Electronic Safety Relays - Spec
Contents
1. 50 60Hz ieee e per unit number price aneo dela 24VAC 24VDC 3N 0 1N C 3 4 8 47 1 1SAR501031RO0001 340 Description e Operating voltage U at Emergency Stop button or limit switch e Single or two channel connection e Feedback circuit for monitoring external contactors e LED indicators for Power Channels 1 and 2 e Output 3NO and 1 NC positively driven e Overall width 45mm Application The safety relays C571 C573 can be used in Emergency Stop circuits as per EN 418 and in safety circuits as per VDE 0113 7 Part 1 11 98 and or EN 60 204 1 11 98 i e with movable covers and guard doors Depending on the external connections categories 3 and 4 with additional external measures as per DIN EN 954 1 are achievable Possible with additional external measures The digit in parenthesis applies only if the cables and sensors are laid safely and protected mechanically 7 23 AC 1000 11 03 Low Voltage Products amp Systems Discount schedule AR ABB Inc 888 385 1221 www abb control com wv Type C574 Voltage range Output contacts Enable contacts Auxiliary Safety i Piece Catalog List 50 60Hz Instan Time category oz per unit number price taneous delay 24VDC 1SAR503041R0003 1SAR503041R0002 2 N O 2 N O 1 N C 3 15 87 1 1SAR503041R0004 1SAR503041R0005 Description Emergency Stop switching device and safety door monitor with time delay C574 Sing2. EMERGENCY STOP i ja a2 Ji4 24l32 Tas 58 CICI i KIKI H1 i Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Approximate dimensions L C570 C571 C573 C576 C577 C579 C572 C574 C575 C578 C6700 C6701 C6702 73 5 C565 S i Power g RUN Low Voltage Products amp Systems 7 49 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 ow ye Notes 7 50 Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com
3. TI O A1 Y11 Y12 Y33 Y34 oats rO RE IS i 1O Y20Y21Y22 A2 14 24 k 22 A2 14 24 open closed Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Application examples C6701 Application The C 6701 safety combination can be used in EMERGENCY STOP circuits according to EN 418 and in safety circuits according to EN 60 204 1 11 98 e g in movable guards and safety gates Depending on the external circuit elements safety category 4 according to DIN EN 954 1 or SIL 3 according to IEC 61508 can be achieved Functions and connections The C 6701 safety combination has two reliable solid state outputs Three LEDs indicate the operating state and the function When the device is put into operation it runs through a self test to test the correct functioning of the internal electronics All internal circuit Components are monitored for faults cyclically during operation The EMERGENCY STOP button and or the position switches or light arrays are connected to terminals Y11 Y12 and Y21 Y22 The ON button is connected in series with the NC contacts of the external actuators to the supply voltage L 24 V DC and to terminal Y34 The cascading input 1 is connected either via a safe output or directly to the supply voltage L 24 V DC External actuators or loads can be switched via safe outputs 14 24 It must be ensured that the actuators or loads and the C 6701 electronic sa
4. 1x 0 5 4 2 x 0 5 2 5 AC DC stranded with wire end ferrule mm 1x 0 5 2 5 24 240 VAC DC 2 x 0 5 1 5 single core or stranded AWG 2x 20 14 Terminal screws for normal screw driver size 3 and Pozidrive 2 M 3 5 Permissible normal position any Resistance to shock semi sinusoidal acc to IEC 60068 2 27 g ms 15 11 die lis J26 28 Vibrostability acc to IEC 60068 2 6 Hz mm 10 55 0 35 EMV tests by basic specification EN 50081 1 EN 50082 2 Unless otherwise specified For C565 S open aA Without any welding as per IEC 60947 5 1 Wide range voltage power pack voltage dependent 10 to 250 ms Low Voltage Products amp Systems Discount schedule AR 7 31 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 Solid state control of actuators therfore no wear No contact failure at currents of 17V 1mA Short circuit proof High switching frequencies e 24VDC sensor supply Economical Internal standard circuit diagram of a safe circuit in accordance to C 6700 LI L2 L3 EMERGENCY STOP Internal standard circuit diagram of safety relay C 6701with solid state output Emergency 7 32 AC 1000 11 03 Electronic safety relays with soid state output C67xx Electronic safety relays with solid state output C 67xx e Solid state outputs no contacts no wear e Low weight amp small size Space and weight advantage e Positively guided standard contactors operate as s
5. 1 N C 3 4 15 17 1 1SAR533141R0003 24VAC 2 N O 2 N O 1 N C 3 4 21 16 1 1SAR533141R0002 110VAC E 2 N O 2 N O 1 N C 3 40 21 16 1 1SAR533141R0004 675 230VAC 2 N O 2 N O 1 N C 3 4 15 17 1 1SAR533141R0005 Possible with additional external measures The digit in parenthesis apply only if the cables and sensors are laid safely and protected mechanically 7 24 Discount schedule AR Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Type C575 8 Me Fey Up 9 Wy Voltage range Output contacts Enable contacts Auxiliary Safety Weight Piece Catalog List 50 60Hz VDC Instan Time category oz per unit number price taneous delay a 24VDC 1SAR504022R0003 24VAC 1SAR504022R0002 110VAC es 2N C 4 12 35 1 4SaR504022R0004 230VAC 1SAR504022R0005 780 Description Two hand control C 575 For activating presses e g in conjunction with overtravel monitor C 578 24 V DC at the two hand control switches e Feedback circuit for monitoring external contactors e 5 LED circuit state indicators for Power S1 ON S1 OFF S2 ON S2 OFF e Simultaneity monitoring 0 5 s e Output 2 NO 2 NC positively driven e Overall width 45 mm Application C575 is suitable for installation in controls for presses e Hydraulic presses DIN EN 693 e Eccentric and related presses EN 692 e Screw presses EN 692 Low Voltage Produc
6. Discount schedule AR ABB Inc 888 385 1221 www abb control com C565 S LY with positively guided contacts Multifunction time relay 8 functions 15 time ranges 2 c o positively guided amp gold plated Time range with rotary Supply ae pan Piece Catalog List switch can be set to AC 50 60Hz per unit number price 0 05s 100h 24 240V 24 E EE 1SAR330030R0000 129 00 Functions can be set by a rotary switch Separate markers allow a clearly legible and distinctive setting of the timing functions The markers are available as an accessory Accessories Item Ident Piece List description letter per unit price C560 10 cover sealable i For protecting against unauthorized 5 1SAR390000R1000 30 00 1SAR330030R0000 readjustment C560 20 plug in tab for screw mounting Mounting 5 with 2 on panel pieces each C560 40 Set of labels for multifunction relay C565 full set with 16 functions ON delay OFF delay with auxiliary voltage ON and OFF delay with auxiliary voltage Flascher starting with OFF 5 sets 1SAR390000R4000 42 00 1SAR390000R2000 Impulse ON Impulse OFF with auxiliary voltage Pulseformer with auxiliary voltage Switch position y no timing To be used for testing purposes ON OFF function within the installation When voltage is applied the relay remains energized or remains de energizes permanently Operating range 0 7 to 1 25 x U Operating range 0 85 to 1 1 x U The c o contac
7. Personnel safety and machine protection Risk category according to EN 954 1 F Frequency and or duration of the risk exposure F1 Rare to frequent and or short duration of exposure F1 Frequent to sustained and or longduration of exposure P Options for risk avoidance Generally referred to the speed and frequency at which the dangerous components moves and to the clearance from the dangerous component P1 Possible under certain conditions P2 Hardly possible Categories B1 4 Categories for safety related components of controls Preferred category Possible category requiring additional measures O Disproportionately extensive measures by comparison with the risk Principles for System behaviour ae achieving safety The occurrence of a fault may lead to loss of the safety function Predominantly characterised by selection of componentsl The occurrence of a fault may lead to loss of the safety function but the probability of occurrence is less than in category B The occurrence of a fault may lead to loss of the safety function between the inspection intervals The loss of the safety function is detected by the check inspection If the single fault occurs the safety function is always retained Certain faults but not all faults are detected An accumulation of undetected faults may lead to loss of the safety function Predominantly characterised by the structure If the faults occur the safety fun
8. S2 Serious normally irreversible injuries including death Safety Summary of requirements category y q B The safety related components of controls and or their protection devices and their components must be designed constructed selected assembled and combined in compliance with the applicable standards such that they can withstand the anticipated influences 1 The requirements of B must be complied with Time proven components and time proven safety principles must be applied 2 The requirements of B and the use of the time proven safety principles must be complied with The safety function must be checked at appropriate intervals by the machine control 8 The requirements of B and the use of the time proven safety principles must be complied with Safety related components must be designed such that e a single fault in any of these components does not lead to loss of the safety function and e the individual fault is detected wherever feasible in an appropriate manner 4 The requirements of B and the use of the time proven safety principles must be complied with Safety related components must be designed such that e a single fault in any of these components does not lead to loss of the safety function and e the individual fault is detected at or before the next requirement applicable to the safety function or if this is not possible an accumulation offaults may then not lead to loss of the safety function
9. fault current Terminal marking Ikmin 0 5A PTC fuse trips Supply voltage A1 L A2 N Sensors Y11 12 Channel 1 EMERGENCY C 577 with monitored start for EMERGENCY STOP STOP Category 4 acc to EN 954 1 or limit switch es Y21 22 Channel 2 EMERGENCY STOP or limit switch Al RL 13 23 Y33 34 ON button feedback loop ool lig E i Outputs 13 14 Safety output 1 n o contact open closed 23 24 Safety output 2 n o contact Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cape engt C 577 with monitored start for EMERGENCY STOP for 2 x 1 5mm max 1000m total cable length for Category 4 acc to EN 954 1 150nF km sensors and power supply lines 24V ACIDC __ Internal circuit L s 4 ON K2 gt _ siysaiy34_ st fas ie Cy K2 fray 24 K1 K2 Al Y11 Y21 REA 13_23 7 46 Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Application examples 8 Me C578 Application The overtravel distance tester C 578 is intended for checking the overtravel of linearly operating hydraulic pneumatic and spindle presses in accordance with VBG 7n5 2 11 Functions and connections The overtravel distance tester C 578 has four safety outputs three NO contacts and one NC contact Two LEDs indicate the functions The C 578 tests the overtravel distance in connection with a position swit
10. fault or replace device 3 Switch supply voltage back on Cable length for 2x 1 5 mm max 1000m total cable length for 150nF km sensors and power supply lines Monitored start for EMERGENCY STOP Safety category 2 acc to EN 954 1 Ly LA EMERGENCY STOP AtlyioviNyi2lyaiy22 413123133 _l4115 tv tv tv Safety gate monitoring Safety category 3 and 4 acc to EN 954 1 i 1 open closed Safety gate monitoring Safety category 2 acc to EN 954 1 Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Application examples 8 Me ey U C575 tr On te ys a 4g Application Operation C 575 is suitable for installation in controls for presses 7 e Hydraulic presses DIN EN 693 LEDs Operation e Eccentric and related presses EN 692 POWER S1 ON S2 ON Channel 1 Channel 2 Pushbutton Functions and connections z o e e EEE The two hand control unit C 575 possesses two release circuits safety outputs configure as NO contacts and two signal outputs configured as NC contacts Five only S2 activated LEDs indicate the operating status and the functions pe TE PE fe Saree ANd The safety outputs are closed by simultaneous operation lt 0 5s of the push buttons S1 S2 If one pushbutton is no longer pressed the outputs The unit cannot be started with the following faults open They do not close again until both pushbuttons are no longer pressed and then
11. off AT PE AE on start up self test approx 7 sec Roan Defect in the electronic off D Change in terminal flashes assignment during operation Short circuit to 24V2 O No supply voltage Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 2000m total cable length for 150nF km sensors EMERGENCY STOP single channel monitored start Category 2 SIL 1 O O i Y35 Y21 Y22 A2 14 24 peepee K2 3 Ki K2 EMERGENCY STOP two channel monitored start with additional ON button category Category 4 SIL3 L Light array monitoring two channel autostart category Category 4 SIL3 L 7 35 AC 1000 11 03 os O e 2 gE 5 ope C6702 Emergency Stop two channel monitored start with additional ON button and safety gate monitoring category 4 SIL 3 L PS EIN A1 lyi1 v12 Y32 1 Y34 Ki O O O O 14 24 C6701 K2 _ e O Y35 Y21 Y22 A2 O b Y11 Y12 32 1 1 Y34 aa ae O O O O i C670 J GY C a rc t Sapa O Y35 Y21 on A2 T 24 _ BT Listy K1 K2 Application The C 6702 safety combination can be used in EMERGENCY STOP circuits according to EN 418 and in safety circuits according to EN 60 204 1 11 98 e g in movable guards and safety gates Depending on the external circuit elements safety category 4 accordin
12. on 1 Switch on the hydraulic pump with S5 move plunger to top dead centre if necessary by means of S6 2 Operate S1 S2 on the two hand control console until the position switch for test cam S4 opens 3 Stop operating S1 S2 4 Operate S1 S2 again Indicator light H1 lights up if the overtravel distance is OK 5 Stop operating S1 S2 The plunger returns to top dead centre 6 If overtravel distance is OK all outputs remain active until the control voltage is switched OFF LEDs Operation POWER gt Overtravel distance OK Q o Overtravel distance incorrect or test not yet performed Fault If the cam overtravels position switch S4 indicator light H1 does not light up The hazardous part of the machine can be moved up to top dead centre only by means of S6 The press can no longer be used for production When this happens notify the maintenance staff that the press needs attention Internal circuit 23 33 _ 41 7 47 AC 1000 11 03 G a m FORG Application examples eo Oo C579 oe Applications Operation You can use the C 579 expansion unit in combination with all F the C 57x basic units It extends the number of release circuits Depending on LEDs Operation the external connection category 4 as per DIN EN 954 1 is achievable with this device Functions and connections The C 579 expansion unit has four release circuits safety circuits configured as NO circuits Two LEDs indic
13. simultaneously pressed again e Short circuit e g between the pushbuttons e Defective relay coils 1 Operating voltage to be applied to the terminals A1 and A2 e Conductor failure The operating voltage must be de energized with the operating e Welded contacts energy of the press 2 Feedback loop to be closed The output relays does not enegize if Y11 Y12 to be jumperd or connected to the NC contacts of e The pushbuttons are not pressed simultaneously lt 0 5s external contactors e Only one pushbutton is pressed 3 Input circuits to be connected e The feedback loop Y11 Y12 is open Pushbutton S1 to terminals Y21 Y22 Y23 and Cable length pushbutton S2 to terminals Y31 Y32 Y33 g max 1000m for 2 x 1 5mm Total cable length for sensors Terminal marking and power supply lines Supply voltage A1 L A2 N External circuit S1 S2 pushbuttons on two hand control console Outputs 13 14 Safety output 1 n o contact H1 indicator light K1and K2 must be positively guided contactors 23 24 Safety output 2 n o contact Safety category 4 acc to EN 954 1 31 32 n c signal output 41 42 n c signal output Inputs Y11 12 Feedback loop Y21 22 23 Pushbutton S1 Y31 32 33 Pushbutton S2 Internal circuit Low Voltage Products amp Systems 7 45 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 xo RC Application examples eO C576 C577 of Application Operation The safety relay C 576 can be us
14. 2 Terminal markings Operation Operating states indication READY indicates that the supply voltage is applied to the unit provided that the contacts of the EMERGENCY STOP pushbutton or door safety switch are closed ON lights up when the ON button is pressed and the enabling circuits are switched through Safety gate X3 131o 330 57yo T monitoring OO0000000 A door open C570 B door closed 14no 34no 58No 0000000000 X X 24no 44no 66nc x Operating states LEDs Operation POWER Channel 1 Channel 2 PS EMERG Safety STOP output xt activated closed eee gt activated open A A open ER TA Relay fusion welded open Motor contactor fusion welded Defects in electronic Cross or ground faults in EMERG STOP circuit Supply A1 L min fault currentlkmin 0 5A voltage A2 N PTC fuse trips or supply Sensors Y1 Y2 ON button feedback loop voltage missing Outputs 13 14 Safety output 1 n o 23 24 Safety output 2 n o Fault clearance 33 34 Safety output 3 n o 1 Switch supply voltage off 41 42 Signal circuit 1 n c 2 Clear fault or replace device with C 573 only 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 1000m total cable length for 150 nF km sensors and power supply lines linternal circuit Emergency Stop category 2 acc to EN 954 1 EMERGENCY STOP category 3 and 4 acc to EN 954 1 13 23 33 41 24 V AC DC PTC fuse Power p
15. 5A DC 13 24V 2A 115 V 0 2 A 230 V 0 1 A Continuous current Enable circuits 2FK 3FK 4FK UT 70 C 4A 35A 3A UT60 C 4 5A 4A 35A UT 50 C 5A 45A 4A Mounting positions With mm 225 Possible with additional external measures The figures in bracket apply only if the cables and sensors are laid safely and protected mechanically Applies only to undelayed FK category 3 applies to time delayed FK IP 20 terminals IP 40 housing Low Voltage Products amp Systems 1 33 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 gn Application examples ory C6700 se Ge Applications Operation The C 6700 safety combination can be used in EMERGENCY STOP circuits ac cording to EN 418 and in safety circuits according to EN 60 204 1 11 98 e g for moving covers and safety gates Safety catetory 3 according to DIN EN 954 1 or SIL2 according to IEC 61508 can be achieved depending on the external circuits Functions and connections The C 6700 safety relay has two solid state outputs Three LEDs indicate the operating state and the function During operation all internal circuit elements are cyclically monitored for faults The EMERGENCY STOP button or the position switch are connected to termi nals Y11 12 or Y21 22 The ON button is connected in series to the NC contacts of the external actuators feedback loop to terminals Y33 34 The C 6700 safety relay and the activated contactors K1 and K2 must have the same f
16. 70x Y Ne Y 4g Safety gate monitoring two channel autostart category 4 SIL 3 EMERGENCY STOP single channel monitored start with additional with voltage operated e c b and delayed disconnection stop category 1 ON button category 2 SIL 1 with voltage operated e l c b and delayed L disconnection stop category 1 L EIN a O O EMERGENCY STOP two channel monitored start with additional ON button category 4 SIL 3 with voltage operated e l c b and delayed EMERGENCY STOP and safety gate monitoring two channel with disconnection stop category 1 tumbler monitored start category 4 SIL 3 L L K1 K2 e 1 Y34 F 1 gt Lt A1 Y11 Y12_Y32 ssk e EMERGENCY STOP two channel monitored start with additional ON Light array monitoring two channel autostart category 4 SIL 3 button and safety gate monitoring two channel autostart category 4 SIL 3 L K1 a i EIN K1 A1 Y11 Y12_Y32 1 Y34 K2 C6702 A ine O O 0 0 CO Y35 Y21 Y22 A2 114 24 A1 lyiily12 Y3211 y34 ae pees 5 mO oO O O O K1 1 1O a 1 N E eters 9 0 0 0 Y35 Y21 Y22 A2 14 28 L FU ru E O O O OQ AREA Y35 Y21 Y22 A2 14 28 FU BR G pi E ii l CJC AN M 7 Ki m Safety mat two channel autostart category 3 SIL2 r o 0 0 O Ki A1 Y11 Y12 Y32 1 Y34 H C6702 Orff r L 7 37 AC 1000 11 03 Low Voltage Products amp Systems
17. A 0 7 Wy Delayed Enable contacts Drives which have a long overtravel must be decelerated in the event of danger For this purpose the energy supply must be maintained for electrical braking stop category 1 to EN 60 204 1 The safety switching device C 574 also feature OFF delayed Enable contacts besides undelayed Enable contacts Delay times of 0 5 to 30 s are available The sealable cover cap C 560 10 see Selection data and Ordering details Accessories can be fitted onto C 574 C 6702 to protect against unauthorised adjust ment of the set delay time Contact expansion If the Enable contacts of the basic device do not suffice positively driven contactors e g B6 B7 may be used for contact expansion One solution for increasing the number of Enable contacts which is both simple to use and space saving is the expansion unit C 579 only 22 5mm wide The expansion unit C 579 provides 4 additional En able contacts Expansion unit C 579 Expansion unit C 579 may not be operated separately in safety related circuits but must be combined with a safety switching device C 57x One Enable contact of the basic device is required for connection of an ex pansion unit The category of a control with expansion units corresponds to the category of the basic device Mounting Snap on mounting on 35mm top hat rail to EN 50 022 Screw mounting of the safety switching devices C 57x can be implemented with two addi tional plug i
18. ABB Inc 888 385 1221 www abb control com Classification of a machine into categories to EN 954 1 Pursuant to the Machinery Directive 89 393 EEC every machine must comply with the relevant directives and standards Measures must be taken to keep the risk to persons below a tolerable extent In the first step the project planner performs a risk evaluation to EN 1050 Risk Assessment This must take into consideration the machine s ambient conditions for instance Any overall risk must then be assessed This risk assessment must be conducted in such a form as to allow documentation of the procedure and the results achieved The risks dangers and possible technical measures to reduce risks and dangers must be stipulated in this risk assessment After stipulating the extent of the risk the category on the basis of which the safety circuits are to be designed is determined with the aid of EN 954 1 Safety Related Components of Controls This determined category defines the technical requirements applicable to the design of the safety equipment There are five categories B 1 2 3 and 4 whereby B standing for basic category defines the lowest risk and thus also the minimum requirements applicable to the controller Possible selection of categories pursuant to EN 954 1 Starting point for the risk assessment of the safety related component of the controller S Serious injuries S1 Slight normally reversible injuries
19. AK ED ED Electronic relays PR Safety bim ae a ee ie er ER x Description The C57x series covers 10 safety relays contacts it is also possible to monitor signalling which perform safety functions on machines devices such as emergency stop buttons or limit Their elds of application extend from switches of the guard doors This ensures the emergency stop circuits through guard required level of safety even on systems subject door monitoring functions and tread mats to to a high level of pollution presses and punches All C57x products are In the event of a fault or error the safe state of UL Listed CSA approved and bear the CE the system is achieved directly after opening Mark the safety contacts These enable circuits are All safety relays can be used on the basis N O contacts which open reliably in the event of their classiLcation into the risk categories of fault or error and thus reliably switch off the to EN 954 1 they are approved by the potentially hazardous drives or machines employers liability insurance associations Additional signalling contacts N C contacts and or the German Technical Inspection which close in the event of a fault or error or Authority TUV and comply with the semiconductor outputs are available depending requirements of EN 60204 Part 1 on the type of equipment Redundancy is achieved by series connection Easy reliable and fast wiring is achieved by of two N O contacts These N O co
20. MERGENCY STOP button or the limit switch to terminals Y11 12 and Y21 22 The ON button is connected in series with the NC contacts of the external contactor feedback loop between terminals Y33 34 Terminal marking Supply voltage Sensors Outputs Internal circuit Power pole Control logic Channel 1 Channel 2 7 42 AC 1000 11 03 A1 A2 Y11 12 Y21 22 Y33 34 13 14 23 24 L N Channel 1 EMERGENCY STOP or limit switch Channel 2 EMERGENCY STOP or limit switch ON button feedback loop Safety output 1 n o Safety output 2 n o Two channel autostart for contactor monitoring Safety category 3 and 4 acc to EN 954 1 L 50 60 Hz o ge oO 5 ee O n oO a C571 AC Safety gate monitoring category 3 and 4 acc to EN 954 1 24 V AC DC C571 C573 Li Li open closed Operating states LEDs Operation see a 3 non activated closed activated activated non open activated y non non open activated activated Relay fusion welded open Faults X Motor cont fusion welded Defects in electronic Cross or ground faults in EMERG STOP circuit Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 1000m total cable length for 150 nF km sensors and power supply lines Single channel EMERGENCY STOP with additional ON button Safety
21. Rated power consumption 1 5W 1 3W 1 3W Operational voltage range 0 9 1 15 X Vg 0 9 1 15 xX Vg 0 9 1 15 X Vg Shock resistance half sine acc to IEC 60068 89 10ms 8g 10ms 8g 10ms Weight 150g 0 33lb 150g 0 33Ib 150g 0 33Ib Recovery time after EMERGENCY STOP min 20ms min 30ms min 30ms Recovery time after power failure 7S Release time after EMERGENCY STOP lt 30ms min 30ms 30ms 0 05 3s or 0 5 30s adjustable Recovery time after power failure max 25ms Response time max 40ms max 40ms Response time monitored start lt 125ms Response time Auto start lt 250ms Short circuit protection no fusing necessary no fusing necessary no fusing necessary Utilization category acc to IEC 60947 5 1 Rated operational Rated operational voltage V current C 6700 DC 13 24V 0 5A per output 60 C C 6701 DC 13 24V 2 0A C 6702 DC 13 24V 2 0A Discount schedule AR Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Technical data Sop bo ey og Ls Type C570 C571 C572 C573 C574 C575 C576 C577 C578 C579 semen lo el ok EO EE 2 channel connection Cross short protection Test certificate BIA BIA SUVA ss BG SUVA UL CSA Safety category to EN 954 1 BOO WOO ae a p Mechanical service life 10 million operations Rated insulation voltage U 250 V control circuit 300 V Pollution severity 3 400 V output contacts Overvoltage category Ill to DIN VDE 0110 Rat
22. ack Control logic Channel 1 Channel 2 NOT AUS 14 24134 42 C571 C573 T Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com 7 41 AC 1000 11 03 AO re ae Ge os S Application examples C571 AC Safety gate monitoring category 2 acc to EN 954 1 24 V AC DC 1 1 open closed n 1 g open closed The safety relay C 571 AC can be used in EMERGENCY STOP circuits as per EN 418 and in safety circuits as per VDE 0113 Part 1 11 98 and or EN 60 204 1 12 97 e g with movable covers and safety gates Depending on the external connections safety categories 3 and 4 as per DIN EN 954 1 are achievable When the safety combination is used in automatic start mode automatic restart ing as per EN 60 204 1 sections 9 2 5 4 2 and 10 8 3 must be prevented by the higher level control system in the event of EMERGENCY STOP Functions and connections The safety relay C 571 AC has two release circuits safety outputs which are con figured as NO contacts The number of safety outputs can be increased by adding one or more C 579 extension modules Three LEDs indicate the operating state and function When the EMERGENCY STOP button or the limit switch is unlocked and when the ON button is pressed the internal circuits of the safety relay and the external contactors are checked for proper functioning Connect the E
23. ate operating state and function The device is controlled via any release circuit of the safety relays C 57x When the EMERGENCY STOP pushbutton or the limit switch is unlocked and the ON button is pressed the internal circuit of the safety relay and the external contactors are checked for correct functioning EG Termina marking Supply voltage A1 L A2 N Outputs 13 14 Safety output 1 n o contact 23 24 Safety output 2 n o contact 33 34 Safety output 3 n o contact 43 44 Safety output 4 n o contact Feedback loop 51 52 Monitoring of the extension unit Internal circuit 14 24134 44 5 EMERGENCY STOP Safety category 4 acc to EN 954 1 24 V AC DC EMERGENCY STOP 4 7 N 7 48 AC 1000 11 03 Channel 1 Channel 2 PS Safety output of C 57x safety relays op o o a o o Faults Relay fusion welded Defect in electronics Motor contactor fusion welded O Ss l Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length For 2 x 1 5mm max 1000m total cable length for 150nF km sensors and power supply lines Safety gate monitoring Safety category 4 acc to EN 954 1 24 V AC DC L 13 23 33 51 lyaaly34l Y43 i Ao PE N N I i ii ai 13 23 33 43 51 K1 K6 Loa open closed 13123 31 147 57 TAL lvi yY11lY12lY211Y22
24. category 2 acc to EN 954 1 Lir EIN Ki 4 K2 aije yaslysa fejz L 50 60Hz EMERGENCY STOP Two channel EMERGENCY STOP with additional ON button Safety category 3 and 4 acc to EN 954 1 L EIN K1 4 K2 Al Y11 Y12 _ LY33 Y34 E 3 23 L 50 60 Hz EMERGENCY STOP sE i T i 14 24 C K1 K2 N A Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Application examples Sapo C572 Application The safety relay C 572 can be used in EMERGENCY STOP circuits as per EN 418 in safety circuits as per VDE 0113 Part 1 06 93 and or EN 60 204 1 12 97 e g with movable covers and safety gates Depending on the external connection safety category 4 as per DIN EN 945 1 is achievable with this device Functions and connections The safety relay C 572 has three release circuits Safety outputs which are configured as NO contacts and two signal circuits configured as an NC contact Three LEDs indicate operating state and function When the EMERGENCY STOP pushbutton or limit pushbutton is unlocked and the ON pushbutton is pressed the redundant safety relays electronic circuitry and external contactors are tested for proper functioning On the C 572 the ON circuit Y33 34 is checked for short circuit This means that a fault ist detected when Y33 34 is closed before the EMERGENCY STOP button is closed Terminal marking Supply A1 L
25. ce to device characteristics Characteristics suitable for device C570 C571 C572 C573 C574 C575 C576 C577 C578 C579 C 6700 C 6701 C 6702 EMERGENCY STOP yes yes yes yes yes yes yes a yes yes yes Safety gate monitoring yes yes yes yes yes yes yes aa yes yes yes Two hand control yes s e g presses Feedback loop for moni yes yes yes yes yes yes yes yes yes yes yes toring of external contactors Two channel a yes yes yes a yes yes yes i yes yes yes 24VDC at the EMERGENCY yes yes yes yes yes yes yes yes STOP limit switch Operating voltage at the yes yes yes yes EMERG STOP limit switch No of time delayed 1 1 safety output contacts Monitoring overtravel yes e g presses Possible with additional external measures Applies only to undelayed contact Category 3 applies to delayed contact Contact extension Solid state outputs requirements of safety in acc to 954 1 only in combination with positively guided contactors Solid state outputs could also be used as safe messaging outputs 7 40 AC 1000 11 03 Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Application examples Sop C570 C571 C573 Information The safety relays are tested by BIA The shown external wiring diagrams application examples are examples of use only A risk appraisal has to be done by the user Further application examples on request C570 Application The safety
26. ch every time the control voltage is switched on The permissible overtravel distance corresponds to dimension s of the cam that is used to operate the position switch Obtain dimension s from the press manufacturer in accordance with ZH 1 456 published by the German central office for accident prevention and labour safety Cologne Terminal marking Supply A1 L voltage A2 N Outputs 13 14 Safety output 1 tool down 23 24 n o contact tool up 33 34 n o contact overtravel distance OK 41 42 n c contact hydraulic pump ON Inputs Y11 12 13 14 Feedback loop K4 21 22 Position switch S4 Y31 32 33 34 Top dead centre switch S3 External circuit PA ft T C 575 two hand control unit SO Main switch DoD i S1 S2 keys at two hand K4 control console ia t ___ 883 Position switch for top Y22 Y23 13 23 31 41 A1 Y11Y 1213 14 Y21 2713 23 33 41 dead centre e 1 S4 Position switch for test cam eats O 2 0 24 32 42 RN To a s6 N K4 N di K4 A1 Y11lY12 S5 Hydraulic pump ON S6 Tool up manual mode K1 Contactor for hydr pump K2 Tool up K3 K4 Tool down H1 Indicator light eeg H1 K1 Sa Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Fey Up 9 Wy Operation Sequence of operations after the press has been switched
27. contacts of the relays comply with the requirement in respect of posi tively driven operation to ZH 1 457 Edition 2 1978 This means that NO contact and NC contact may not be closed simultaneously Safety relays with positively driven contacts are used in the newly developed safety switching devices C 571 C 574 C 576 C 577 the contact expansion C 579 and on the press controllers C 575 and C 578 This series of devices is character ised by an extremely narrow design 22 5mm and 45 mm Approvals and test certificates conventional on the market have been issued by BG SUVA UL and CSA The function of the internal contactor relays relays is monitored in a redundant circuit In the event of failure of a relay the safety switching device always switches to de energised state The fault is detected and the safety switching device can no longer be switched on Using normally closed contacts and normally open contacts for the same function complies with the re quirement in respect of diversity Enable contacts FK The safety related function must be controlled via safe output contacts the so called Enable contacts Enable contacts are always normally open contacts and switch off without delay Signalling contacts MK Normally open contacts and normally closed contacts which may not perform safety related functions are used as the signalling contact An Enable contact may also be used as a signalling contact S So he
28. ction is always retained The faults are detected in good time to prevent loss of the safety function This mandatory classification runs likes a red thread from selection of the smallest limit switch through to the overall concept of the entire machine whereby it is necessary to grapple with the permanent conflict between what is technically feasible and what is permitted on the basis of pure theory Thus Depending on application not every technically feasible safety category is also permitted For instance in the case of contactless protection devices light barriers etc only categories 2 or 4 are permitted By contrast in the case of tread mats categories B to 4 can be used depending on risk assessment provided these categories can be reached at all owing to the design The 2 hand control C575 would technically also comply with the lower categories but it cannot be connected in categories 1 3 The categories are not intended to be applied in any specific order or hierarchical arrangements with respect to the technical safety requirements The risk assessment will indicate whether full or partial loss of the safety function s as the result of fault is acceptable 7 38 AC 1000 11 03 Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Personnel and machine protection Classification of a machine into categories to EN 954 1 Pursuant to the Machinery Directive 89 393 EEC ev ery machi
29. d power supply lines Autostart and safety gate monitoring Safety category 4 acc to EN 954 1 Monitored start for EMERGENCY STOP Safety category 2 acc to EN 954 1 Monitored start for EMERGENCY STOP Safety category 3 and 4 ac to EN 954 1 7 48 AC 1000 11 03 cP oS oy C574 re 5 Application The safety relay C 574 can be used in EMERGENCY STOP devices as per EN 418 in safety circuits as per VDE 0113 Part 1 06 93 and or EN 60 204 1 12 97 such as for monitoring safety gates or in circuits with controlled stand still requirement STOP Category 1 Depending on the external circuitry this device can be used to realize Safety Category 4 instantaneous release circuits and Safety Category 3 delayed release circuits according to DIN EN 954 1 Functions and connections The C 574 safety relay possesses two delayed and two instantaneous re lease circuits safety outputs as NO contacts and one instantaneous signal output as NC contact Five LEDs indicate the operating status and the func tions The redundant safety relays the electronics and the operated motor contactors are tested for proper functioning when the EMERGENCY STOP button or the limit switch button is unlatched and when ON circuit Y33 Y34 is closed On the C 574 monitored start the ON circuit Y33 34 is checked for short circuit This means that a fault ist detected when Y33 34 is closed before the EMERGENCY STOP button is closed Termina
30. devices can be used for EMERGENCY STOP applications up to maximum category 4 to EN 954 1 Depending on external wiring and cable routing of the sensors category 3 resp 4 to EN 954 1 must be reached Safety door monitoring Pursuant to EN 1088 a distinction is made between interlocked separating protective devices and inter locked separating protective devices with follower Here as well the safety switching devices are used for EMERGENCY STOP applications Controls up to category 4 to EN 954 1 are possible Presses and punches The two hand control C 575 is a device on which the operator must use both hands simultaneously thus protecting him against risks and dangers The overtravel monitor C 578 is used on linear driven presses e g hydraulic pneumatic and spindle presses in accordance with VBG7n52 It checks for the following only once during the test stroke Correct connection of the operating controls External cable discontinuity Possible failure of the components to be monitored cyclically The overtravel monitor can be used only in conjunc tion with a two hand control The press controllers and overtravel monitors are suitable for installation in controls for eccentric hydraulic and spindle presses They can be used up to category 4 to EN 954 1 Type Ill C to DIN 574 is possible specifically for presses Device construction The safety switching device C 570 operates internally with several contactor relays The
31. ed impulse strength Uimp 4kV Pollution severity 3 4 kV output contacts Permissible ambient temperature for operation 25 to 55 C 25 to 60 C suitable for butt mounting design for storage 25 to 80 C 40 to 80 C Enclosure 15 EN 6052S P20 Shock hazard protection to VDE 0106 Safe from finger touch Rated power DC AC operation at 1 0 x U 6 W 15W 3W 15W 4W 3 W 15W 15W 4W 1 5 W Operating range AC operation 0 8 to 1 1 x Us 0 85 to 1 1 x Us DC operation 0 8 to 1 1 x Us 0 85 to 1 1 x Us Switching frequency 500 h 1000 h when loaded with at AC 15 resp DC 13 Resistance to shock Rectangular shock 10 5 and 6 10 g ms 8 9 10 ms Sinusoidal shock 30 5 and 8 10 g ms semi sinusoidal to IEC 60 068 Short circuit protection non welding fusing at 1kA Fuse links for Enable signalling Fuse links I v h b c Type 3NA DIAZED Type 5SB NEOZED Type 5SE6A contacts I v h b c neozed and diazed Utilisation category gL gG quick acting utilization cats gL gG quick acting Fuse supply C570 Cartridge fuse quick acting slow blow power circuit bkr A B C characteristic Wire ranges Flexible with wire end ferrule 2 x 0 5 1 5 mm or 1 x 0 5 2 5 mm Single core 2 x 0 5 2 5 mm or 1 x 0 5 4 mm Tightening torque terminal screw M3 5 Electrical service life at a 100 000 operations Rated operating currents to IEC 60 947 5 1 Thermal continuous current lip 6A 5A AC 15 115 V 5A up to 230 V 4A 230 V
32. ed in safety circuits as per LEDs Operation VDE 0113 Part 1 11 98 or EN 60 204 1 11 98 e g with movable covers and safety gates the safety relay C 577 in EMERGENCY STOP circuits as per EN POWER 1 2 Channel 2 PS E au ON Safety outputs ls Depending on external connections category 4 as per DIN EN 954 1 is xe activated closed achievable ieee i activated non open Functions and connections xt rere The safety relays C 576 C 577 have two release circuits Safety outputs configured lt as NO contacts The number of release circuits can be increased by adding one or Las CPEN more C 579 extension units activated activated Three LEDs indicate operating state and function When the EMERGENCY STOP button or the limit switch is unlocked Faults and when the ON button is pressed the internal circuit of the safety relay and the 2 Relay fusion welded open external contactors are checked for proper functioning Y Motor cont fusion welded On the C 577 the ON circuit Y33 34 is checked for short circuit Defect in electronic This means that a fault is detected when Y33 34 is closed before s Short circuit in ON circuit the EMERGENCY STOP button is closed The EMERGENCY STOP button or the limit switch are connected to terminals Y11 O Cross or ground faults in 12 21 22 The ON button is connected in series to the NC contacts of the external EMERGENCY STOP circuit contactors feedback loop to terminals Y33 34 min
33. fety combination have the same frame potential Paralleling outputs 14 and 24 to increase the load current is not permissible If electronic sensors e g light array monitoring are used in single channel operation Y35 must be connected to L 24VDC For autostart operation Y32 must be connected directly to L 24VDC and Y34 must be connected to it via NC contacts of the external actuators Use a power pack to IEC 60536 safety class III SELV or PELV for power supply Terminal marking Supply voltage A1 L A2 M Inputs Y11 12 Channel 1 EMERGENCY STOP or position switch Y21 22 Channel 2 EMERGENCY STOP or position switch Y35 With without cross circuit detection Y32 Autostart switch Y34 ON button feedback loop Input 1 Cascading input Outputs 14 24 Safe solid state outputs Internal circuit A1 vit yet Y35 Y32 Power pack Sensors Output 1 Output 2 Safety gate monitoring two channel autostart Category 4 SIL 3 L 11 ie Qz gt FERS Y35 Y21 Y22 A2 14 24 O M F C6701 A N n o Sensor circuits open Cross circuit between the sensors Short circuit of sensors to frame Only when using circuit variant with cross circuit detection Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Sox oy C ip tay vs Operation LEDs Operation POWER FAIL Outputs 2 xf a es ue activated on aT activated non off 1 activated
34. g to DIN EN 954 1 or SIL 3 according to IEC 61508 can be achieved Functions and connections The C 6702 solid state safety combination has one safe solid state output and one time delayed safe solid state output Three LEDs indicate the operating state and the function When the device is put into operation it runs through a self test to test the correct functioning of the internal electronics All internal circuit components are monitored for faults cyclically during operation The EMERGENCY STOP button and or the position switches or light arrays are connected to terminals Y11 Y12 and Y21 Y22 The ON button is connected in series with the NC contacts of the external The cascading input 1 is connected either via a safe output or directly to the supply voltage L 24 V DC External actuators or loads can be switched via safe outputs 14 28 It must be ensured that the actuators or loads and the C 6702 electronic safety combination have the same frame potential Paralleling outputs 14 and 28 to increase the load current is not permissible If electronic sensors e g light array monitoring are used in single channel operation Y35 must be connected to L 24VDC For autostart operation Y32 must be connected directly to L 24VDC and Y34 must be connected to it via NC contacts of the external actuators Use a power pack to IEC 60536 safety class Ill SELV or PELV for power supply Terminal marking Supply voltage A1 L A2 M I
35. intended for checking the overtravel of linearly operating hydraulic pneumatic and spindle presses in accordance with VBG 7n5 2 11 7 28 Discount schedule AR Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Type C579 LY o A w te ay S Voltage range Output contacts Safety Piece Catalog List 50 60Hz Instan Time category per unit number price taneous delay 24VAC 1SAR502040R0001 110VAC 1SAR502040R0004 390 230VAC 1SAR502040R0003 Description Expansion unit for contact expansion of the safety switching devices C 579 One enable contact of the basic device is required for connection to the expansion unit e 4 NO positively driven e Overall width 22 5 mm Application You can use the C579 expansion unit in combination with all the C57x basic units It extends the number of release circuits Depending on the external connection category 4 as per DIN EN 954 1 is achievable with this device Low Voltage Products amp Systems Discount schedule AR 7 29 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 7 30 AC 1000 11 03 Accessories Type Description i Pcs per Catalog List oz unit pk number price Cover cap sealable for protection against C560 10 unauthorized adjustment aC 1SAR390000R1000 30 5 sets C560 20 Panel mounting bracket 47 of two 1SAR390000R2000 22 pcs ea Low Voltage Products amp Systems
36. l marking Supply voltage A1 L A2 N Output 13 14 Safety output 1 instantaneous 23 24 Safety output 2 instantaneous 31 32 Signal output instantaneous 47 48 Safety output 1 delayed t 57 58 Safety output 2 delayed t Function Monitored Start 1 channel ON pushbutton Jumper from Y11 toY12 at Y33 34 Jumper from Y21 to Y22 EMERGENCY STOP circuits at Y10 11 2 channel Jumper from Y10 to Y11 EMERGENCY STOP circuits at Y11 12 and Y21 22 Internal circuit Power pack PTC fuse Control logic Channel 1 Channel 2 gt Channel 1 Channel 2 a Y34 Monitored start for EMERGENCY STOP Safety category 3 and 4 acc to EN 954 1 EMERGENCY j i A2 h4 24 32 48 58 7 44 AC 1000 11 03 So Application examples Operation LEDs Operation POWER PS E STOP ON Safety outputs 7 XE IIE Xe et non _ activated closed activated activated non open delay activated time elapsed non non open activated activated activated non FK 1 amp 2 open delay activated FK1 t amp FK2 t time closed elapsed Faults O it Relay fusion welded open A GER RIDOEI Motor cont fusion welded e Defect in electronic Short circuit in ON circuit Cross or ground faults in emergency trip circuit min fault current Ixmin 0 0A PTC fuse trips Fault clearance 1 Switch supply voltage off 2 Clear
37. l width 75mm Application The safety relay can be used to monitor Emergency Stop circuits and for monitoring of other protective devices i e safety gates 7 20 Discount schedule AR Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Type C571 LY fag to Y Voltage range Output contacts Enable contacts Auxiliary Safety Weight Piece Catalog List 50 60Hz category oz per unit number price 24VAC 1SAR501020R0001 A 1SAR501020R0003 280 115 VAC l 1SAR501020R0004 230 VAC 1SAR501020R0005 Description Emergency Stop monitor and safety gate monitor C571 e Auto start monitored start e Operating voltage Vc at Emergency Stop button or limit switch e Feedback loop for monitoring of external contactors e LED indicators for power channel 1 and 2 e Safety outputs 2 N O contacts positively guided e Width of enclosure 22 5mm Application Use the safety control gears C571 C573 in Emergency Stop devices as per EN418 and in safety circuits as per VDE 0113 Part 1 11 98 and or EN 60 204 1 11 98 e g with moveable covers and guard doors Depending on the external connections categories 3 and 4 with additional external measures as per DIN EN 954 1 are achievable Possible with additional external measures The digit in parenthesis applies only if the cables and sensors are laid safely and protected mechanically Low Voltage Products amp Systems Discount
38. le or two channel connection e Feedback circuit for monitoring external contactors e LED indicators for Power Channels 1 and 2 delayed channel 1 2 e Release time adjustable steplessly up to 30 s e Output 2 NO 1 NC 2 NO time delayed e Overall width 45 mm Application The safety relay C574 can be used in Emergency Stop devices as per EN 418 in safety circuits as per VDE 0113 Part 1 06 93 and or EN 60 204 1 12 97 such as for monitoring safety gates or in circuits with controlled stand still requirement Stop Category 1 Depending on the external circuitry this device can be used to realize Safety Category 4 instantaneous release circuits and Safety Category 3 delayed release circuits according to DIN EN 954 1 e Delay time 0 5 to 30 s stepless adjustment e Auto start 24VDC 2 N O 2 N O 1 N C 3 4 15 17 1 1SAR503141R0003 24VAC 2 N O 2 N O 1 N C 3 4 21 16 1 1SAR503141R0002 110VAC 2 N O 2 N O 1 N C 3 40 21 16 1 1SAR503141R0004 675 230VAC 2 N O 2 N O 1 N C 3 4 15 17 1 1SAR503141R0005 e Delay time 0 05 to 3 s stepless adjustment e Monitoring start 24VDC 2 N O 2 N O 1 N C 3 4 15 17 1 1SAR533241R0003 24VAC 2 N O 2 N O 1 N C 3 4 21 16 1 1SAR533241R0002 110VAC 2 N O 2 N O 1N C 3 40 21 16 1 1SAR533241R0004 675 230VAC 2 N O 2 N O 1 N C 3 4 15 17 1 1SAR533241R0005 Auto start 24VDC 2 N O 2 N O
39. n tabs C 560 20 see Selection data and Ordering details Accessories User Manual A User Manual with a device description connec tion diagrams and application information in several languages is enclosed with every safety switching devices of Series C 570 and C 67xx Safety Engineering Application Manual You can find further information in the Safety Engineering Application Manual It provides you with the required information on the relevant safety stan dards and project planning information The entire range of components used for safety ap plications is explained in this Manual from the sensor Emergency Stop command devices and position switches through evaluation units safety switching devices C 57x and fail safe control AC 31 S to the actuator e g contactor for switching motors All these components must be selected cor rectly in order to meet the requirements applicable to modern safety facilities Please order the Safety Engineering Application Manual 1SAC 103 201 H0101 German 1SAC 103 201 H 0201 English 7 39 AC 1000 11 03 ow ye Selection table se ee a Selection table for ABB safety relays in accordance to risk category EN 954 1 Category C 570 C 571 Gore G5 s C 574 C575 C 576 CIS C 578 C 6700 C 6701 C 6702 B O OO O i 1 Oox M e M l M e A l 2 EM EE EE EH E E 3 T le E EE e 4 XV X XV x X X X X X X Selection table for ABB safety relays in accordan
40. ne must comply with the relevant Directives and Standards Measures must be taken to keep the risk to persons below a tolerable extent In the first step the project planner performs a risk evaluation to EN 1050 Risk Assessment This must take into consideration the machine s ambient conditions for instance Any overall risk must then be assessed This risk assessment must be conducted in such a form as to allow documentation of the proce dure and the results achieved The risks dangers and possible technical measures to reduce risks and dan gers must be stipulated in this risk assessment After stipulating the extent of the risk the category on the basis of which the safety circuits are to be designed is determined with the aid of EN 954 1 Safety Related Components of Controls This determined category defines the technical requirements applicable to the design of the safety equipment There are five categories B 1 2 3 and 4 whereby B standing for basic category defines the lowest risk and thus also the minimum require ments applicable to the controller Possible selection of categories pursuant to EN 954 1 Starting point for risk assessment of the safety related components of the control Description Scope of application Potential risks and hazards posed by a machine must be eliminated as quickly as possible in the event of danger For dangerous movements the safe state is generally standstill All
41. nputs Y11 12 Channel 1 EMERGENCY STOP or position switch Y21 22 Channel 1 EMERGENCY STOP or position switch Y35 With without cross circuit detection Y32 Autostart changeover switch Y34 ON button feedback circuit Input 1 Cascading input Outputs 14 Safe solid state output 28 Safe solid state output time delayed Sensor circuits open Cross circuit between the sensors Short circuit of sensors to frame Only when using device with cross circuit detection 7 36 AC 1000 11 03 So Application examples Safety mat two channel autostart category 3 SIL 2 Operation LEDs Operation Tee spe fete non activated on activated ee non activated o D 8 activated no off on flashes IES te D on start up self test approx 7 sec flashes l i Fault Defect in electronic off xt D Change in terminal flashes assignment during operation Short circuit to 24V O No supply voltage Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 2000m total cable length for 150nF km sensors Internal circuit A1 Vit Yat Y35 Y32 poe 2S SSeS SO AO 0 0 77 na Power pack 6 3 A ll Sensors Output 1 Output 2 ai ae ee es ee OC ee y a Oe a Ce eS ee eS eS ee CYS Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Application examples Son Foy Of Op C6
42. ntacts are a clear and manageable terminal designation located in two mutually independent positive system This allows wiring errors to be action all or nothing relays which monitor minimized each other by means of a special purpose In addition to all these safe features the C57x circuit safety relays correspond to the product design of Diversity is provided thanks to the ABB s range of switchgear and control systems combination of N C contact and N O contact They 1 in perfectly with the overall design of the Cyclic monitoring of the safety circuit in each switch cabinet On Off cycle ensures maximum reliability Thanks to the two channel control and or control which is immune to shorts across Safety relays Electronic Spec Tech Industrial 203 Vest Ave Valley Park MO 63088 Phone 888 SPECTECH Fax 636 537 1405 www spectechind com Low Voltage Products amp Systems 7 19 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 wv Type C570 O x oy oS oe Voltage range Output contacts Enable contacts Auxiliary Safety Weight Piece Catalog List 50 60Hz category oz per unit number price taneous delay 1SAR501042R0003 24VAC 1SAR501042R0002 870 110VAC 1SAR501042R0004 230VAC 1SAR501042R0005 Description Single channel connection e Feedback circuit for monitoring external contactors e LED indicators for power and operation e Output 4 N O and 1 N O amp 1 N C positively driven e Overal
43. or monitor C577 e Cross short detection at the Emergency Stop button or limit switch e 24 V DC at the Emergency Stop button Single or two channel connection e Feedback circuit for monitoring external contactors e LED indicators for Power Channel 1 Channel 2 and Power e Output 2 NO e Controlled start r e Overall width 22 5 mm Application The safety relay C576 can be used in safety circuits as per VDE 0113 Part 1 11 98 or EN 60 204 1 11 98 i e with mov able covers and safety gates the safety relay C577 in Emergency Stop circuits as per EN 418 Depending on external con nections category 4 as per DIN EN 954 1 is achievable Low Voltage Products amp Systems Discount schedule AR 7 27 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 of Type C578 O Ors oS Ge Voltage range Output contacts Safety Weight Piece Catalog List 50 60Hz VDC Instan Time category oz per unit number price taneous delay 24VDC 1SAR505031 ROO03 24VAC a 1SAR505031R0002 110VAC S AAR e ca S 1SAR505031R0004 out 230VAC 1SAR505031R0005 Description Overtravel monitor C 578 e Cross short detection at the EMERGENCY STOP button or limit switch 24 V DC at the EMERGENCY STOP button e Feedback circuit for monitoring external contactors e LED indicators for Power and Enable Output 3 NO and 1 NC positively driven e Controlled start e Overall width 45 mm Application The overtravel distance tester C578 is
44. rame potential Safety category 3 to EN 954 1 is achieved only in combi nation with 2 external actuators with positively driven feedback contacts Use a power pack to IEC 60536 safety class III SELV or PELV for power supply Terminal marking Supply voltage A1 L A2 M Inputs Y11 12 Channel 1 EMERGENCY STOP or position switch Channel 2 EMERGENCY STOP or position switch Y20 Single channel switch Y33 34 ON button feedback loop 14 24 Solid state outputs Y21 22 Outputs Internal circuit Power pack Control logic Output 1 Output 2 Two channel autostart for safety gate monitoring Category 3 SIL2 7 34 AC 1000 11 03 LEDs Operation G non activated on activated xt activated non off activated non non off activated activated Faults e Defect in electronic off oe D e Crossover in EMERGENCY STOP circ Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 2000m total cable length for 150nF km sensors EMERGENCY STOP single channel with monitored start Category 3 SIL2 4 EIN Q Y20 Y21 Y22 A2 44 24 k1 K2 EMERGENCY STOP single channel with monitored start Category 2 SIL1 EMERGENCY STOP q y s o 5 Y20 Y21 Y22 A2 14 24 K1 K2 M Single channel autostart for safety gate monitoring Category 2 SIL1 L
45. relay can be used to monitor EMERGENCY STOP circuits and for monitoring of other protective devices e g safety gates EMERGENCY STOP circuit 23no 43no 65nc C570 14No 34no 58no C571 C573 Application The safety relays C 571 C 573 can be used in EMERGENCY STOP circuits as per EN 418 and in safety circuits as per VDE 0113 Part 1 11 98 and or EN 60 204 1 11 98 e g with movable covers and guard doors Depending on the external connections categories 3 and 4 with additional external measures as per DIN EN 954 1 are achievable Functions and connection The safety relay C 573 has three release circuits Safety outputs which are configured as NO contacts and a signal circuit configured as a NC contact The safety relay C 571 has two release safe circuits which are configured as NO contacts The number of release circuits can be increased by adding one or more C 579 extension units Three LEDs indicate the operating state and function When the EMERGENCY STOP button or the limit switch is unlocked and when the ON button is pressed the internal circuits of the safety relays and the external contactors are checked for proper functioning Connect the EMERGENCY STOP pushbutton or the limit switch in the supply cable from A1 to 24 or L24 V To evaluate over two channels connect Channel 2 from A2 to 0 V or N Connect the ON button in series with the NC contacts of the external contactor feedback loop between terminals Y1 and Y
46. safety switching devices of Series C 570 switch to de energised state i e standstill for drives in the event of danger or fault Standard EN 60204 demands that every machine must feature the Stop function of category 0 Stop functions of categories 1 and or 2 must be pro vided if necessary for technical safety and or techni cal function requirements of the machine Category 0 and category 1 stops must be operable independently of the operating mode and a category 0 stop must have priority There are three categories of stop function Category 0 Shut down by immediate switch off of the energy sup ply to the machine drives Category 1 Controlled shut down whereby the energy supply to the machine drive is retained in order to achieve shut down and the energy supply is only interrupted when shut down has been reached Category 2 A controlled shut down in which the energy supply to the machine drive is retained EMERGENCY STOP EMERGENCY STOP devices must have priority over all other functions The energy supplied to the machine drives which may cause dangerous states must be switched off as quickly as possible without further risks or dangers Resetting of the drives may not trigger a restart The EMERGENCY STOP must act either as a stop of category 0 or as a stop of cat egory 1 Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com The basic device of the 570 Series of safety switch ing
47. schedule AR 7 21 ABB Inc 888 385 1221 www abb conirol com AC 1000 11 03 wv Type C572 O N AX og os Ge Voltage range Output contacts Safety Weight Piece Catalog List 50 60Hz VDC Instan Time category oz per unit number price taneous delay 24VDC 0 360 1SAR501032R0003 24VAC 3 N O 2 N C 4 0 450 1 1SAR501032R0002 520 110VAC 3N 0 2N C 0 450 1SAR501032R0004 230VAC 3N 0 2N C 0 360 1SAR501032R0005 Description Emergency Stop monitor and safety gate monitor C572 e Auto start monitored start e 24 VDC at Emergency Stop button or limit switch e Cross short circuit detection at Emergency Stop button or limit switch e Feedback loop for monitoring of external contactors e LED indicators for power channel 1 and 2 Safety outputs 3 NO contacts positively guided e Signalling contacts 2 NC contacts positively guided e Width of enclosure 45mm Application Use safety control gear C572 in Emergency Stop devices as per EN 418 in safety circuits as per VDE 0113 Part 1 06 93 and or EN 60 204 1 12 97 e g with moveable covers and guard doors Depending on the external connection safety category 4 as per DIN EN 945 1 is achievable with this device 7 22 Discount schedule AR Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Type C573 Soo Voltage range Output contacts woe Enable contacts Auxiliary Safety Piece Catalog List VDC
48. ts amp Systems Discount schedule AR 7 25 ABB Inc 888 385 1221 www abb control com AC 1000 11 03 wv Type C576 Voltage range Output contacts VDC Instan Time category taneous delay 2avoc 2N0 4 847 1 1SARs01120R0001 List price Piece Catalog 50 60Hz per unit number Description Emergency Stop switching device and safety door monitor C 576 e Cross short detection at the EMERGENCY STOP button or limit switch 24 V DC at the EMERGENCY STOP button Single or two channel connection e Feedback circuit for monitoring external contactors e LED indicators for Power Channel 1 Channel 2 and Power e Output 2 NO e Auto start e Overall width 22 5 mm Application The safety relay C576 can be used in safety circuits as per VDE 0113 Part 1 11 98 or EN 60 204 1 11 98 i e with movable covers and safety gates the safety relay C577 in Emergency Stop circuits as per EN 418 Depending on external connec tions category 4 as per DIN EN 954 1 is achievable 7 26 Discount schedule AR Low Voltage Products amp Systems AC 1000 11 03 ABB Inc 888 385 1221 www abb control com Type C577 8 Me Fey A w Op te 7 Voltage range Output contacts Safety Piece Catalog List 50 60Hz VDC Instan Time category per unit number price taneous delay 24VAC 24VDC 2N 0 4 8 47 1 1SAR501220R0001 350 Description Emergency stop switching device and safety do
49. ts are operated simultaneously so that 8 functions can be selected no Ym no instantaneous contact Positively guided N C and N O contacts are never closed both contact distance of 22 5mm is guaranteed minimum switching load 12V 3mA 1SAR390000R2000 22 00 QOmnmmMvoagw gt Technical data Time relay C 565 S Mechanical service life operations 30x 106 Rated insulated voltage Pollution degree 3 ACV 300 Overvoltage categorie Ill acc to DIN VDE 0110 Permissible ambient temperature during operation C 25 to 60 1SAR390000R4000 storage C 40 to 80 Operating range of excitation 0 85 to 1 1 x U with AC 0 8 to 1 25 x U with DC 0 95 to 1 05 times rated frequency Rated power Wi 2 at AC 230V 50 Hz VA 6 Terminal positioning C 565 S Rated operating currents AC 15 at AC 230V 50 Hz A 3 Output relay AC 140 DC 13 DC 13 at DC 24V AJ 1 DC 13 at DC 48V A 0 45 DC 13 at DC 60V A 0 35 DC 13 at DC 110V AJ 0 2 DC 13 at DC 230V A 0 1 Fusing DIAZED Utilization category gL gG A 4 Switching frequency g i i when loaded with AC 230V 1 h 2500 apaa e when loaded with contactors B6 B7 AC 230 V 1 h 5000 Terminals A B Recovery time ms 150 Minimum ON period ms 35 Setting tolerance referred to full scale value typically 5 Repeat accuracy lt 1 Enclosure IP 20 terminals Circuit di C 565 S acc to DIN EN 60 529 IP 40 covers ircuit diagram C 565 Wire size single core mm in
50. voltage A2 N Outputs 13 14 Safety output 1 n o 23 24 Safety output 2 n o 33 34 Safety output 3 n o 41 42 Signal output 1 n c 51 52 Signal output 2 n c Function Monitored Monitored start Autostart start Autostart 1 channel ON push button Jumper from Y11 to Y12 Feedback loop at Y33 34 Jumper from Y21 to Y22 or jumper to EMERGENCY STOP Y33 34 and circuits at Y10 11 jumper from 2 channel Jumper from Y10 to Y11 Y43 auf Y44 EMERGENCY STOP Important circuits at Y11 12 and Y21 22 Y21 22 must be closed before or at the same time as Y11 12 Internal circuit T Poar perk PTC lee 0 Coira logic 1 2 Chena 7 i Charani 2 Ht Hel THT oe tee HE Low Voltage Products amp Systems ABB Inc 888 385 1221 www abb control com Operation states LEDs POWER Channel 1 Channel 2 1 Operation PS E STOP ON Safety outputs activated closed Pere activated non open activated non open pene activated Faults zi Relay fusion welded open a Se Channel 2 Motor cont fusion welded Defects in electronic Short circuit in ON circuit Cross or ground faults in EMERG STOP circuit min fault current Ixmin 0 5A PTC fuse trips or supply voltage missing Fault clearance 1 Switch supply voltage off 2 Clear fault or replace device 3 Switch supply voltage back on Cable length for 2 x 1 5mm max 1000m total cable length for 150 nF km sensors an
51. witching elements C 67xx safety relays are solely used to monitor the sensors connected e g limit switches resp EMERGENCY STOP buttons and actuators positively guided standard contactors The basic unit C 6700 itself does not feature safe outputs Only when the unit is used together with positively guided actuators e g contactors B6 B7 the complete circuit fulfills up to category 3 to EN 954 1 Us 24VDC Ue 24VDC le 0 5ADC 13 The safety relay C 6701 with solid state outputs can be used directly to switch off connected devices up to category 3 or 4 to EN 954 1 Us 24VDC Ue 24VDC le 1 5ADC 13 The safety relay C 6702 with solid state outputs can also be used to directly switch off connected devices up to category 3 to EN 954 1 and stop categories 0 and 1 at a width of 22 5 mm only Time delay settable from 0 05 3 or 0 5 30s Us 24VDC Ue 24VDC le 1 5ADC 13 Type Supply voltage Package Weight Catalog List Vo unit 1 piece number Price piece kg Ib C 6700 1SAR 510 120 R 0003 C 6701 0 150 0 33 1SAR 511 320 R 0003 Consult C 6702 1SAR 543 320 R 0003 factory C 6702 1SAR 513 320 R 0003 Technical data C 6700 C 6701 C 6702 Permissible ambient temperature Ty Operation storage Degree of protection acc to EN 60 529 25 60 C 40 4 80 C IP40 IP20 at terminals Rated insulation voltage V SOV Rated impulse withstand voltage Vimp 500V 2kV 2kV Rated control supply voltage Vs 24VDC 24VDC 24VDC
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