704064B1 / 04 01 / 2010 Original operating instructions Safety
Contents
1. 01 2010 704064 1 04 ifm electronic Original operating instructions Safety relay with relay outputs efectorno 1501 Contents UB CAO TTL 4 T3 MENU MES ED UI Mu RI 4 2 ED MM SI de en 4 3 tems ig cu 6 4 F nctions and features ennemies EI DOE TN ED ea 6 4 1 Requirements for the hardware configuration T 4 1 1 Product independent requirements ssss 7 4 1 2 Product dependent requirements 7 5 Structure and operating principle 8 5 1 Indicators and COMMOCIONS 8 9 E tie 10 7 Electrical connection ss 10 1 Supply VONAGE een tete es te 10 7 2 Feedback contacts monitored or automatic start 11 Lo CUI RTT 12 8 Connection Function Fault diagnosis 13 8 1 Safety relay for fail safe sensors switches with 2 PNP outputs 14 ELT ES Die ie Pee ee eee eee ee ee een ere 14 oA VI LUE 15 8 1 3 Fault 4 22523 ss 18 8 2 Safety relay for clocked fail safe sensors 20 COCO 20 S PARANT2. according to EN 574 4 1 Requirements for the hardware configuration The following requirements must be complied with when using the safety relay G15018 4 1 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 principle of normally closed operation must be applied to all external safety circuits connected to the system UK By taking administrative measures in the application it must be ensured that e the safety relays type 615015 in operation are subjected to a self test switching off within a period of maximum 12 months intermittent operation the safety related relay contacts are protected using a suitable fuse of 3 6 A as short circuit overload protection 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 E bus IE 9 or Lm E2 D EE Supply voltage L L function terminals Y1 Y2 Operating mode section ane
3. Ou 803 956 S43 54 Conecto far sleyinpus oupus ki Tigerna raay output horne 0 k2 ED yelow Triggering othe roy oupitchamel2 E1 ED yelow put channel TE _ E2 Dew sgnal channel A for decked sorso LED green Voltage supply EE 13 14 Connection of relay output without delay 1 x normally open closed when enabled 23 24 Connection of relay output 1 x normally open closed when enabled 5 2 Block diagram PEt TT mil INPUT CIRCUIT L L CONTROLLER E MCU 2 K2 CONTROLLER 6 Installation gt Mount the unit on a DIN rail in a housing protected against dust and humidity min IP54 degree of soiling 2 7 Electrical connection Use 60 75 C copper conductors only 7 1 Supply voltage The external supply unit must have a safe separation 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 24V DC Manual reset 24V DC RESET For safety reasons the unit can only be restarted by 2 ak T 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 After power or a RESET the unit carries out self diagnostic functions After this self diagnosis the unit is ready for operation 10 7 2 Feedback contacts monitored o
4. PLC Programmable Logic Controller Technical data and further information at www ifm com S
5. can result in malfunction or interference Information Supplementary note 2 Safety instructions Follow the operating instructions mproper use 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 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 In 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 Use only as described below 4 3 Items supplied e 1 615015 safety relay includi
6. e i ERO OEC 20 8 2 3 Fault diagnosis nondam x a nt Kit dam 24 8 3 Two hand control using electronic sensors switches 27 5 9 1 COMME NON a en 27 TN 28 D Sa ie 30 8 4 Two hand control using mechanical switches with simultaneity monitoring 32 32 Fhe de 34 am 37 8 5 Safety relay for mechanical switches or 2 channel fail safe sensors switches with contact output and without simultaneity monitoring 39 CRIRE 39 5 02 40 0 99 CACO SS NN RE E TT T T 42 45 I INIS i ee A 45 Ti OR 47 12 Terms mu 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 LED flashes quickly Important note Non compliance
7. 4 534 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 E1 Power e e K2 E2 Fault K1 E1 Power e OO 0 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 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 wiring Check wiring LED display Cause of the fault Troubleshooting Overvoltage gt Check wiring Undervoltage Check power supply Overvoltage gt Check wiring po Undervoltage gt Check power supply O 0O E2 Fault Undervoltage gt Check wiring Check power supply E1 Power x ee E2 Fault K1 E1 Power e x e K2 E2 Fault Short circuits gt Check wiring K1 E1 Power oe e K2 E2 Fault K1 E1 Power OO e oe o K2 E2 Fault Input S43 active more than 0 5 Check wiring M Lud after input S34 8 1 2 gt S
8. Y5 Open contacts and RESET Short circuit or voltage failure Contacts closed when voltage is applied Connection A2 A3 reversed Check wiring K1 E1 Power e OO K2 E2 Fault Overvoltage Check wiring Undervoltage Check power supply 37 LED display Cause of the fault Troubleshooting Overvoltage Check wiring Undervoltage gt Check power supply Undervoltage Check wiring K1 E1 Power Check power supply x ee E2 Fault E1 Power e x e E2 Fault Short circuits Check wiring E1 Power ee e E2 Fault E1 Power e ee K2 E2 Fault Inputs S34 and S43 not Check wiring e pa activated within 0 5 s gt Deactivate inputs and OX 8 4 2 activate them again K2 E2 Fault Feedback contact error Short circuit 934 544 38 8 5 Safety relay for mechanical switches or 2 channel fail safe sensors switches with contact output and without simultaneity monitoring The 2 channel fail safe sensors switches are for example electro sensitive protective equipment ESPE to EN 61496 1 E The contacts of the sensors switches must allow a minimum current of 6 mA 8 5 1 Connection W 1 Mechanical switch 1 2 Mechanical switch 2 39 8 5 2 Function Input circuit Output status LED display 9 gt Fail safe sensor switch 1 Fail safe sensor switch 2 Order and time difference insignificant indefinite simultaneity N O contact ac
9. citive sensors For product selection see www ifm com This wiring meets the requirements type IIIB to EN 574 Use up to type 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 EEE 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 8 3 2 Function Input circuit Output status LED display 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 28 Input circuit Output status LED display 543 L 534 mu NEA gt 0 5 1 S43 sn a gt 0 5 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 29 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 Check wiring Overvoltage Check power supply Connection A1 A3 or A1 A2 reversed Wire break Check wiring Feedback contacts open Switch the safety relay off Time dependent contacts and on again When voltage is applied Check output circuit a 5 P Feedback contacts open Check feedback contacts Exchange external contactor K2 E2 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 appli
10. ed Connections A3 A2 reversed Check wiring K1 E1 Power e OO O K2 E2 Fault Missing link Y4 Y5 Check wiring K1 E1 Power e K2 E2 Fault 30 LED display Cause of the fault Troubleshooting Overvoltage Check wiring Undervoltage gt Check power supply Overvoltage Check wiring Undervoltage Check power supply E1 Power x O E2 Fault Undervoltage Check wiring Check power supply E1 Power o x ee E2 Fault K1 E1 Power e x OO e K2 E2 Fault Short circuits gt Check wiring K1 E1 Power oe OO e K2 E2 Fault K1 E1 Power OO e oe o K2 E2 Fault Inputs S34 and 543 not Check wiring e activated within 0 5 s gt Deactivate inputs and OX gt 8 3 2 activate them again K2 E2 Fault Feedback contact error Short circuit 534 544 31 8 4 Two hand control using mechanical switches with simulta neity 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 EB 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 This wiring with only one normally open contact per sensor switch meets the requirements of type IIIB to EN 574 Use up to type is possible using corresponding sensors switches approved
11. ifferent ways 1 Safety relay for fail safe sensors switches with 2 PNP outputs e g 5 7015 2 Safety relay for clocked fail safe sensors e g GM504S 3 Two hand control to EN 574 type with electronic sensors switches 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 mechanical switches or 2 channel fail safe sensors switches UK e g non contact safety devices EN 61496 1 with contact output and without simultaneity monitoring indefinite simultaneity 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 scanner 8 1 1 Connection Fail safe sensor switch with a current consumption of S 50 mA SEE SISE 1 Fail safe sensor switch Fail safe sensor switch with a current consumption of gt 50 mA SEE SISE 1 Fail safe sensor switch 8 1 2 Function Input circuit Output status LED display OSSD1 534 1 05502 543 0 1 05501 0 34 OSSD2 S43 Stop flashing gt Activate inputs in correct time sequence fig above 15 Input circuit Output status LED display 16 Input circuit Output status LED display 1 05501 0 05502 5
12. ng 5 Combicon connectors with screw terminals 1 copy of the operating instructions safety relay reference 704064 If one of the above mentioned components is missing or damaged please contact one of the ifm branch offices 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 e Safety relay for clocked fail safe sensors e g GM504S Two hand control to EN 574 type with electronic sensors switches 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 Safety relay for mechanical switches or 2 channel fail safe sensors switches e g non contact safety devices EN 61496 1 with contact output and without simultaneity monitoring indefinite simultaneity The safe state is when the output contacts 13 14 or 23 24 are open ifm electronic gmbh assumes no liability for the use of units made by external manufacturers Suitability of the product for a certain application cannot be assured and must be ensured by the user The safety relay conforms to the category 4 according to EN 954 1 valid until 31 December 2011 Performance Level e according to EN ISO 13849 1 2008 as well as to the requirements SIL 3 to IEC 61508 and the classification type
13. pply Connection A1 A2 reversed Wire break Check wiring Feedback contacts open Switch the safety relay off Time dependent contacts and on again When voltage is applied Check output circuit _ Pa Feedback contacts open Check feedback contacts Exchange external contactor K2 E2 Fault Short circuit Check wiring Connection A1 A3 or A2 A3 reversed Short circuit S43 L or S44 L Check wiring K1 E1 Power e e K2 E2 Fault Short circuit 534 844 or 533 Check wiring K1 E1 Power 943 e K2 E2 Fault 24 LED display Cause of the fault Troubleshooting Short circuit S34 L Check wiring E1 Power oe e o K2 E2 Fault Short circuit S43 L or S34 gt Check wiring E1 Power S44 ce e o E2 Fault Missing clock Check wiring e P Wiring fault Connection A2 A3 reversed E2 Fault Short circuit S43 L Overvoltage gt Check wiring Undervoltage Check power supply E1 Power e x O O E2 Fault Overvoltage Check wiring Undervoltage Check power supply K1 E1 Power eo x ee o K2 E2 Fault Undervoltage Check wiring K1 E1 Power Check power supply oe e K2 E2 Fault K1 E1 Power O e OO e K2 E2 Fault 25 LED display Cause of the fault Troubleshooting Short circuits gt Check wiring 26 8 3 Two hand control using electronic sensors switches Example of electronic sensors switches Capa
14. provals The safety relay G1501S was tested and certified by T V Nord The safety relay was developed and tested in accordance with the following directives and standards 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 73 23 EEC or 93 68 Low voltage directive DIN EN 954 1 1996 category 4 safety of machinery safety related parts of control systems valid until 31 December 2011 EN ISO 13849 1 2008 category 4 PL e safety of machinery safety related parts of control systems DIN EN 60204 1 1997 where applicable Electrical equipment of machines DIN EN 574 type IIIC 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 UL 508 47 12 Terms and abbreviations ESPE Electro Sensitive Protective Equipment Cat Category Category Classification of the safety related parts of a controller as regards their resistance to failures Diagnostic Coverage Diagnostic coverage MTTF Mean Time to Failure Mean time to failure MTTF Mean Time To Dangerous Mean time to dangerous failure Failure OSSD Output Signal Switching Device Switching output triggering the safety circuit PFH Probability of dangerous Probability of a dangerous failure per PFH Failure per Hour hour PL Performance Level PL to EN ISO 13849 1 IL Safety Integrity Level SIL 1 4 to IEC 61508
15. r automatic start Automatic start A1 Automatic activation without monitoring Monitoring of the feedback contacts normally closed for automatic start his Q 1 Feedback contact Monitored start The circuit is enabled when the feedback contacts are closed Consider the current flowing through the feedback contacts 10 Technical data Activate the relay 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 DADA 1 Feedback contact 2 Start button Activate the relay outputs 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 contacts 10 Technical data 7 3 Output circuit Connect the load 12 Connect the load to be controlled to the outputs C1 13 14 or C2 23 24 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 that triggering the relays at the outputs 13 14 and 23 24 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 d
16. relay outputs Terminal block Phoenix Contact MSTBO Meets the requirements of EN ISO 13849 1 2008 category 4 PL e SIL 3 IEC 61508 type IIIC EN 574 Electrical design Output function 2 safety related NO floating contacts 1 signal output positive switching Operating voltage 24 V DC 19 2 30 incl 5 residual ripple Contact rating 6 A 250 V AC 24 V DC min 6 mA Short circuit protection overload The contacts are to be protected by means of fuses protection with a nominal current of 3 6 A Current consumption 200 mA Function display voltage green error red output status 2 x yellow input 2 x yellow 45 Power on delay time 25 55 C Input characteristics S34 43 1 gt 11 V 6 mA 0 lt 5 V lt 500 uA Output characteristics S33 push pull short circuit proof 0 d 30 mA 1 loce gt 90 mA U gt 18 V 44 0 Ik lt 300 uA 1 gt 90 MA U gt 18 V 0 Ip lt 300 uA 1 luce gt 11 V 30 mA gt 15 V 15 mA Y 7 Y1 Y2 or Y1 Y6 Comments Additional comments concerning the cULus approval UL 508 Maximum ambient temperature 55 C in the control cabinet The safety functions were not assessed by UL The approval has been made according to UL 508 for general applications Use 60 75 C copper conductors only For use in pollution degree 2 environment Same polarity phase referred to the output contacts 46 11 Tests ap
17. tivated 40 Input circuit Output status LED display 1 Fail safe sensor switch 1 2 Fail safe sensor switch 2 ft N O contact activated 41 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 Check wiring Overvoltage gt Check power supply Short circuit gt Check wiring Wire break Short circuit gt Check wiring Wire break Short circuit Check wiring Wire break Feedback contacts open gt Check wiring Wire break When voltage is applied gt Check output circuit Feedback contacts open Check feedback contacts Exchange external contactor K2 E2 Fault K1 E1 Power e 42 LED display Cause of the fault Troubleshooting Wiring fault gt Check wiring Missing link Y4 Y5 Short circuit Connection A2 A3 reversed Check wiring K1 E1 Power e Qo K2 E2 Fault Missing link Y4 Y5 Check wiring K1 E1 Power Ok e Oe o K2 E2 Fault Overvoltage Check wiring Undervoltage Check power supply Overvoltage Check wiring Undervoltage Check power supply Undervoltage Check wiring Check power supply 43 LED display Cause of the fault Troubleshooting Short circuits gt Check wiring 44 9 Scale drawing 0000 DAAA 1 Combicon connector with screw terminals supplied 10 Technical data G1501S Safety relay with
18. to EN 60947 5 1 annex K and protected or screened wires M 1 Mechanical fail safe switch 1 2 Mechanical fail safe switch 2 32 Connection of mechanical switches according to type IIIC to EN 574 BEEF CELLS 1 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 1 Contact 1 of the ESPE 2 Contact 2 of the ESPE 33 8 4 2 Function Input circuit Output status LED display ft N O contact activated 34 Input circuit Output status LED display 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 1 35 Input circuit Output status LED display 1 Electronic fail safe sensor 1 2 Electronic fail safe sensor 2 1 N O contact activated 36 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 No voltage supply Check wiring Overvoltage Check power supply Connection A1 A3 or A1 A2 reversed Wire break Check wiring Feedback contacts open Switch the safety relay off Time dependent contacts and on again When voltage is applied Check output circuit _ Pa Feedback contacts open Check feedback contacts Exchange external contactor K2 E2 Fault Wiring fault Check wiring Missing link Y4
19. witch the fail safe sensor e OX Feedback contact error switch off and on again K2 E2 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 1 Fail safe sensor switch 1 2 Fail safe sensor switch 2 20 The use of the safety splitter box E11569 is recommended mo MX fr 1 Fail safe sensor switch 1 3 E11569 wh white 2 Fail safe sensor switch 2 4 e g E10884 bk black 5 e g E10662 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 E10884 bk black 3 Fail safe sensor switch 3 6 e g E10662 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 No voltage supply Check wiring Overvoltage gt Check power su
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