regulations, IEC standards
VDE-Verlag GmbH
Bismarckstr. 33
10625 Berlin, Germany
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: +49 - 30 - 26 01 0
Fax: +49 - 30 - 26 01 12 60
Website: http://www2.din.de
Phone: +49 - 221 - 97 66 80
Fax: +49 - 221 - 97 66 82 88
Website: http://www.bundesanzeiger.de
Phone: +49 - 30 - 26 01 0
Fax: +49 - 30 - 26 01 12 60
Website: http://www2.beuth.de
Phone: +49 - 30 - 34 80 01 0
Fax: +49 - 30 - 34 17 09 3
Website: http://www.vde-verlag.de
Phone: +49 - 221 - 94 37 30
Fax: +49 - 221 - 94 37 39 01
Website: http://www.heymanns.com
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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)
Overview of the latest applicable standards and regulations
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
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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."
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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
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
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.
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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
Figure 2-8 Relationship between OSHA and consensus standards
Occupational
Safety and Health
Administration
(OSHA)
ANSI
Other
NFPA RIA
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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.
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.
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.
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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 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
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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.
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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
– 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.
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Application of EN 61508
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
Figure 2-10 Structure of EN 61508
The general safety-related requirements and tests for plants and systems are defined in
Part 1.
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Sensor E/E/PES Actuator
35% 15% 50%
102597A035
Part 1
(normative)
Part 2
(normative)
Part 3
(normative)
Part 1
(normative)
Part 5
(informative)
Part 6
(informative)
Part 4
(normative)
Part 7
(informative)
– Risk analysis
– Assignment of measures for risk reduction
– Specification of safety functions for E/E/PES
Implementation of E/E/PES
Hardware
requirements for
systems and
subsystems
Software
requirements
– Installation, startup
– Operation and maintenance
– Decommissioning
Methods for
determining the
required system
Guidelines for
Part 2 and Part 3
Definitions
Description of
measures and
technology
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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
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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.
Figure 2-11 Relationship between risk graph according to EN 954-1 and IEC 61508
MTTFd Mean Time To Failure dangerous - time available to perform a safety function
on demand.
CCF Common Cause Failure Management - also known as 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.
Performance level
for each
safety function
Low risk Category
(EN 954-1)
SIL
(IEC 61508)
High risk
No special
safety
requirements
UM EN SAFETY RELAY APPLICATION
2-22 PHOENIX CONTACT 102597_01_en
2.3.5 Safety Categories According to DIN EN 954-1
2.3.5.1 Risk Graph According to DIN EN 954-1
The risk graph is only a selection tool for determining the safety category in cases where
there have so far been no relevant C standards or where the standards do not list any
safety category for the application in question.
Figure 2-12 Selection of category B, 1, 2, 3, and 4 for safety-related parts of control
systems
S Severity of injury
S1 Slight (normally reversible)
injury
S2 Serious (normally irreversible)
injury
Preferred categories for reference
points
F Frequency and/or exposure time
to the hazard
F1 Seldom to quite often and/or
the exposure time is short
F2 Frequent to continuous and/or
the exposure time is long
Possible categories which can
require additional measures
P Possibility of avoiding the
hazard
P1 Possibility under specific
conditions
P2 Scarcely possible
Measures which can be over
dimensioned for the relevant risk
B1234
S1
S2
F1
F2
P1
P2
P1
P2
Safety Technology
102597_01_en PHOENIX CONTACT 2-23
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)
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
The occurrence of a fault can lead to the loss of the safety functions.
Note:
For parts that meet safety category B, no special safety measures are used.
UM EN SAFETY RELAY APPLICATION
2-24 PHOENIX CONTACT 102597_01_en
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.
Figure 2-13 Safety category 1
S1
1
2
K1
K1
Positively
actuated
Open
Closed
Movable guard
Safety Technology
102597_01_en PHOENIX CONTACT 2-25
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.
Figure 2-14 Safety category 2
Function of the circuit
for 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.
S1
1
2
F02
3
4
K1 K2 AW
K2
K1 K01
K3
K1
5
6
H1
F02
Π
K3
S2
S02
S01
K1
K2
K01
K01
V1
M
3~
F01
K01
=Safety circuit
AW = Disconnect wiping relay
Warning
OFF
ON
Danger
Positively
actuated
Open
Closed
Movable guard
Dangerous
drive
OFF
UM EN SAFETY RELAY APPLICATION
2-26 PHOENIX CONTACT 102597_01_en
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.
Figure 2-15 Safety category 3
S1
1
2
K1 K2
S1
3
4
K1
K2
K1
K2
Safety circuits
Control signals at PLC input via
optocoupler
Positively
actuated
Not positively
actuated
Open
Closed
Movable guard
Safety Technology
102597_01_en PHOENIX CONTACT 2-27
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.
Figure 2-16 Safety category 4
S1
1
2
K1 K3
S2
3
4
K2 K3
K1K1K3
5
S3
K2K3
K2
K1
K2
K1
K2
K3 K3
Positively
actuated
Not positively
actuated
START
Safety circuits
Open
Closed
Movable guard
UM EN SAFETY RELAY APPLICATION
2-28 PHOENIX CONTACT 102597_01_en
Wiring Examples
102597_01_en PHOENIX CONTACT 3-1
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
Figure 3-1 PSR-ESA4: Application example 1
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
0V
EMERGENCY
STOP
PSR-ESA4 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K1
102597A001
Reset
Fault 3
Fault 1 Fault 2
11 21
12 22
3
4
2
1
S33 S34
PSR-ESA4
Power
K1
K2
31 13 14
32 23 24
A1 S34 S33 S11
S12 S21 S22 A2
Fault 5
UM EN SAFETY RELAY APPLICATION
3-2 PHOENIX CONTACT 102597_01_en
Fault Monitoring
–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
Wiring Examples
102597_01_en PHOENIX CONTACT 3-3
3.1.2 PSR-ESA4: Application Example 2
Figure 3-2 PSR-ESA4: Application example 2
PSR-ESA4 Application Features
Emergency stop monitoring Two-channel (S11-S12, S21-S22)
Up to safety category 4, EN 954-1 2 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
0V
PSR-ESA4
A1
23
14
13 23 31
13 31
14 24 32
24 32
S11 S12 S21 S22
A2
-K2
S33 S34
+24 V DC/AC
102597A002
EMERGENCY
STOP
PSR-ESA4
Power
K1
K2
31 13 14
32 23 24
A1 S34 S33 S11
S12 S21 S22 A2
UM EN SAFETY RELAY APPLICATION
3-4 PHOENIX CONTACT 102597_01_en
3.1.3 PSR-ESA4: Application Example 3
Figure 3-3 PSR-ESA4: Application example 3
PSR-ESA4 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
0V
PSR-ESA4
A1
23
14
13 23 31
13 31
14 24 32
24 32
S11 S12 S21 S22
A2
-K2
S33 S34
+24 V DC/AC
102597A003
EMERGENCY
STOP
Reset
PSR-ESA4
Power
K1
K2
31 13 14
32 23 24
A1 S34 S33 S11
S12 S21 S22 A2
Wiring Examples
102597_01_en PHOENIX CONTACT 3-5
3.2 PSR-ESM4: Emergency Stop Applications With
Start Button Monitoring
3.2.1 PSR-ESM4: Application Example 1 With Fault Monitoring
Figure 3-4 PSR-ESM4: Application example 1
PSR-ESM4 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
+24 V DC/AC
0V
EMERGENCY
STOP
PSR-ESM4 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K2
102597A004
Reset
Fault 1
Fault 2
S33 S34
41
41
42
42
PSR-ESM4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S11
S12 S21 S22 A2
UM EN SAFETY RELAY APPLICATION
3-6 PHOENIX CONTACT 102597_01_en
Fault Monitoring
–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
Wiring Examples
102597_01_en PHOENIX CONTACT 3-7
3.2.2 PSR-ESM4: Application Example 2
Figure 3-5 PSR-ESM4: Application example 2
PSR-ESM4 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
+24 V DC/AC
0V
EMERGENCY
STOP
PSR-ESM4 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K1
102597A005
Reset
S33 S34
41
41
42
42
PSR-ESM4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S11
S12 S21 S22 A2
UM EN SAFETY RELAY APPLICATION
3-8 PHOENIX CONTACT 102597_01_en
3.2.3 PSR-ESM4: Application Example 3
Figure 3-6 PSR-ESM4: Application example 3
PSR-ESM4 Application Features
Emergency stop monitoring Two-channel (S11-S12, S21-S22)
Up to safety category 4, EN 954-1 3 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
+24 V DC/AC
0V
EMERGENCY
STOP
PSR-ESM4 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K1
102597A006
Reset
S33 S34
41
41
42
42
L
K2
K1
N
K1 ext
K2 ext
PSR-ESM4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S11
S12 S21 S22 A2
Wiring Examples
102597_01_en PHOENIX CONTACT 3-9
3.3 PSR-ESAM4: Emergency Stop Applications With
Start Button Monitoring
3.3.1 PSR-ESAM4: Application Example 1 With Fault Monitoring
Figure 3-7 PSR-ESMA4: Application example 1
PSR-ESAM4 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
0V
EMERGENCY
STOP
PSR-ESAM4 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K1
102597A007
Reset
Fault 3
Fault 1 Fault 2
11 21
12 22
S33 S34 S35
S10
53
44
43 53 63
43 63
44 54 64
54 64
83
74
73 83 91
73 91
74 84 92
84 92
Fault 4
PSR-ESAM4
Power
K1
K2
13 14 23 24
83 63 64
84 73 74
S12 S34 S33 S35
S10 S11 S11 S12
91 33 43 53
92 34
A1 S21 S22 A2
44 54
3
4
2
1
Fault 5
UM EN SAFETY RELAY APPLICATION
3-10 PHOENIX CONTACT 102597_01_en
Fault Monitoring
–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
Wiring Examples
102597_01_en PHOENIX CONTACT 3-11
3.3.2 PSR-ESAM4: Application Example 2
Figure 3-8 PSR-ESMA4: Application example 2
PSR-ESAM4 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
102597A008
+24 V DC/AC
0V
EMERGENCY
STOP
A1 S11 S12 S21 S22
A2
-K2
S33 S34 S35
S10
23
13 33 53
43 63 83
73 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
PSR-ESAM4
PSR-ESAM4
Power
K1
K2
13 14 23 24
83 63 64
84 73 74
S12 S34 S33 S35
S10 S11 S11 S12
91 33 43 53
92 34
A1 S21 S22 A2
44 54
UM EN SAFETY RELAY APPLICATION
3-12 PHOENIX CONTACT 102597_01_en
3.3.3 PSR-ESAM4: Application Example 3
Figure 3-9 PSR-ESMA4: Application example 3
PSR-ESAM4 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
102597A009
+24 V DC/AC
0V
EMERGENCY
STOP
A1 S11 S12 S21 S22
A2
-K2
S33 S34 S35
S10
23
13 33 53
43 63 83
73 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
PSR-ESAM4
Reset
PSR-ESAM4
Power
K1
K2
13 14 23 24
83 63 64
84 73 74
S12 S34 S33 S35
S10 S11 S11 S12
91 33 43 53
92 34
A1 S21 S22 A2
44 54
Wiring Examples
102597_01_en PHOENIX CONTACT 3-13
3.3.4 PSR-ESAM4/3X1: Application Example 1 With Fault
Monitoring
Figure 3-10 PSR-ESMA4/3X1: Application example 1
PSR-ESAM4/3X1 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
102597B038
PSR-ESAM4/3X1
Power
K1
K2
41 42
13 23 24
14 33 34
A1 A1
S12 S11 S11 S10
S34 S33 S35
S10 S12 S21 S22
+24...230 V DC/AC
0V
EMERGENCY
STOP
PSR-ESAM4/3X1 23
14
13 23 33
13 33
14 24 34
24 34
A1 S11 S12 S21 S22
A2
-K1
Reset
Fault 3
Fault 1 Fault 2
11 21
12 22
S33 S34 S35
S10
42
41
41
42
Fault 4
3
4
2
1
Fault 5
UM EN SAFETY RELAY APPLICATION
3-14 PHOENIX CONTACT 102597_01_en
Fault Monitoring
–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
Wiring Examples
102597_01_en PHOENIX CONTACT 3-15
3.3.5 PSR-ESAM4/3X1: Application Example 2
Figure 3-11 PSR-ESMA4/3X1: Application example 2
PSR-ESAM4/3X1 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
102597A039
PSR-ESAM4/3X1
Power
K1
K2
41 42
13 23 24
14 33 34
A1 A1
S12 S11 S11 S10
S34 S33 S35
S10 S12 S21 S22
+24...230 V DC/AC
0V
EMERGENCY
STOP
A1 S11 S12 S21 S22
A2
-K2
S33 S34 S35
S10
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
PSR-ESAM4/3X1
UM EN SAFETY RELAY APPLICATION
3-16 PHOENIX CONTACT 102597_01_en
3.3.6 PSR-ESAM4/3X1: Application Example 3
Figure 3-12 PSR-ESMA4/3X1: Application example 3
PSR-ESAM4/3X1 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
102597A040
PSR-ESAM4/3X1
Power
K1
K2
41 42
13 23 24
14 33 34
A1 A1
S12 S11 S11 S10
S34 S33 S35
S10 S12 S21 S22
+24...230 V DC/AC
0V
EMERGENCY
STOP
A1 S11 S12 S21 S22
A2
-K2
S33 S34 S35
S10
PSR-ESAM4/3X1
Reset
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
Wiring Examples
102597_01_en PHOENIX CONTACT 3-17
3.4 PSR-THC4: Two-Hand Controls
3.4.1 PSR-THC4: Application Example 1 With Fault Monitoring
Figure 3-13 PSR-THC4: Application example 1
Fault Monitoring
–Fault 1: Short circuit S11, S12, S14
Power ON
K1 OFF
K2 ON
–Fault 2: No bridge between Y1-Y2
Power ON
K1 OFF
K2 OFF
PSR-THC4 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
0V
PSR-THC4 23
14
13 23 31
13 31
14 24 32
24 32
A1 S11 S14
S22 S21
S12
S24
A2
-K1
102597A010
Y1 Y2
S1 S2
12
11
13
14 12
11
13
14
PSR-THC4
Power
K1
K2
31 13 14
32 23 24
A1 Y2 S11 S21
Y2 A2
S14
S22 S12
S24
S21 S24 S22S11 S14 S12
Fault 1 Fault 4
Fault 2
3
2
1
Fault 5
4
UM EN SAFETY RELAY APPLICATION
3-18 PHOENIX CONTACT 102597_01_en
–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: Application Example 2
Figure 3-14 PSR-THC4: Application example 2
PSR-THC4 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
0V
PSR-THC4 23
14
13 23 31
13 31
14 24 32
24 32
A1 S21 S14
S22 S12
S24
S11
A2
-K2
102597A011
Y1 Y2
PSR-THC4
Power
K1
K2
31 13 14
32 23 24
A1 Y2 S11 S21
Y2 A2
S14
S22
S12
S24
Wiring Examples
102597_01_en PHOENIX CONTACT 3-19
3.4.3 PSR-THC4: Application Example 3
Figure 3-15 PSR-THC4: Application example 3
PSR-THC4 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
0V
PSR-THC4 23
14
13 23 31
13 31
14 24 32
24 32
A1 S11 S14
S22 S21
S12
S24
A2
-K2
102597A012
Y1 Y2
S1 S2
12
11
13
14 12
11
13
14
LL
N
K1 ext
K2 ext
K1 ext
K2 ext
PSR-THC4
Power
K1
K2
31 13 14
32 23 24
A1 Y2 S11 S21
Y2 A2
S14
S22
S12
S24
S11 S14 S12 S21 S24 S22
UM EN SAFETY RELAY APPLICATION
3-20 PHOENIX CONTACT 102597_01_en
3.5 PSR-ESL4: Light Grid Applications
3.5.1 PSR-ESL4: Application Example 1 With Fault Monitoring
Figure 3-16 PSR-ESL4: Application example 1
PSR-ESL4 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
0V
A1 S22
S11 S12
A2
-K1
S33 S34
PSR-ESL4
S35
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
Reset
OSSD1 OSSD2
Light
grid
102597A013
PSR-ESL4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S35
S11 S12 S22 A2
Fault 1
1
Wiring Examples
102597_01_en PHOENIX CONTACT 3-21
Fault Monitoring
–Fault 1: Cross circuit of both light grid channels OSSD1 and OSSD2
Power ON
K1 OFF
K2 OFF
–Fault 2: Light grid channels OSSD1 and OSSD2 not connected 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
UM EN SAFETY RELAY APPLICATION
3-22 PHOENIX CONTACT 102597_01_en
3.5.2 PSR-ESL4: Application Example 2
Figure 3-17 PSR-ESL4: Application example 2
PSR-ESL4 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
+24 V DC/AC
0V
A1 S22
S11 S12
A2
-K1
S33 S34
PSR-ESL4
S35
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
Reset
102597A014
K4
K3
PSR-ESL4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S35
S11 S12 S22 A2
K4
K3
EMERGENCY
STOP
LL
Wiring Examples
102597_01_en PHOENIX CONTACT 3-23
3.5.3 PSR-ESL4: Application Example 3
Figure 3-18 PSR-ESL4: Application example 3
PSR-ESL4 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
+24 V DC/AC
0V
A1 S22
S11 S12
A2
-K1
S33 S34
PSR-ESL4
S35
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
Reset EMERGENCY
STOP
102597A015
PSR-ESL4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S35
S11 S12 S22 A2
UM EN SAFETY RELAY APPLICATION
3-24 PHOENIX CONTACT 102597_01_en
3.5.4 PSR-ESL4: Application Example 4
Figure 3-19 PSR-ESL4: Application example 4
PSR-ESL4 Application Features
Light grid monitoring Two-channel (OSSD1-S12, OSSD2-S22)
Up to safety category 4, EN 954-1 3 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
0V
A1 S22
S11 S12
A2
-K1
S33 S34
PSR-ESL4
S35
23
13 33 41
13 23 33 41
14 24 34 42
14 24 34 42
102597A016
OSSD1 OSSD2
Light
grid
K3
K4
K3
K4
PSR-ESL4
Power
K1
K2
41 33 13 14
42 34 23 24
A1 S34 S33 S35
S11 S12 S22 A2
LL
Wiring Examples
102597_01_en PHOENIX CONTACT 3-25
3.6 PSR-ESP4: Process Technology Applications
3.6.1 PSR-ESP4: Application Example 1
Figure 3-20 PSR-ESP4: Application example 1
PSR-ESP4 Application Features
Emergency stop monitoring Single-channel (in circuit A1)
Up to safety category 2, EN 954-1 2 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
+24 V DC
0V
EMERGENCY
STOP
PSR-ESP4 23
13 31
14 24 32
14
13 23 31
24 32
A1 Y1 Y2
A2
-K2
102597A017
Reset
N
K3
K4
K4
K3
PSR-ESP4
K1
K2
31 13 14
32 23 24
A1 Y1 Y2 A2
LL
UM EN SAFETY RELAY APPLICATION
3-26 PHOENIX CONTACT 102597_01_en
3.6.2 PSR-ESP4: Application Example 2 With Fault Monitoring
Figure 3-21 PSR-ESP4: Application example 2
Fault Monitoring
–Fault 1: Recovery time not reached. Remove fault through voltage reset.
Power at A1-A2
K1 ON
K2 OFF
–Fault 2: Bridge Y1-Y2 missing.
Power at A1-A2
K1 OFF
K2 OFF
PSR-ESP4 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
+24 V DC
0V
EMERGENCY
STOP
PSR-ESP4 23
13 31
14 24 32
14
13 23 31
24 32
A1 Y1 Y2
A2
-K2
102597A018
PSR-ESP4
K1
K2
31 13 14
32 23 24
A1 Y1 Y2 A2
Fault 2
Wiring Examples
102597_01_en PHOENIX CONTACT 3-27
3.6.3 PSR-ESP4: Application Example 3
Figure 3-22 PSR-ESP4: Application example 3
PSR-ESP4 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
0V
PSR-ESP4
23
13 31
14 24 32
14
13 23 31
24 32
A1 Y1 Y2
A2
-K2
102597A019
N
K3
K4
K4
K3
L
Safe PLC OUT,
e.g., S7...F
24VDC
PSR-ESP4
K1
K2
31 13 14
32 23 24
A1 Y1 Y2 A2
UM EN SAFETY RELAY APPLICATION
3-28 PHOENIX CONTACT 102597_01_en
3.7 PSR-ESD: Emergency Stop With Delayed Contacts
3.7.1 PSR-ESD: Application Example 1 With Fault Monitoring
Figure 3-23 PSR-ESD: Application example 1
PSR-ESD/300 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
102597A020
+24 V DC
0V
A1 Y2 S10 S11 S12
A2
-K1
S33 S34 S35
Y1
23
13 33 57
41 67
13 23 33 41 57 67
14 24 34 42 58 68
14 24 34 42 58 68
PSR-ESD
S21 S22
Reset
123
4
5
6AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
123
4
5
61 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
50 100 150 200 250 300
PSR-ESD
Power
K1
K2
13 23 24
14 33 34
S12 S34 S33 S35
S10 S11 S11 S12
A1 S21 S22 A2
Y1 Y2
58 68 42
K3(t)
K4(t)
57 67 41
Fault 2
Fault 3
Fault 1
12
3
4
Fault 4
EMERGENCY
STOP
Wiring Examples
102597_01_en PHOENIX CONTACT 3-29
Fault Monitoring
–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
UM EN SAFETY RELAY APPLICATION
3-30 PHOENIX CONTACT 102597_01_en
3.7.2 PSR-ESD: Application Example 2
Figure 3-24 PSR-ESD: Application example 2
PSR-ESD/300 Application Features
Emergency stop monitoring Single-channel (S11-S12, bridge S10-S12,
Y1-Y2)
Up to safety category 2, EN 954-1 3 undelayed N/O contacts, 2 delayed N/O
contacts, 1 N/O contact
Up to safety category 4 only when using
positive-opening switches and installing
cable in separate cable sheaths
US = 24 V DC
Manual activation (S33-S34)
Monitored start
Stop category 0/1
102597A021
+24 V DC
0V
EMERGENCY
STOP
A1 Y2 S10 S11 S12
A2
-K1
S33 S34 S35
Y1
23
13 33 57
41 67
13 23 33 41 57 67
14 24 34 42 58 68
14 24 34 42 58 68
PSR-ESD
S21 S22
Reset
123
4
5
6AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
123
4
5
61 2 3 4 5 6
50 100 150 200 250 300
PSR-ESD
Power
K1
K2
13 23 24
14 33 34
S12 S34 S33 S35
S10 S11 S11 S12
A1 S21 S22 A2
Y1 Y2
58 68 42
K3(t)
K4(t)
57 67 41
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
Wiring Examples
102597_01_en PHOENIX CONTACT 3-31
3.7.3 PSR-ESD: Application Example 3
Figure 3-25 PSR-ESD: Application example 3
PSR-ESD/300 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
102597A022
+24 V DC
0V
A1 Y2 S10 S11 S12
A2
-K1
S33 S34 S35
Y1
23
13 33 57
41 67
13 23 33 41 57 67
14 24 34 42 58 68
14 24 34 42 58 68
PSR-ESD
S21 S22
Reset
123
4
5
6AB
ON
OFF
Semiconductor output
GND +24 V DC
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
AB
ON
OFF
123
4
5
61 2 3 4 5 6
50 100 150 200 250 300
PSR-ESD
Power
K1
K2
13 23 24
14 33 34
S12 S34 S33 S35
S10 S11 S11 S12
A1 S21 S22 A2
Y1 Y2
58 68 42
K3(t)
K4(t)
57 67 41
OUT1 OUT2
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
UM EN SAFETY RELAY APPLICATION
3-32 PHOENIX CONTACT 102597_01_en
3.8 PSR-RSM, PSR-SSM: Speed and Downtime
Monitoring
3.8.1 PSR-RSM: Application Example 1 (Most Basic Machine)
Figure 3-26 PSR-RSM: Application example 1 (most basic machine)
SK = Safety contact
ÜK = Monitoring contact
PSR-RSM Application Features
Evaluation of a safe speed 4 N/O contacts
Encoder sensors US = 24 V DC
Connection via RJ45 Automatic activation (bridge S33-S35)
Up to safety category 3, EN 954-1 Stop category 0
SIL 3 according to EN 61508
(SIL data on request)
102597A023
+24 V DC
0V
S33 S34 13 23 33
14 24 34
PSR-ESM4
43
44
Downtime
Overspeed
PSR-RSM
S35
A1 MI I3 I2 I1
A2
+24 V
+24 V
IN1
IN2
FO MO1 MO2
RJ45
S21
S11 S12
S33 S34
2313 33 41
13 23 33 41
14 24 34 42
14 24 34 42
A1
A2
S22
EMERGENCY
STOP
Reset
K4 K3
K3
K4
K4
K3
NM
LL
ÜK
SK
Release
Servo
Wiring Examples
102597_01_en PHOENIX CONTACT 3-33
3.8.2 PSR-RSM: Application Example 2 (Basic Machine With a
Monitored Drive)
Figure 3-27 PSR-RSM: Application example 2 (basic machine with a monitored drive)
SK = Safety contact
ÜK = Monitoring contact
PSR-RSM 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)
102597A024
+24 V DC
0V
13 23 33
14 24 34
PSR-ESM4
43
44
Downtime
Overspeed
PSR-RSM
S21S11 S12
S33 S34
2313 33 41
13 23 33 41
14 24 34 42
14 24 34 42
A1
A2
S22
EMERGENCY
STOP
Reset
K4
K3
LL
MO2
S33 S34 S35
A1 MI I3 I2 I1
A2
+24 V
+24 V
IN1
IN2
FO MO1
RJ45
ÜK
Operating mode
switch
Enabling switch
K3
K4
K4
K3
NM
OM
Servo
SK
Release
UM EN SAFETY RELAY APPLICATION
3-34 PHOENIX CONTACT 102597_01_en
3.8.3 PSR-RSM: Application Example 3 (Machine Tool With
Several Drives and Differentiated Operating Modes)
Figure 3-28 PSR-RSM: Application example 3 (machine tool with several drives and
differentiated operating modes)
SK = Safety contact
ÜK = Monitoring contact
PSR-RSM 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)
102597A025
+24 V DC
0V
PSR-ESM4
S21S11 S12
S33 S34
2313 33 41
13 23 33 41
14 24 34 42
14 24 34 42
A1
A2
S22
EMERGENCY
STOP
Reset
K4
K3
LL
Operating
mode
switch
Enabling switch
OM
SK ÜK
13 23 33
14 24 34
43
44
Downtime
Overspeed
PSR-RSM
MO2
S33 S34 S35
A1 MI I3 I2 I1
A2
+24 V
+24 V
IN1
IN2
FO MO1
RJ45
13 23 33
14 24 34
43
44
Downtime
Overspeed
PSR-RSM
MO2
S33 S34 S35
A1 MI I3 I2 I1
A2
+24 V
+24 V
IN1
IN2
FO MO1
RJ45
K3
K4
N
K4
K3
M
Release
Servo
Servo M
Wiring Examples
102597_01_en PHOENIX CONTACT 3-35
3.8.4 PSR-RSM: Application Example 4 (Speed Monitoring Using
2-Wire Proximity Switches)
Figure 3-29 PSR-RSM: Application example 4 (speed monitoring using 2-wire
proximity switches)
S1, S2:
1 = Contact (tooth)
0 = No contact (gap)
PSR-RSM 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
102597A026
+24 V DC
0V
PSR-ESM4
S21S11 S12
S33 S34
2313 33 41
13 23 33 41
14 24 34 42
14 24 34 42
A1
A2
S22
EMERGENCY
STOP
LL
Operating mode
switch
S1
13 23 33
14 24 34
43
44
Downtime
Overspeed
PSR-RSM
MO2
S33 S34 S35
A1 MI I1 I2 I3
A2
+24 V
+24 V
IN1
IN2
FO MO1
RJ45
S2
Reset
K4
K3
K3
K4
N
K4
K3
M
1
0
UM EN SAFETY RELAY APPLICATION
3-36 PHOENIX CONTACT 102597_01_en
3.8.5 PSR-RSM: Application Example 5 (Basic Machine With
Monitored Drive and Additional Drive Shaft Monitoring)
Figure 3-30 PSR-SSM: Application example 5 (basic machine with monitored drive and
additional drive shaft monitoring)
PSR-SSM Application Features
Evaluation of a safe speed 4 N/O contacts
Additional drive shaft monitoring
(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)
102597A037
+24 V DC
0V
PSR-ESM4
PSR-RSM
EMERGENCY
STOP
ÜK
Operating mode
switch
Enabling
switch OM
Servo
SK
Release
13 23 33
14 24 34
43
44
Downtime
Overspeed
MO2
S33 S34 S35
A1 MI I3 I2 I1
A2
+24 V
+24 V
IN1
IN2
FO MO1
RJ45
Start
S21S11 S12
S33 S34
2313 33 41
13 23 33 41
14 24 34 42
14 24 34 42
A1
A2
S22
Reset
K4
K3
LL
K3
K4
N
K4
K3
M
Encoder
Drive Shaft
Gearwheel
Proximity switch
Wiring Examples
102597_01_en PHOENIX CONTACT 3-37
3.8.6 PSR-SSM: Application Example 1 (Downtime Monitoring
Using PNP or 2-Wire Proximity Switches)
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)
PSR-SSM Application Features
Downtime monitoring Two-channel (IN1/SEN1, IN2/+SEN2) using
two PNP or 2-wire proximity switches
Up to safety category 3*, EN 954-1
SIL 3 according to EN 61508
*Safety category 4 is possible if a test is performed within 24 hours of machine downtime to detect the internal
sensor errors.
102597A027
+24 V DC
0V
13 23 31
14 24 32
41
42
A1
A2
IN1 IN2
FO MO
S1
S2
PSR-SSM
+SEN1 +SEN2
1
0
UM EN SAFETY RELAY APPLICATION
3-38 PHOENIX CONTACT 102597_01_en
3.9 PSR-SDC4, PSR-URD4, PSR-URM4:
Emergency Stop Monitoring
3.9.1 PSR-SDC4: Application Example 1
Figure 3-32 PSR-SDC4: Application example 1
PSR-SDC4 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
102597A041
+24 V DC
0V
EMERGENCY
STOP
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
Reset
... TBUS ...
... TBUS ...
PSR-SDC4
A1 Y30 S22 A2
S11 S10 S12 S13
Power
IN1
IN2
K1
K2
S34 S33 S35 Y1
13 14 23 24
Wiring Examples
102597_01_en PHOENIX CONTACT 3-39
3.9.2 PSR-SDC4: Application Example 2
Figure 3-33 PSR-SDC4: Application example 2
PSR-SDC4 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
102597A042
+24 V DC
0V
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
... TBUS ...
... TBUS ...
PSR-SDC4
A1 Y30 S22 A2
S11 S10 S12 S13
Power
IN1
IN2
K1
K2
S34 S33 S35 Y1
13 14 23 24
EMERGENCY
STOP
UM EN SAFETY RELAY APPLICATION
3-40 PHOENIX CONTACT 102597_01_en
3.9.3 PSR-SDC4: Application Example 3
Figure 3-34 PSR-SDC4: Application example 3
PSR-SDC4 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
102597A043
+24 V DC
0V
Safety door
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
Reset
... TBUS ...
... TBUS ...
PSR-SDC4
A1 Y30 S22 A2
S11 S10 S12 S13
Power
IN1
IN2
K1
K2
S34 S33 S35 Y1
13 14 23 24
Wiring Examples
102597_01_en PHOENIX CONTACT 3-41
3.9.4 PSR-SDC4: Application Example 4
Figure 3-35 PSR-SDC4: Application example 4
PSR-SDC4 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
102597A044
+24 V DC
0V
EMERGENCY
STOP
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
Reset
... TBUS ...
... TBUS ...
K3
K4
K3
K4
N
PSR-SDC4
A1 Y30 S22 A2
S11 S10 S12 S13
Power
IN1
IN2
K1
K2
S34 S33 S35 Y1
13 14 23 24
UM EN SAFETY RELAY APPLICATION
3-42 PHOENIX CONTACT 102597_01_en
3.9.5 PSR-SDC4: Application Example 5
Figure 3-36 PSR-SDC4: Application example 5
PSR-SDC4 Application Features
Light grid monitoring Two-channel (OSSD1-S10, OSSD2-S12,
bridge A2-S22)
Up to safety category 4, EN 954-1 2 N/O contacts
US = 24 V DC
Automatic activation
(bridge Y1-S33-S35)
Cross-circuit detection (OSSD1-OSSD2)
(fault detected by light grid)
Stop category 0
102597A045
+24 V DC
0V
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
... TBUS ...
... TBUS ...
Light
grid
OSSD1 OSSD2
Wiring Examples
102597_01_en PHOENIX CONTACT 3-43
3.9.6 PSR-SDC4 and PSR-URM4/4X1 Extension Module:
Application Example 6
Figure 3-37 PSR-SDC4 and PSR-URM4/4X1 extension module:
Application example 6
Figure 3-38 Wiring via T-BUS DIN rail connector
PSR-SDC4 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
102597A046
+24 V DC
0V
EMERGENCY
STOP
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
Reset
... TBUS ...
... TBUS ...
11 12 23 33 43 53 61
24 34 44 54 62
PSR-URM4/4X1
A1 K1/K2
A2
62
A2 Y1
PSR-URM4_B
PSR-TBUS-TP
2981716
PSR-SDC...
61
54
53
44
43
34
33
24
23
1211
K1/
K2
A1
A1
A1 A1
A2
A2 A2
K1/K2
K1/K2 K1/
K2
11
S33 12
Y1
Y1 Y1
UM EN SAFETY RELAY APPLICATION
3-44 PHOENIX CONTACT 102597_01_en
3.9.7 PSR-SDC4 and PSR-URD3 Extension Module:
Application Example 7
Figure 3-39 PSR-SDC4 and PSR-URD3 extension module: Application example 7
Figure 3-40 Wiring via T-BUS DIN rail connector
PSR-SDC4 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
0V
EMERGENCY
STOP
A1 S33 S34 S35
A2
-K2
S22 S10 S12
S11 S13
Y1
23
13
13 23
14 24
14 24
PSR-SDC4
Reset
... TBUS ...
... TBUS ...
15 16 27 37 47 57 65
28 38 48 58 66
PSR-URD3
A1 K1/K2
A2
102597A047
PSR-SDC...
A1
A2
K1/K2
S33
Y1
PSR-TBUS-TP
2981716
A1
A2
K1/
K2
16
Y1
A1
A2
K1/K2
15
Y1
66
A2 Y1
65
58
57
48
47
38
37
28
27
1615
)
)
K1/
K2
PSR-URD3
Wiring Examples
102597_01_en PHOENIX CONTACT 3-45
3.10 PSR-ES...4: Connection of Several Safety Relays
3.10.1 PSR-ES...4: Application Example 1
Figure 3-41 PSR-ES...4: Application example 1
PSR-ES...4 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
0V
Reset
EMERGENCY
STOP
PSR-ESM4
PSR-ESA4
EMERGENCY
STOP
PSR-ESM4
PSR-ESA4
13 23 33
13 23 33
14 24 34
14 24 34
A1 S11 S12 S21 S22 S33 S34
A2
-K1
A1 13 23 33
13 23 33
14 24 34
14 24 34
S11 S12 S21 S22 S33 S34
A2
-K2
102597A028
UM EN SAFETY RELAY APPLICATION
3-46 PHOENIX CONTACT 102597_01_en
3.10.2 PSR-ESA2: Application Example 2
Figure 3-42 PSR-ESA2: Application example 2
PSR-ESA2 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
0V
Reset
EMERGENCY
STOP
PSR-ESA2
13 23 33
13 23 33
14 24 34
14 24 34
A1 S11 S12 S33 S34
A2
-K1
102597A029
43 51
43 51
43 52
44 52
PSR-ESA2
13 23 33
13 23 33
14 24 34
14 24 34
A1 S11 S12 S33 S34
A2
-K2
EMERGENCY
STOP
Wiring Examples
102597_01_en PHOENIX CONTACT 3-47
3.10.3 PSR-ES...4 and PSR-URM4 Extension Module:
Application Example 3
Figure 3-43 PSR-ES...4 and PSR-URM4 extension modules: Application example 3
PSR-ES...4/PSR-URM4 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
102597A030
+24 V DC/AC
0V
EMERGENCY
STOP
A1 S12 S21 S22
A2
-K1
S33 S34
S11
23
11 33 53
43 63 71
11 23 33 43 53 63 71
12 24 34 44 54 64 72
12 24 34 44 54 64 72
PSR-ESA4
PSR-ESM4
12
21
22
11
13 31
13 23 31
14 32
14 24 32
23
24
-K2
PSR-URM4
A1
A2 A2 A12
Reset
UM EN SAFETY RELAY APPLICATION
3-48 PHOENIX CONTACT 102597_01_en
3.11 PSR-ESAM4, PSR-ESA4: Machines in Integrated
Systems
3.11.1 PSR-ESAM4, PSR-ESA4: Application Example 1
PSR-ESAM4/PSR-ESA4 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)
Wiring Examples
102597_01_en PHOENIX CONTACT 3-49
Figure 3-44 PSR-ESAM4, PSR-ESA4: Application example 1
102597A031
+24 V DC/AC
0V
A1
S12S21S22
A2
S33S34
S11
23
13 31
13 23 31
14 24 32
14 24 32
PSR-ESAM4
14
14
13
13
34
34
33
33
24
23
24
23
K3
PSR-ESA4
A1
A2
Machine 1 (Master)
Machine 2 (Slave)
K4
K3
K4
X1.8 X1.6
X1.7 X1.5
L2 L1
S10
EMERGENCY
STOP
44
44
43
43
64
64
63
63
54
53
54
53
74
74
73
73
92
92
91
91
84
83
84
83
S35
Reset
X1 .5 .6 .7 .8 .4 .3 .2 .1
+24 V DC/AC
0V
X2 .5 .6 .7 .8 .4 .3 .2 .1
S12 S21 S22
S33 S34
S11
EMERGENCY
STOP
UM EN SAFETY RELAY APPLICATION
3-50 PHOENIX CONTACT 102597_01_en
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-1
A Approvals and Certificates
A 1 Approvals
Order No. Type CE BG TÜV CUL Fuel
Technology
(EN 50156-1/
VDE 0116)
EN 954-1 IEC 61508,
SIL 3
2963718-07 PSR-SCP- 24UC/ESM4/2X1/1X2 • • • •
2963705-00 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 • • • •
UM EN SAFETY RELAY APPLICATION
A-2 PHOENIX CONTACT 102597_01_en
2981428-02 PSR-SCP- 24DC/ESD/5X1/1X2/300 • • • •
2981431-02 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 • • • • •
Order No. Type CE BG TÜV CUL Fuel
Technology
(EN 50156-1/
VDE 0116)
EN 954-1 IEC 61508,
SIL 3
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-3
A 2 Certificates
Auxiliary Devices Certified for Canada
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-..P-
120UC, followed by alpha numeric characters; Types PSR-SCP24UC/ESL4/3X1/1X2/B and PSR-
SPP24UC/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.
This page and all contents are Copyright © 2005 by Underwriters Laboratories Inc.®
The appearance of a company's name or product in this database does not in itself assure that products so identified have
been manufactured under UL's Follow-Up Service. Only those products bearing the UL Mark should be considered to be
Listed and covered under UL's Follow-Up Service. Always look for the Mark on the product.
UL permits the reproduction of the material contained in the Online Certification Directory subject to the following
conditions: 1. The Guide Information, Designs and/or Listings (files) must be presented in their entirety and in a non-
misleading manner, without any manipulation of the data (or drawings). 2. The statement "Reprinted from the Online
Certifications Directory with permission from Underwriters Laboratories Inc." must appear adjacent to the extracted
material. In addition, the reprinted material must include a copyright notice in the following format: "Copyright © 2005
Underwriters Laboratories Inc.®"
NKCR7.E140324
Auxiliary Devices Certified for Canada
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See General Information for Auxiliary Devices Certified for Canada
PHOENIX CONTACT GMBH & CO K
G
E140324
FLACHSMARKTSTRASSE 8
32825 BLOMBERG, GERMANY
Last Updated on 2004-11-18
Page Top Notice of Disclaimer Questions? Previous Page
UL Listed and Classified
Products UL Recognized
Components
Products Certified
for Canada
UM EN SAFETY RELAY APPLICATION
A-4 PHOENIX CONTACT 102597_01_en
A 2.1 PSR-ESA4
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-5
A 2.2 PSR-ESM4
UM EN SAFETY RELAY APPLICATION
A-6 PHOENIX CONTACT 102597_01_en
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-7
A 2.3 PSR-ESAM4
UM EN SAFETY RELAY APPLICATION
A-8 PHOENIX CONTACT 102597_01_en
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-9
A 2.4 PSR-THC
UM EN SAFETY RELAY APPLICATION
A-10 PHOENIX CONTACT 102597_01_en
A 2.5 PSR-ESP
Approvals and Certificates
102597_01_en PHOENIX CONTACT A-11
A 2.6 PSR-ESD
UM EN SAFETY RELAY APPLICATION
A-12 PHOENIX CONTACT 102597_01_en
Ordering Data
102597_01_en PHOENIX CONTACT B-1
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.
Emergency stop and safety door monitoring,
24 V AC/DC, single and two-channel,
2 enabling current paths, with cross-circuit detection
Manual*
Manual and
automatic
PSR-SCP- 24UC/ESM4/2X1/1X2
PSR-SPP- 24UC/ESM4/2X1/1X2
PSR-SCP- 24UC/ESA4/2X1/1X2
PSR-SPP- 24UC/ESA4/2X1/1X2
2963718
2963705
2963750
2963938
1
1
1
1
Emergency stop and safety door monitoring,
24 V AC/DC, single and two-channel,
3 enabling current paths, with cross-circuit detection
Manual*
Manual and
automatic
PSR-SCP- 24UC/ESM4/3X1/1X2/B
PSR-SPP- 24UC/ESM4/3X1/1X2/B
PSR-SCP- 24UC/ESA4/3X1/1X2/B
PSR-SPP- 24UC/ESA4/3X1/1X2/B
2963776
2963925
2963763
2963941
1
1
1
1
Emergency stop and safety door monitoring,
24 V AC/DC, single-channel, 4 enabling current
paths
Manual and
automatic
PSR-SCP- 24UC/ESA2/4X1/1X2/B
PSR-SPP- 24UC/ESA2/4X1/1X2/B
2963802
2963954
1
1
Process technology, emergency stop and safety
door monitoring,
24 V DC, single-channel, 2 enabling current paths
Manual and
automatic
PSR-SCP- 24DC/ESP4/2X1/1X2
PSR-SPP- 24DC/ESP4/2X1/1X2
2981020
2981017
1
1
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
PSR-THC
Description Activation Type Order No. Pcs./Pck.
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
Automatic PSR-SCP- 24UC/THC4/2X1/1X2
PSR-SPP- 24UC/THC4/2X1/1X2
2963721
2963983
1
1
PSR-ESL
Description Activation Type Order No. Pcs./Pck.
Light grid, emergency stop, and safety door
monitoring,
24 V AC/DC, single and two-channel
Manual* and
automatic
PSR-SCP- 24UC/ESL4/3X1/1X2/B
PSR-SPP- 24UC/ESL4/3X1/1X2/B
2981059
2981062
1
1
* With start button monitoring
UM EN SAFETY RELAY APPLICATION
B-2 PHOENIX CONTACT 102597_01_en
PSR-ESD
Description Activation Type Order No. Pcs./Pck.
Emergency stop and safety door monitoring,
with delayed and undelayed contacts,
24 V DC, single and two-channel, adjustable from
200 ms to 300 s, with/without cross-circuit detection
Manual* and
automatic
PSR-SCP- 24DC/ESD/5X1/1X2/300
PSR-SPP- 24DC/ESD/5X1/1X2/300
2981428
2981431
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)
Manual* and
automatic
PSR-SCP- 24DC/ESD/5X1/1X2/T...
PSR-SPP- 24DC/ESD/5X1/1X2/T...
See table
See table
1
1
* With start button monitoring
PSR-ESD-T Order Versions
Type
Screw Connection
Order No. Delay
Time
PSR-SCP- 24DC/ESD/5X1/1X2/0T5
PSR-SCP- 24DC/ESD/5X1/1X2/T1
PSR-SCP- 24DC/ESD/5X1/1X2/1T5
PSR-SCP- 24DC/ESD/5X1/1X2/T2
PSR-SCP- 24DC/ESD/5X1/1X2/2T5
PSR-SCP- 24DC/ESD/5X1/1X2/T3
PSR-SCP- 24DC/ESD/5X1/1X2/T4
PSR-SCP- 24DC/ESD/5X1/1X2/T5
PSR-SCP- 24DC/ESD/5X1/1X2/T6
PSR-SCP- 24DC/ESD/5X1/1X2/T10
PSR-SCP- 24DC/ESD/5X1/1X2/T15
PSR-SCP- 24DC/ESD/5X1/1X2/T20
PSR-SCP- 24DC/ESD/5X1/1X2/T30
2981101
2981143
2981169
2981125
2981208
2981224
2981240
2981266
2981282
2981088
2981305
2981321
2981347
0.5 s
1 s
1.5 s
2 s
2.5 s
3 s
4 s
5 s
6 s
10 s
15 s
20 s
30 s
Type
Spring-Cage Connection
Order No. Delay
Time
PSR-SPP- 24DC/ESD/5X1/1X2/0T5
PSR-SPP- 24DC/ESD/5X1/1X2/T1
PSR-SPP- 24DC/ESD/5X1/1X2/1T5
PSR-SPP- 24DC/ESD/5X1/1X2/T2
PSR-SPP- 24DC/ESD/5X1/1X2/2T5
PSR-SPP- 24DC/ESD/5X1/1X2/T3
PSR-SPP- 24DC/ESD/5X1/1X2/T4
PSR-SPP- 24DC/ESD/5X1/1X2/T5
PSR-SPP- 24DC/ESD/5X1/1X2/T6
PSR-SPP- 24DC/ESD/5X1/1X2/T10
PSR-SPP- 24DC/ESD/5X1/1X2/T15
PSR-SPP- 24DC/ESD/5X1/1X2/T20
PSR-SPP- 24DC/ESD/5X1/1X2/T30
2981130
2981156
2981172
2981198
2981211
2981237
2981253
2981279
2981295
2981091
2981318
2981334
2981350
0.5 s
1 s
1.5 s
2 s
2.5 s
3 s
4 s
5 s
6 s
10 s
15 s
20 s
30 s
PSR-RSM
Description Activation Type Order No. Pcs./Pck.
Speed and downtime monitoring,
24 V DC, two-channel, automatic control via cable
adapter or two initiators
Manual* and
automatic
PSR-SCP- 24DC/RSM4/4X1
PSR-SPP- 24DC/RSM4/4X1
29 81 53 8
29 81 54 1
1
1
* With start button monitoring
Ordering Data
102597_01_en PHOENIX CONTACT B-3
PSR-SSM
Description Activation Type Order No. Pcs./Pck.
Downtime monitoring,
24 V DC, two-channel, automatic control via two
standard initiators
Manual* and
automatic
PSR-SCP- 24DC/SSM/2X1
PSR-SPP- 24DC/SSM/2X1
29 81 56 7
29 81 57 0
1
1
* With start button monitoring
PSR-SDC
Description Activation Type Order No. Pcs./Pck.
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
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 Type Order No. Pcs./Pck.
Extension module with off-delay contacts,
with single-channel control, 24 V DC, with interface for DIN rail
connector
PSR-SCP- 24DC/URD3/4X1/2X2
PSR-SPP- 24DC/URD3/4X1/2X2
2981512
2981525
1
1
PSR-URM
Description 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
Universal safety relay, with positively driven contacts,
24 V AC/DC
120 V AC/DC
PSR-SCP- 24UC/URM/5X1/2X2
PSR-SPP- 24UC/URM/5X1/2X2
PSR-SCP-120UC/URM/5X1/2X2
PSR-SPP-120UC/URM/5X1/2X2
2963747
2963970
2981402
2981415
1
1
1
1
Universal safety relay, with positively driven contacts
24 V AC/DC
120 V AC/DC
PSR-SCF- 24UC/URM/2X21
PSR-SCF-120UC/URM/2X21
2981363
2981376
1
1
Universal safety relay, with positively driven contacts
24 V AC/DC
120 V AC/DC
PSR-SCF- 24UC/URM/4X1/2X2
PSR-SPF- 24UC/URM/4X1/2X2
PSR-SCF-120UC/URM/4X1/2X2
PSR-SPF-120UC/URM/4X1/2X2
2981444
2981457
2981460
2981473
1
1
1
1
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
UM EN SAFETY RELAY APPLICATION
B-4 PHOENIX CONTACT 102597_01_en
List of Figures
102597_01_en PHOENIX CONTACT C-1
C Appendices
C 1 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
Section 2
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
Section 3
Figure 3-1: PSR-ESA4: Application example 1 ...................................................3-1
Figure 3-2: PSR-ESA4: Application example 2 ...................................................3-3
UM EN SAFETY RELAY APPLICATION
C-2 PHOENIX CONTACT 102597_01_en
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
List of Figures
102597_01_en PHOENIX CONTACT C-3
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
UM EN SAFETY RELAY APPLICATION
C-4 PHOENIX CONTACT 102597_01_en
List of Tables
102597_01_en PHOENIX CONTACT C-5
C 2 List of Tables
Section 1
Table 1-1: Requirements according to EN 574 ...................................................1-6
Section 2
Table 2-1: Typical examples of standards...........................................................2-9
Table 2-2: Interesting links on the Internet ........................................................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
UM EN SAFETY RELAY APPLICATION
C-6 PHOENIX CONTACT 102597_01_en
Revision History
102597_01_en PHOENIX CONTACT D-1
D Revision History
Version Date Contents
01 05/2006 First publication of the application manual in English.
UM EN SAFETY RELAY APPLICATION
D-2 PHOENIX CONTACT 102597_01_en

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