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704598 / 01 04 / 2012 Original operating instructions Safety relay

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1. 4 Functions and features The safety relay is a redundant system and suited for use as Safety relay for fail safe sensors switches with 2 PNP outputs e g GM701S chapter 8 1 Safety relay for clocked fail safe sensors e g GM504S chapter 8 2 Two hand control to EN 574 type IIIC with electronic sensors switches chapter 8 3 Two hand control to EN 574 type with mechanical switches safety relay for mechanical switches or 2 channel fail safe sensors switches e g ESPE to EN 61496 1 with contact output with simultaneity monitoring chapter 8 4 Safety relay for e stop for two channel fail safe sensors switches e g ESPE to EN 61496 1 with contact output without simultaneity monitoring indefinite simultaneity or for mechanical switches chapter 8 5 u ifm electronic gmbh assumes no liability for the use of units made by external manufacturers The safe state is when the output is switched off zero current state logic 0 of at least one of the semiconductor outputs 13 or 14 C1 4 1 Requirements for the hardware configuration The following requirements must be complied with when using the safety relay G1503S 41 1 Product independent requirements It must be ensured that the safety requirements of the respective application correspond to the requirements stated in these instructions The specified technical data indicated in these instructions must be complied with The pr
2. Connection A2 A3 exchanged Overvoltage Undervoltage Overvoltage Undervoltage gt Check wiring gt Check power supply Check wiring Switch the safety relay off and on again Check output circuit Check feedback contacts Exchange external contactor Check wiring Open contacts and RESET or voltage failure Check wiring Check wiring Check power supply Check wiring Check power supply LED display Cause of the fault Troubleshooting Undervoltage gt Check wiring gt Check power supply Short circuits gt Check wiring s Inputs S34 and S43 not gt Check wiring e activated within 0 5 s 8 4 2 o Feedback contact error K2 E2 Fault Short circuit 534 544 gt Deactivate inputs and activate them again 37 8 5 Safety relay for e stop for 2 channel fail safe sensors switches with contact output without simultaneity monitoring or for mechanical switches The 2 channel fail safe sensors switches are for example electro sensitive protective equipment ESPE to EN 61496 1 EB The contacts of the sensors switches must allow a minimum current of 6 mA 8 5 1 Connection Connection e stop 2 channel fail safe sensors switches BEER IF 1 Fail safe sensor switch Connection of two mechanical switches LEGER EERE _ 1 Mechanical switch 1 2 Mechanical switch 2 8 5 2 Function Input circuit Output status LED display 1 Fail safe senso
3. In case of a fault the voltage can exceed the value of 60 V DC for a maximum of 200 ms but must not exceed the value of 120 V DC gt Connect supply voltage L Manual reset L RESET For safety reasons the unit can only be restarted by H separation from the supply voltage in case of a fault It is thus recommended to install a RESET switch in series with the L circuit MAT After power on or a RESE T the unit carries out self diagnostic functions After this self diagnosis the unit is ready for operation 10 7 2 Feedback contacts monitored or automatic start Automatic start A1 Automatic activation without monitoring Monitoring of the feedback contacts normally closed for automatic start 1 Feedback contact Monitored start Release is made when the feedback contacts are closed Consider the current flowing through the feedback contacts 10 Technical data Release of the solid state outputs gt Press and release the start button gt 50 ms This function is not active when used as two hand control Monitoring of the feedback contacts normally closed for monitored start MEL 1 Feedback contact 2 Start button Release of the solid state outputs The feedback contacts are closed gt Press and release the start button gt 50 ms This function is not active when used as two hand control Consider the current flowing through the feedback conta
4. failures MTTF Mean Time To Dangerous Failure OSSD Output Signal Switching Device Output signal switch element static safety related output PFH Probability of dangerous PFH Failure per Hour PL Performance Level PL to EN ISO 13849 1 IL Safety Integrity Level SIL 1 4 to IEC 61508 PLC Programmable Logic Controller Technical data and further information at www ifm com Select your country Data sheet direct S
5. scanner 8 1 1 Connection Fail safe sensor switch with a current consumption of S 50 mA gsm 1 Fail safe sensor switch Fail safe sensor switch with a current consumption of gt 50 mA RE 2 1 Fail safe sensor switch 8 1 2 Function Input circuit Output status 1 01 055 0 1 05502 0 I 1 05501 0 1 02 055 0 gt 0 55 Stop flashing gt Activate inputs in correct time sequence fig above LED display Input circuit Output status LED display 16 Input circuit Output status LED display 1 0 05502 543 05501 534 17 8 1 3 Fault diagnosis In case of a fault switch the safety relay off and on again LED display Cause of the fault Troubleshooting 18 K1 Power e K2 Fault K1 Power ok e OO O K2 E2 Fault K1 E1 Power e o K2 E2 Fault No voltage supply Overvoltage Connection A1 A3 or A1 A2 reversed Wire break Feedback contacts open When voltage is applied feedback contacts open Wiring fault Short circuit Inputs 534 and S43 1 when voltage is applied Short circuit 533 543 Short circuit 533 543 gt Check wiring gt Check power supply Check wiring Switch the safety relay off and on again Check output circuit Check feedback contacts Exchange external contactor Check wiring Switch the fail safe sensor switch off and on again Check wiri
6. C 04 2012 704598 01 ifm electronic Original operating instructions Safety relay with semiconductor outputs efectorno 1503 DOO eee Contents MOIS EU TM TS 4 4 5 Me UN UE 6 4 F nctions and features LLULLU LULU aa art 6 4 1 Requirements for the hardware configuration 7 4 1 1 Product independent requirements f 4 1 2 Product dependent requirements 7 5 Structure and operating principles 8 5 1 Indicators and CONNECTIONS ULU 8 s a aol eer rece earner et tere 9 10 7 Electrical connection 10 1 Supply VONAGE mmmmmmmm mm mmmmm mmmm mmmmm mm mm mmmrmrmrmrmm 10 7 2 Feedback contacts monitored or automatic 5 11 eT D RET 12 8 Connection Function Fault diagnosis 13 8 1 Safety relay for fail safe sensors switches with 2 PNP outputs 14 BL ei serren 14 LE a co 15 8 1 3 Fault diagnosis mn n nee 18 8 2 Safety relay for clocked fail safe sensors 20 COMECON 20 022 FUNCION 23 8 2 3 FUN CIACMOSIS mmmmm m m m m m m mmmmmm mm m mrmrmrmmrmrmrmrmrmrmrmrmrmrmrmrmrmmm 24 8 3 Two
7. afety relay with semiconductor outputs Terminal block Phoenix Contact MSTBO Conforms to the requirements of EN ISO 13849 1 2008 category 4 PL e SIL 3 IEC 61508 type EN 574 semiconductor 2 OSSD 2 safe short circuit proof semiconductor outputs positive switching 1 signal output positive switching 24 V DC 19 2 30 incl 5 residual ripple Output current per safe 100 mA semiconductor output 13 14 Min load current of the feedback 10 mA contacts Short circuit protection overload short circuit proof and overload protected protection semiconductor outputs overvoltage max 13 14 60 V DC duration 120 V 200ms Current consumption lt 500 mA Function display voltage green error 1 x red output status 2 x yellow input 2 x yellow Power on delay time Duration of switch off test pulses lt 500 us Voltage drop per OSSD lt 2 5 V 100 mA Response time ms acc to input circuit chapter 8 1 8 2 8 3 8 4 8 5 110 ms m Input characteristics 534 43 1 gt 11 V 6 mA 0 lt 5 V lt 500 uA Output characteristics 33 push pull short circuit proof 0 ad 30 mA 1 luc gt 50 mA U gt 18 V S44 0 Ip lt 300 uA 1 Fouce gt 50 mA U gt 18 V 0 Ip lt 300 uA 1 luc gt 11 V 30 mA gt 15 V 15 mA DC CCF Cat gt 99 80 4 Comments Additional information in the context with the cULus approval UL 508 Maximum ambient tempera
8. cts 10 Technical data 7 3 Output circuit Connect the load 12 gt Connect the load to be controlled to the semiconductor outputs C1 13 14 Adhere to the maximum and minimum load conditions 10 Technical data Output Y7 provides a non safety related signal for communication to a PLC The signal corresponds to the logical levels of the safe semiconductor outputs 13 14 The output data is compatible with the input data of the current sinking inputs of type 1 2 3 to EN 61131 2 8 Connection Function Fault diagnosis The safety relay can be connected or used in different ways 1 Safety relay for fail safe sensors switches with 2 PNP outputs e g GM701S 2 Safety relay for clocked fail safe sensors e g GM504S 3 Two hand control to EN 574 type 1 with electronic sensors 4 Two hand control to EN 574 type with mechanical switches safety relay for mechanical switches or 2 channel fail safe sensors switches e g ESPE to EN 61496 1 with contact output with simultaneity monitoring 5 Safety relay for e stop for two channel fail safe sensors switches e g ESPE UK to EN 61496 1 with contact output without simultaneity monitoring indefinite simultaneity or for mechanical switches 8 1 Safety relay for fail safe sensors switches with 2 PNP outputs Example of fail safe sensors switches Fail safe inductive sensor GM701S Light barrier Light curtain ESPE to EN 61496 1 Laser
9. e may result in malfunctions of the unit This can lead to personal injury and or damage to property during operation of the machine For this reason note all remarks on installation and handling given in these instructions Also adhere to the safety instructions for the operation of the whole installation n case of non observance of notes or standards specially when tampering with and or modifying the unit any liability and warranty is excluded The unit must be installed connected and put into operation by a qualified 3 electrician trained in safety technology The applicable technical standards for the corresponding application must be complied with Forinstallation the requirements according to EN 60204 must be observed n case of malfunction of the unit please contact the manufacturer Tampering with the unit is not allowed Disconnect the unit externally before handling it Also disconnect any independently supplied relay load circuits After setup the system has to be subjected to a complete function check Only use the unit under the specified operating conditions 10 Technical data In case of special operating conditions please contact the manufacturer Useonly as described below 4 3 Items supplied e 1 safety relay G1503S 1 operating instructions safety relay reference 704598 If one of the above mentioned components is missing or damaged please contact one of the ifm branch offices
10. g EVT001 bn brown bu blue 22 8 2 2 Function Input circuit Output status LED display 1 First or last fail safe sensor switch of a row of sensors switches 2 td 16 ms 23 8 2 3 Fault diagnosis In case of a fault switch the safety relay off and on again LED display Cause of the fault Troubleshooting 24 K1 E1 Power OO O OO O K2 E2 Fault K1 E1 Power K2 E2 Fault K1 E1 Power ox e ox e K2 E2 Fault K1 E1 Power ok e OO O K2 E2 Fault K1 E1 Power oe o K2 E2 Fault No voltage supply Overvoltage Connection A1 A2 reversed gt Check wiring gt Check power supply Wire break Feedback contacts open Time dependent contacts Check wiring Switch the safety relay off and on again When voltage is applied feedback contacts open Check output circuit Check feedback contacts Exchange external contactor Check wiring Short circuit Connection A1 A3 or A2 A3 exchanged gt Short circuit S43 L or S44 L Check wiring Short circuit 534 544 S33 Check wiring S43 gt Check wiring e Short circuit S34 L LED display Cause of the fault Troubleshooting Short circuit S43 L or 534 544 p Check wiring Missing clock gt Check wiring Wiring fault Connection A2 A3 exchanged Short circuit S43 L Overvoltage gt Check wiring Undervoltage gt Check power supply Overvoltage gt Chec
11. hand control using electronic sensors switches 26 0 9 1 AS ce i UL LLL U uu u cn ass 26 PT PPS 27 uuu u u R no 29 8 4 Two hand control using mechanical switches with simultaneity monitoring 31 u u sasa a 31 s NUN So NETT 33 54 9 T eo came 36 8 5 Safety relay for e stop for 2 channel fail safe sensors switches with contact output without simultaneity monitoring or for mechanical switches 38 Ro Stein sel lo 38 WO EE OO qana 39 ao ce 41 s 44 10 Ol 2 um as 44 46 12 lermssandabbreviatighS LLL mo 1 Preliminary note The instructions are part of the unit They are intended for authorised persons according to the EMC and Low Voltage Directive and safety regulations The instructions contain information about the correct handling of the product Read the instructions before use to familiarise yourself with operating conditions installation and operation Adhere to the safety instructions 1 1 Symbols used Instructions Reaction result Cross reference LED off LED on LED flashes XX LED flashes quickly Important note Non compliance can result in malfunction or interference Information Supplementary note We ol v 2 Safety instructions Follow the operating instructions mproper us
12. inciple of normally closed operation must be applied to all external safety circuits connected to the system The safety relays type G1503S in operation have to be subjected to a self test switching off within a period of maximum 12 months The self test can be carried out by switching the supply voltage off and on or by a safety request 4 1 2 Product dependent requirements In case of faults within the safety relay which result in the defined safe state the safety relay must be replaced Any faulty unit should be returned to the manufacturer 5 Structure and operating principle 5 1 Indicators and connections gogon a Casper egoo m Supply voltage L L function terminals Y1 Y2 Az Va VE VB YT Operating mode selon au out 553 634 543 548 Comecion _ OUTi LED yelow Tiggeing ofthe semiconductor ouput _ UT2 LED yelow Tiggeing ofthe semiconductor ouput dume2 DT LED yolow pu sinalcanrel or TE for docked serso N2 LED yen tsa channel or or docked senso Power LED green i il Fan LED re Faut _ I Connection tone 5 2 Block diagram MCU 2 CONTROLLER 6 Installation gt Mount the unit on a DIN rail in a housing protected against dust and humidity min 54 degree of soiling 2 Use 60 75 copper conductors only 7 Electrical connection 7 1 Supply voltage The external supply unit must have a safe separation
13. k wiring Undervoltage gt Check power supply Undervoltage gt Check wiring gt Check power supply Short circuits gt Check wiring 8 3 Two hand control using electronic sensors switches Example of electronic sensors switches Capacitive sensors For product selection see www ifm electronic com This wiring meets the requirements type to EN 574 Use up to type IIIC is possible using corresponding sensors switches with two independent switching elements internal plausibility check and protected or screened wires 8 3 1 Connection Connection of two 2 wire DC III 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 26 8 3 2 Function Input circuit Output status LED display 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 27 Input circuit Output status LED display NN 1 o 534 EA SES NE gt 0 5 s 1 0 543 a nii gt 0 5 5 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 28 8 3 3 Fault diagnosis In case of a fault switch the safety relay off and on again LED display Cause of the fault Troubleshooting No voltage supply gt Check wiring Do o Overvoltage gt Check power supply OG Connection A1 A3 or A1 A2 K2 E2 Fault reversed Wire break Check wiring Feedback contacts open Switch the safety relay off ceo Time dependent contacts and on again K2 Faul
14. ng Check wiring LED display Cause of the fault Troubleshooting Overvoltage gt Check wiring Undervoltage gt Check power supply Overvoltage gt Check wiring Undervoltage gt Check power supply Undervoltage gt Check wiring gt Check power supply Short circuits gt Check wiring Input S43 active more than 0 5 Check wiring P x P after input 34 8 1 2 gt Switch the fail safe sensor Feedback contact error switch off and on again K2 Fault Short circuit 534 544 19 8 2 Safety relay for clocked fail safe sensors Example of fail safe sensors switches Fail safe inductive sensor GM504S Up to 10 clocked fail safe sensors can be connected to one safety relay 8 2 1 Connection Connection of one fail safe sensor switch IN TT 1 Fail safe sensor switch 1 2 Fail safe sensor switch 2 20 The use of the safety splitter box E11569 is recommended X f 1 Fail safe sensor switch 1 3 E11569 wh white 2 Fail safe sensor switch 2 4 e g EVC014 bk black 5 eg EVT001 bn brown bu blue Connection of 3 to 10 fail safe sensors switches 1 Fail safe sensor switch 1 3 Fail safe sensor switch 3 2 Fail safe sensor switch 2 The use of the safety splitter box E11569 is recommended co bk bu 1 Fail safe sensor switch 1 4 E11569 wh white 2 Fail safe sensor switch 2 5 e g EVC014 bk black 3 Fail safe sensor switch 3 6 e
15. r switch 1 2 Fail safe sensor switch 2 3 Order and time difference insignificant indefinite simultaneity 1 N O contact activated 39 Input circuit Output status LED display 1 N O contact activated 40 8 5 3 Fault diagnosis In case of a fault switch the safety relay off and on again LED display Cause of the fault Troubleshooting No voltage supply gt Check wiring K1 Power 00 Overvoltage gt Check power supply Short circuit gt Check wiring Wire break Short circuit gt Check wiring Wire break OO O K2 E2 Fault Short circuit gt Check wiring Wire break Feedback contacts open gt Check wiring Wire break When voltage is applied gt Check output circuit x A Pu feedback contacts open gt Check feedback contacts Exchange external contactor K2 E2 Fault Wiring fault gt Check wiring Missing link Y4 Y5 Short circuit LED display Cause of the fault Troubleshooting Connection A2 A3 exchanged gt Check wiring K1 E1 Power e OO O K2 E2 Fault Missing link Y4 Y5 Check wiring K1 E1 Power e o K2 E2 Fault Overvoltage Check wiring Undervoltage Check power supply Overvoltage Check wiring Undervoltage Check power supply Undervoltage Check wiring Check power supply Short circuits Check wiring 43 9 Scale drawing oooo AAA 1 screw terminal supplied 10 Technical data G1503S S
16. sensor switch meets the requirements of type IIIB to EN 574 Use up to type is possible using corresponding sensors switches approved to EN 60947 5 1 annex K and protected or screened wires lll 1 Mechanical fail safe switch 1 2 Mechanical fail safe switch 2 31 Connection of mechanical switches according to type to EN 574 LEGER Ce 1 L 1 Mechanical switch 1 no positively 2 Mechanical switch 2 no positively driven driven contacts contacts Connection of a 2 channel fail safe sensor switch e g electro sensitive protective equipment ESPE to EN 61496 1 lll 1 Contact 1 of the ESPE 2 Contact 2 of the ESPE 32 8 4 2 Function Input circuit Output status LED display ft N O contact activated 33 Input circuit Output status LED display 1 N O contact activated 34 Input circuit Output status LED display 1 N O contact activated 35 8 4 3 Fault diagnosis In case of a fault switch the safety relay off and on again LED display Cause of the fault Troubleshooting K1 Power K2 E2 Fault K1 E1 Power e K2 E2 Fault No voltage supply Overvoltage Connection A1 A3 or A1 A2 reversed Wire break Feedback contacts open Time dependent contacts When voltage is applied feedback contacts open Wiring fault Missing link Y4 Y5 Short circuit Contacts closed when voltage is applied
17. t When voltage is applied Check output circuit x d feedback contacts open Check feedback contacts Exchange external contactor K2 Fault Wiring fault Check wiring Missing link Y4 Y5 Deactivate inputs and Short circuit RESET or voltage failure Inputs 534 and 543 activated when voltage is applied Connections A3 A2 Check wiring OX e exchanged OO O K2 E2 Fault Missing link Y4 Y5 Check wiring K1 E1 Power e O0 K2 E2 Fault Overvoltage Check wiring Undervoltage Check power supply 29 LED display Cause of the fault Troubleshooting Overvoltage gt Check wiring Undervoltage gt Check power supply Undervoltage gt Check wiring gt Check power supply Short circuits gt Check wiring Me Inputs 34 and 43 not gt Check wiring activated within 0 5 s 8 3 2 o Feedback contact error K2 E2 Fault e Short circuit 534 544 gt Deactivate inputs and activate them again 30 8 4 Two hand control using mechanical switches with simultaneity monitoring Two hand control with mechanical switches safety relay for mechanical switches or 2 channel fail safe sensors switches with contact output with simultaneity monitoring E13 The contacts of the mechanical switches must allow a minimum current of 6 mA 8 4 1 Connection Connection of two mechanical fail safe switches UK This wiring with only one normally open contact per
18. ture 55 C The safety functions are not evaluated by UL The approval is accomplished according to UL 508 general use applications Use 60 75 C copper conductors only For use in pollution degree 2 environment e Same polarity related to output contacts 45 11 Tests approvals The safety relay G1503S was tested and certified by T V Nord The safety relay was developed and tested in accordance with for example the following directives and standards 46 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2006 95 EC Low Voltage Directive DIN EN 50178 1998 Electronic equipment for use in power installations DIN EN ISO 13849 1 2008 Safety of machines safety related parts of control systems DIN EN 60204 1 2007 where applicable Electrical equipment of machines DIN EN 61496 1 2009 Non contact protective equipment General requirements and tests DIN EN 574 1996 A1 2008 Safety of Machinery Two Hand Control Devices Functional Aspects Principles for Design IEC 61508 2000 2003 Functional safety of electrical electronic programmable electronic safety related systems DIN EN 62061 2005 Safety of Machinery Functional safety of electrical electronic and programmable safety related control systems UL 508 12 Terms and abbreviations ESPE Electro Sensitive Protective Equipment Cat Category Classification of the safety related parts of a controller as regards their resistance to

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