System Manual Modular Safety System ESM-F

Transcription

1 System Manual Modular Safety System ESM-F GB Me than safety.

2 Contents Crect use 3 Exclusion of liability and warranty 3 General safety instructions 3 Function 4 Status LEDs and pin assignment 5 Status LEDs and connections on the base units 5 Status LEDs and connections on the input modules 5 Status LEDs and connections on the output modules 5 Technical data 6 General technical data 6 Items supplied 14 Items supplied, base units 14 Items supplied, input modules 14 Items supplied, output modules 14 Accessies 14 Connection set 14 Mounting and replacing modules 15 Mounting 15 Replacing modules 16 Electrical connection 17 Starting behavi 18 Connecting safety inputs 19 Connecting safety contacts and feedback loop 2 Connecting base unit moniting outputs 3 Connecting group outputs 3 Connecting expansion modules 24 Connecting input modules 4 Connecting output modules 6 Expanding time-delay output modules 7 Fming safety groups 28 Fming a group with the outputs GO1 and GO2 on an input module 8 Fming a group with the outputs GO1 and GO2 on a base unit 9 Response times of the ESM-F system 29 Setup 30 Trouble shooting 31 Status table 31 Inspection and service 34 Service 34 Declaration of confmity 35

3 Crect use Exclusion of liability and warranty General safety instructions The base unit ESM-F-B... is used to evaluate safety-related signals in safety circuits accding to EN With this unit safety categy 4 accding to EN can be achieved. The base unit can only be expanded using expansion devices in the modular safety system ESM-F from EUCHNER. The device is not allowed to be opened, tampered with, modified. The permissible operating parameters are to be observed during operation (see section Technical data ). Befe the safety module is used, a risk assessment must be perfmed on the machine in accdance with: EN 954-1, Safety of machinery. Safety related parts of control systems. General principles f design, Annex B EN 1050, Safety of machinery. Principles f risk assessment IEC 62061, Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems Crect use includes compliance with the relevant requirements f installation and operation, particularly EN , Safety of machinery. Electrical equipment of machines. General requirements In case of failure to comply with the conditions f crect use stated above, if the safety instructions are not followed, if any servicing is not perfmed as required, liability will be excluded and the warranty void. Imptant! The device is only allowed to be installed and placed in operation by authized personnel who are familiar with the crect handling of safety components, who are familiar with the applicable regulations on health and safety and who have read and understood the operating instructions and the system manual. The safety function of the system while the machine is in operation can no longer be ensured if the device is connected increctly used increctly. Fatal injuries may result. Pri to use read the operating instructions and the system manual, and keep these in a safe place. Ensure the operating instructions and the system manual are always available during mounting, setup and servicing. EUCHNER cannot provide any warranty in relation to the readability of the CD f the stage period required. F this reason you should also archive a printed copy of the system manual. If you should lose the operating instructions the system manual, you can download these documents from 3

4 Function The modules in the ESM-F system are used f the evaluation of the safety components connected and the safe interruption of a safety circuit. The base unit ESM-F-B... is part of the ESM-F system from EUCHNER. The ESM-F system comprises at least one base unit. The base unit has several inputs f the connection of safety components. The safety contacts are switched as a function of the input signals. Subsequent parts of the safety circuit can be monited using a feedback loop. Different device states can be signaled using moniting outputs. The base unit can be expanded with additional inputs and outputs using expansion modules. The individual modules are connected together using a special connect system. Power is supplied and safety signals are sent via the connect system. If one of the safety components (e.g. an emergency stop) is actuated, the base unit opens its contacts immediately. If additional output modules are used, these also receive a signal to open their contacts. The system is designed such that failures will not result in the loss of the safety function. The occurrence of failures is detected by cyclic self-moniting at the latest on the next demand to close the safety contacts (e.g. on starting). The system can be started either manually using a start button automatically using a jumper. Safety groups with varying safety levels can be fmed using appropriate configurations (see section Fming safety groups). 4

5 Status LEDs and pin assignment All modules in the ESM-F system have status LEDs f the imptant module states. The significance of the individual LED states is given in the section Trouble shooting. Status LEDs and connections on the base units GO1 GI1 GO2 GI2 S13 S11 S12 S14 13 SO A1 SI SA OV In1 1 2 In2 1 2 In B G Rx Tx S23 S21 S22 S24 O1 O2 OI OG Out 1 Out 2 Feedb Out B ESM-F Basic O14 OY Y1 Y A2 ESM-F-BSN-2C2O2 ESM-F-BMN-2C2O2 Status LEDs and connections on the input modules S13 S11 S12 S14 S23 S21 S22 S24 S13 S11 S12 S14 S23 S21 S22 S24 In1 1 2 In2 1 2 Rx Tx ESM-F Input O1 O2 GO1 GO2 ESM-F-ISI-2C2 In1 1 2 In2 1 2 In3 1 2 Rx Tx ESM-F Input S33 S31 S32 S34 O1 O2 O3 ESM-F-I3I-3C2 ESM-F-ISI-6C1 ESM-F-IMI-3C2 ESM-F-ILI-3C2 Status LEDs and connections on the output modules Y1 Y Y1 Y Y1 Y O Y1 Y O17 Out 1 Out 2 Feedb ESM-F Output Out 1 Out 2 Feedb ESM-F Output Feedb Out 1 2 ESM-F Output Feedb t Out 1 2 ESM-F Output ESM-F-OSN-O4 ESM-F-OSN-O3M1 ESM-F-OT05NO4 ESM-F-OTNO

6 Technical data General technical data Parameter Value Unit Housing material Polyamide PA6.6 Dimensions ESM-F-B.. ESM-F-I.. ESM-F-O x 99 x x 99 x x 99 x 22.5 mm Weight Approx Approx Approx kg Connection type Plug-in connection terminals Terminals mm² Ambient temperature at U B = 24 V DC Degree of protection to EN IEC IP 20 Degree of contamination 2 Mounting C Expansion connect on DIN rail 35 mm accding to DIN EN Life Mechanical 1 x 10 7 operating cycles Electrical 1 x 10 5 operating cycles Connection data, base units ESM-F-B... Parameter Value Unit Operating voltage 24 ± 10% 1) V DC Reverse polarity protection Power consumption Approx. 3.5 VA Control voltage at start button Control cable length max. (cross-section 0.75 mm²) Current consumption, max. without moniting outputs Yes V DC 1000 m 140 with moniting outputs 320 External contact fuses (safety circuit) 10 AgG (T6A / F8A) accding to EN IEC Rated impulse withstand voltage 2.5 kv Leakage path and air gap acc. to DIN VDE : kv Cumulative therm. current f all contacts 10 A Safety contacts Switching current, min., at 24 V DC 20 ma Maximum switching voltage 50 V DC 250 V AC Utilization categy accding to U e I e S I e EN IEC AC V 8 A AC V 3 A DC V 8 A 10 A DC V 3 A LEDs 13, diagnostics and status Moniting outputs (semiconduct) Sht circuit-proof Yes Continuous current max. 30 ma Output voltage 24 V DC Inputs Circuit ESM-F-BSN ESM-F-BMN 2 inputs, NC contact/nc contact, 2-channel with sht-circuit moniting and earth fault moniting 2 inputs, NC contact/no contact, 2-channel with sht-circuit moniting and earth fault moniting 1) All the electrical connections must either be isolated from the mains supply by a safety transfmer accding to EN IEC with limited output voltage in the event of a fault, by other equivalent isolation measures. U e = Switching voltage I e = Maximum switching current per contact S I e = Maximum switching current per all safety contacts (cumulative current) ma 6

7 Dimension drawing Suitable f 35 mm DIN rail accding to DIN EN GO1 GI1 GO2 GI2 S13 S11 S12 S A1 SO SI SA OV In1 1 2 Out 1 99 In2 1 2 In B G Rx Tx S23 S21 S22 S24 O1 O2 OI OG Out 2 Feedb Out B ESM-F Basic O14 OY Y1 Y A Block diagram ESM-F-B... A1 A2 SO SI SA S11 S12 S13 S14 S21 S22 S23 S Expansion connect - Power supply - Start function Input circuit 1 Input circuit 2 Inputs Group signal Moniting outputs Feedback loop K1 K2 Expansion connect 0V GO1 GO2 GI1 GI2 O1 O2 OI OG O14 OY Y1 Y

8 Connection data, input modules ESM-F-I Parameter Value Unit Operating voltage 24 ± 10% 1) V DC Reverse polarity protection Power consumption Approx. 4.2 VA Control cable length max. (cross-section 0.75 mm²) Current consumption, max. without moniting outputs with moniting outputs 160 (ESM-F-ISI-2C2) 190 (ESM-F-I3I-3C2, ESM-F-ISI-6C1, ESM-F-IMI-3C2, ESM-F-ILI-3C2) LEDs Moniting outputs (semiconduct) Sht circuit-proof Continuous current max. per output Yes 1000 m 100 9, diagnostics and status Yes ma 30 ma Output voltage 24 V DC Inputs Circuit ESM-F-I3I-3C2 ESM-F-ILI-3C2 ESM-F-ISI-2C2 ESM-F-ISI-6C1 ESM-F-IMI-3C2 1) Supplied via expansion connect 3 inputs, NC contact/nc contact, 2-channel with sht-circuit moniting and earth fault moniting 3 inputs, NC contact/nc contact, 2-channel without sht-circuit moniting and earth fault moniting 2 inputs, NC contact/nc contact, 2-channel with sht-circuit moniting and earth fault moniting outputs f fming a group 6 inputs, NC contact/nc contact, 1-channel with sht-circuit moniting and earth fault moniting 3 inputs, NC contact/no contact, 2-channel with sht-circuit moniting and earth fault moniting f the connection of safety switches with NO contact/nc contact combination (e.g. CMS from EUCHNER) 8

9 Dimension drawing Suitable f 35 mm DIN rail accding to DIN EN S13 S11 S12 S14 S23 S21 S22 S24 S13 S11 S12 S14 S23 S21 S22 S24 99 In1 1 2 In In1 1 2 In2 1 2 Rx Tx ESM-F Input In3 1 2 Rx Tx ESM-F Input O1 O2 GO1 GO2 S33 S31 S32 S34 O1 O2 O3 22,5 22,5 114 Block diagram ESM-ISI-2C2 S11 S12 S13 S14 S21 S22 S23 S24 Expansion connect Input circuit 1 Input circuit 2 Inputs Group signal Moniting outputs Expansion connect GO1 GO2 O1 O2 Block diagram ESM-I3I-3C2, ESM-F-IMI-3C2 and ESM-F-ILI-3C2 S11 S12 S13 S14 S21 S22 S23 S24 S31 S32 S33 S34 Expansion connect Input circuit 1 Input circuit 2 Input circuit 3 Inputs Moniting outputs Expansion connect O1 O2 O3 Block diagram ESM-I..-6C1 S11 S12 S13 S14 S21 S22 S23 S24 S31 S32 S33 S34 Expansion connect Input circuit 1 Input circuit 2 Input circuit 3 Input circuit 4 Input circuit 5 Input circuit 6 Inputs Moniting outputs Expansion connect O1 O2 O3 9

10 Connection data, output modules ESM-F-O... Parameter Value Unit Operating voltage 24 ± 10% 1) V DC Reverse polarity protection Power consumption Approx. 2.4 VA Current consumption, max. 100 ma External contact fuses (safety circuit) 10 AgG (T6A / F8A) accding to EN IEC Rated impulse withstand voltage 2,5 kv Leakage path and air gap acc. to DIN VDE : kv Cumulative therm. current f all contacts 10 A Safety contacts Switching current, min., at 24 V DC 20 ma Maximum switching voltage 50 V DC 250 V AC Utilization categy accding to U e I e S I e EN IEC AC V 8 A AC V 3 A DC V 8 A 10 A DC V 3 A LEDs 4, diagnostics and status Auxillary contact (on ESM-F-OSN-O3M1) Switching current, min., at 24 V DC 20 ma Maximum switching voltage 50 V DC 250 V AC Utilization categy accding to U e I e EN IEC AC V 8 A AC V 3 A DC V 8 A DC V 3 A 1) Power supplied via expansion connect U e = Switching voltage I e = Maximum switching current per contact S I e = Maximum switching current per all safety contacts (cumulative current) Yes 10

11 Dimension drawing ESM-F-O... Suitable f 35 mm DIN rail accding to DIN EN Y1 Y Y1 Y2 99 Out 1 Out 2 Feedb ESM-F Output Out 1 Out 2 Feedb ESM-F Output ,5 22,5 114 Block diagram ESM-F-OSN-O4 Y1 Y Expansion connect Feedback loop K1 K2 Expansion connect Block diagram ESM-F-OSN-O3M1 Y1 Y Expansion connect Feedback loop K1 K2 Expansion connect

12 Connection data output modules ESM-F-OT.. Parameter Value Unit Operating voltage 24 ± 10% 1) V DC Reverse polarity protection Power consumption Approx. 2.4 VA Time-delay ESM-F-OTN 1 30 (adjustable) s ESM-F-OT05N 0.5 (fixed) s Current consumption, max. without moniting output Yes 100 with moniting output 130 Leakage path and air gap acc. to DIN VDE : Cumulative therm. current f all contacts Safety contacts ma 4 kv 10 A Switching current, min., at 24 V DC 20 ma Maximum switching voltage 50 V DC 250 V AC Utilization categy accding to U e I e S I e EN IEC AC V 8 A AC V 3 A DC V 8 A 10 A DC V 3 A LEDs 4, diagnostics and status Moniting output (semiconduct) Sht circuit-proof Yes Continuous current max. 30 ma Output voltage 24 V DC 1) Supplied via expansion connect U e = Switching voltage I e = Maximum switching current per contact S I e = Maximum switching current per all safety contacts (cumulative current) 12

13 Dimension drawing ESM-F-OT... Suitable f 35 mm DIN rail accding to DIN EN Y1 Y2 O Y1 Y2 O17 Feedb Feedb 99 t Out 1 2 ESM-F Output Out 1 2 ESM-F Output ,5 22,5 114 Black diagram ESM-F-OT... Y1 Y Expansion connect Feedback loop Moniting output K1 K2 Expansion connect O

14 Items supplied Warning! Check whether all parts are complete. The connection terminals must be dered separately. The following parts are supplied: Items supplied, base units 1 base unit ESM-F-B... 2 expansion connects 2 terminal plugs with jumpers (already connected) Operating instructions (please retain!) CD with system manual (please retain!) Items supplied, input modules 1 input module ESM-F-I... 1 expansion connect Operating instructions (please retain!) Items supplied, output modules 1 output module ESM-F-O... 1 expansion connect Operating instructions (please retain!) Only use plug connects from EUCHNER f connection and mounting. On the use of parts not approved by EUCHNER, the safety function may be lost the device damaged. Accessies To connect the ESM-F modules you will need appropriate connection terminals that are not included with the modules. Connection set The connection set is available with either screw terminals with spring terminals: Items supplied with connection set with screw terminals 4 plug-in screw terminals 2 jumpers Coding pins Items supplied with connection set with spring terminals 4 plug-in spring terminals 2 jumpers Coding pins You can obtain additional installation material spare parts from EUCHNER. 14

15 Mounting and replacing modules Mounting Imptant! The ESM-F system must be installed in a control cabinet that has a degree of protection of at least IP 54. F fastening, the expansion connects must be clipped to a hizontally mounted DIN rail. The technical data given only apply in this installation position. The individual modules are fitted to the expansion connects and clipped onto the DIN rail. Proceed as follows: 1. Connect the two expansion connects f the base unit. If you use additional expansion modules, you must use a new expansion connect f each module. Input modules must always be connected to the left of the base unit. Output modules must always be connected to the right of the base unit. Each safety group is only allowed to contain one base unit.. Connect a terminating plug at each of the ends. Jumpers Termial plug Jumpers Imptant! Contact spring Expansion connect F the ESM-F system to wk, a terminal plug must be fitted on the end of the first and last expansion connect. The jumpers on the terminal plug are not allowed to be removed the connections changed. The jumpers on the terminal plug must be connected between terminal 1 and 3 (see figure above). 3. Clip the connected expansion connect to the DIN rail. 4. Connect the modules in the crect sequence to the expansion connect. Ensure the modules engage with the DIN rail. The mounting of the modules is complete. 15

16 Replacing modules Warning! Caution! Any expansion modules can be removed from a safety group at any time. The remaining modules will continue to function without limitations. The safety function will be lost if safety modules are removed while the system is in operation. People may be placed in danger and the module system may be damaged. Disconnect the power supply and secure the system against restart befe starting the maintenance job. Proceed as follows: Disconnect power. If the inputs and outputs on the module are already connected, disconnect the plug-in connection terminals from the module you want to remove. Unlock the catch with a screwdriver and tip the module up and away. Fit the new module to the expansion connect. Ensure the modules engage with the DIN rail. If the connection terminals are connected increctly, malfunctions and damage to the device the system may result. Code the connection terminals using the coding pins included in the connection set Re-connect the specified terminals. Connect power. Check the system functions crectly befe you release the system f operation. 16

17 Electrical connection Warning! Caution! The device is only allowed to be installed and placed in operation by authized personnel who are familiar with the crect mounting of safety components. Excessively high loads may cause damage to the base unit. Comply with the operating values in the section Technical data. On the use of several expansion modules the total current consumption must not be me than 3 A. Observe the requirements on connections in these operating instructions. Caution! Power supply The power supply of DC 24 V is supplied to the base unit. All expansion modules f the ESM-F are supplied with DC 24 V via the expansion connect. Only use terminal A2 f the earth connection and not terminal 0V. The terminal 0V is only used as a reference potential f the semiconduct outputs and is not designed f high loads. An increct connection will cause damage to the unit. +24 V 0 V Terminal plug Terminal plug 0V A1 Base PE A2 and 0V are connected together internally PE must be connected to A2 f the earth fault detection A2 Figure 1: Power supply Imptant! F the earth fault moniting, the terminal A2 must be connected to the protective earth (PE) on the machine. 17

18 Starting behavi The base unit can be placed in operation either using the autostart mode by starting it manually. Connection f monited, manual start F monited, manual start, a start button must be connected between the terminals SO and SI. The moniting will detect, e.g. a sticking start button. SO SI SA Base Figure 2: Monited, manual start Imptant! Warning! The safety contacts close immediately when the start button is pressed and all safety circuits connected are closed. The start button is only allowed to be pressed approx. 300 ms after power on. If the start button is pressed earlier, the unit will switch to the fault state and only LED Out1 will illuminate. This fault also occurs if the start button is pressed while the safety inputs are activated (see section Trouble shooting). A sticking start button is only detected if a signal has been deactivated on one of the safety inputs f me than approx. 500 ms. Connection f manual start (not monited) Start button faults will not be detected in case of un-monited, manual start. SO SI SA Base Figure 3: Un-monited, manual start 18

19 Warning! F un-monited, manual start, a start button must be connected between the terminals SI and SA. The safety contacts close immediately when the start button is pressed and all safety circuits connected are closed. Connection f automatic start Impairment of the safety function because of improper connection. Pay attention to sections 5.4 and 5.5 in the standard EN if you want to start the ESM-F system automatically. SO SI SA Base Figure 4: Automatic start Imptant! F the autostart mode, a jumper must be connected between the terminals SI and SA. The safety contacts close immediately if all safety circuits connected are closed. Connecting safety inputs The base unit is, depending on the version, equipped with two safety inputs f the connection of two nmally closed contacts (ESM-F-BSN...) f the connection of one nmally closed contact and one nmally open contact (ESM-F-BMN...). The version ESM-F-BMN... is therefe suitable f the connection of diverse safety switches (e.g. CMS, from EUCHNER). All safety inputs have sht circuit and earth fault moniting. Unused nmally closed contact safety inputs must be fitted with jumpers (see Figure 6 and Figure 8). F the earth fault moniting, the terminal A2 must be connected to the protective earth (PE) (see Figure 1). 19

20 Inputs on the base unit ESM-F-BSN... You can connect two dual-channel safety switches (e.g. two emergency stops) to the base unit. In the example below (Figure 6) only one safety switch has been connected, jumpers must therefe be fitted to the remaining safety inputs. Safety component S13 S11 S12 S14 Base S23 S21 S22 S24 Safety component Figure 5: Safety inputs on the ESM-F-BSN... (both inputs connected) Safety component S13 S11 S12 S14 Base S23 S21 S22 S24 Figure 6: Safety inputs on the ESM-F-BSN... (one input connected, jumper fitted to unused input) 20

21 Inputs on the base unit ESM-F-BMN... You can connect two safety switches with one nmally closed contact and one nmally open contact (e.g. CMS from EUCHNER) to the base unit. If an input is not used, a jumper only needs to be fitted to the pair of contacts to which the nmally closed contact is connected (see Figure 8). Safety component S13 S11 S12 S14 Base S23 S21 S22 S24 Safety component Figure 7: Safety inputs on the ESM-F-BMN... (both inputs connected) Safety component S13 S11 S12 S14 Base S23 S21 S22 S24 Figure 8: Safety inputs on the ESM-F-BMN... (one input connected, jumper fitted to unused input) 21

22 Connecting safety contacts and feedback loop The base unit has three redundant, err monited safety contacts that shut down immediately if one of the safety circuits connected is interrupted a fault occurs. To check the switching state on a connected load, the auxiliary contacts on a contact relay can be connected to terminals Y1 and Y2 to fm a feedback loop. If a feedback loop is not connected, a jumper must be fitted to the terminals Y1 and Y2 (see Figure 9). The system can be expanded with further safety contacts using additional output modules. The function of the safety contacts and the feedback loop f the output modules is the same as f the base unit Base Y1 Y2 Subsequent devices (e.g. contacts) Figure 9: Safety contacts connected and jumper on the feedback loop Base Y1 Y2 Subsequent devices (e.g. contacts) Figure 10: Safety contacts and feedback loop connected Imptant! If you do not connect the feedback loop, the downstream devices will not be monited. This situation will effect the safety categy of your system. Caution! In the event of a fault (e. g. sht circuit) in the load circuit, excessively high currents may flow through the safety contacts. F protection against welding, each contact must be individually protected with an external fuse. 22

23 Connecting base unit moniting outputs The base unit has six sht circuit-proof semiconduct outputs that can be used to signal different operating states, e.g., to a PLC. If the moniting output is active, a voltage of DC 24 V is present at the related terminal (referred to the potential at terminal 0 V). O1 O2 OI OG O14 OY Figure 11: Moniting outputs on the base unit Significance of the signals with moniting output active: O1, O2: Circuit connected to safety input 1 and 2 closed OI: All input modules connected in the enable state OG: Group signal is present O14: Safety relay 1 and 2 in the base unit closed OY: Feedback loop closed Connecting group outputs If you are using only one base unit and do not require the fming of groups, you will have to connect a bridge between the terminals GI1 and GO1 as well as between GI2 and GO2 of the base unit. Linking several base units (fming groups) is described in detail in the section "fming safety groups". GO2 GO1 GI1 GI2 Base Figure 12: Group outputs when using only one base unit 23

24 Connecting expansion modules Imptant! Imptant! All expansion modules are connected to the base unit s power supply via the expansion connects supplied (see section Mounting and replacing modules). The function of the additional inputs and safety contacts is the same as f the base unit. On the use of several expansion modules the total current consumption must not be me than 3 A. Connecting input modules Input modules must always be connected to the left of the base unit. Jumpers must be fitted to unused safety inputs. The following input modules are available: ESM-F-ISI-2C2 2 dual-channel inputs, with group output ESM-F-I3I-3C2 3 dual-channel inputs, without group output ESM-F-ILI-3C2 3 dual-channel inputs, without group output without sht-circuit moniting and earth fault moniting ESM-F-ISI-6C1 6 single-channel inputs, without group output ESM-F-IMI-3C 3 dual-channel inputs f the connection of nmally open contact/nmally closed contact combinations, without group output Safety components with nmally closed contacts such as safety switches, emergency stop buttons, etc. can be connected to the input modules ESM-F-ISI and ESM-F-I3I... The version ESM-F-IMI is suitable f the connection of safety switches with nmally closed/nmally open contacts, e.g. CMS safety switches from EUCHNER. All safety inputs have sht circuit and earth fault moniting (not ESM-F-ILI...). The input modules detect the switch state of each safety component connected a fault and signal this infmation to the base unit. If all safety circuits are closed, the input module sends an enable signal to the base unit. Safety component Safety component Safety component Safety component S13 S11 (S23) (S21) S12 S14 (S22)(S24) S13 S11 (S23) (S21) S12 S14 (S22)(S24) S11 (S13) (S21) (S23) S12 (S14) (S22) (S24) S13 S11 (S23) (S21) S12 S14 (S22)(S24) ESM-F-ISI-2C2 ESM-F-I3I-3C2 ESM-F-ILI-3C2 ESM-F-ISI-6C1 ESM-F-IMI-3C2 S33 S31 S32 S34 (S33) S31 (S34) S32 S33 S31 S32 S34 Safety component Safety component Safety component Figure 13: Input modules ESM-F-ISI..., ESM-F-ILI... and ESM-F-IMI... 24

25 Each input module also has sht circuit-proof semiconduct moniting outputs that can be used to signal the states of the safety inputs to a PLC. If the moniting output is active, a voltage of DC 24 V is present at the related terminal (referred to the potential at terminal 0 V on the base unit). On the input module ESM-F-ISI-6C1 the states of two inputs are always signaled jointly via one moniting output. ESM-F-ISI-2C2 +24 V DC (internal) ESM-F-I3I-3C2 ESM-F-ILI-3C2 ESM-F-ISI-6C1 ESM-F-IMI-3C2 +24 V DC (internal) O1 O2 O1 Figure 14: Moniting outputs on the input modules Significance of the signals with moniting output active: O2 Moniting output Module O1 O2 O3 ESM-F-ISI-2C2 Input 1 closed ESM-F-I3I-3C2 Input 1 closed ESM-F-ILI-3C2 ESM-F-IMI-3C2 ESM-F-ISI-6C1 Input 1/2 closed O3 Input 2 closed Input 2 closed Input 3/4 closed Input 3 closed Input 5/6 closed 25

26 Imptant! Connecting output modules Output modules must always be connected to the right of the base unit. If a feedback loop is not connected, a jumper must be fitted to the terminals Y1 and Y2. Caution! In the event of a fault (e. g. sht circuit) in the load circuit, excessively high currents may flow through the safety contacts. F protection against welding, each contact must be individually protected with an external fuse. The following output modules are available: ESM-F-OSN-O3M1 ESM-F-OSN-O4 ESM-F-OTN-O4 ESM-F-OT05N-O4 3 safety contacts, 1 auxillary contact 4 safety contacts 4 safety contacts, switch-off delayed, adjustable time-delay s 4 safety contacts, switch-off delayed, fixed time-delay 0.5 s The output modules are used to expand the safety contacts on the base unit. The base unit sends the starting command to close the safety contacts. The safety contacts are of redundant design and have err moniting. ESM-F-OSN-04 ESM-F-OSN-03M1 ESM-F-OT Figure 15: Overview of the safety contacts on various output modules Connecting feedback loop To check the switching state on a connected load, the auxiliary contacts on a contact relay can be connected to terminals Y1 and Y2 to fm a feedback loop. The function of the feedback loop f the output modules is the same as f the base unit. (See section Connecting safety circuits and feedback loop f the base unit). 26

27 Output modules with fixed and adjustable time-delay On output modules with time-delay, the safety contacts are not opened immediately after the stop signal from the base unit, but only after a time-delay has elapsed. In this way parts of the system can continue to be supplied with power after an emergency stop request, e.g. to move tools to a safe home position to brake parts of the system that run on (controlled stop, stop categy 1 accding to EN ). Expanding time-delay output modules If me than four time-delay contacts are required, it is possible to fit further standard output modules to the right of the switch-off delayed, output module; these additional standard output modules are then switched at the same time as the switch-off delayed, module. In Base Time- Time- Out delay Out Out delay Out Out Non-time-delay Delay time T1 (e.g. 10 s) Delay time T2 (e.g. 5 s) Figure 16: Expansion of time-delay safety contacts If several different time-delays are required, the system can be expanded with further switch-off delayed, output modules. Each time-delay output module functions independently of the adjacent time-delay modules. The following diagram shows the sequence in which the outputs in the example above will switch. Outputs = switched on Enable Non-time-delay T1 T2 t 0 Figure 17: Pulse diagram T2 5 s) T1 10 s t (s) 27

28 Fming safety groups Imptant! If you do not want to fm safety groups, please read the section "Connecting group outputs" on page 23. Safety groups can be fmed using the ESM-F system. In this way it is possible to shutdown only that part of the system in which maintenance setup wk is to be perfmed. All remaining parts of the system continue to function. A dedicated base unit is used f each group. In this way each group can be evaluated separately. By simply connecting the module groups in a specific manner, it can be achieved that certain safety components only act on one base unit, while other safety components, e. g. emergency stop buttons, act on the entire system. The logical allocation is realized using a twin cable. Here the group outputs (GO1 and GO2) f a higher level base unit input module are fed to the group inputs (GI1 and GI2) on a base unit in a different group. The signal GO on the input module drops out as soon as a safety path is interrupted either on this on any other input module on its left. The higher-level input module then acts on this group. The example given (Figure 18) shows the crect allocation of the modules and the connection of the connection cable. The function of the outputs GO1 and GO2 on the base unit is similar. Here the signal GO is, however, only affected by the inputs S12 and S14 (see Figure 19). The following application examples show the difference. If you using only one base unit, you will have to connect a bridge between the terminals GI1 and GO1 as well as between GI2 and GO2 of the base unit. Fming a group with the outputs GO1 and GO2 on an input module GO1 GO2 GI 2 GI 1 In1 In2 In3 Base 1 Out In4 In5 Base 2 Out Higher-level input signals Group 1 Group 2 Figure 18: Fmation of a group with input modules and base units The input modules In1 and In2 shut down the output modules in both groups, the input module In3 only acts on group 1. The modules In4 and In5 only act on group 2. The connection cable is connected between the terminals GO on the last input module on the right that is to act on all groups (here: In2), and the terminals GI on the base unit f group 2 (base 2). Using the ESM-F system it is also possible to fm me than two groups. A wide range of combinations of input modules can be allocated to each group. 28

29 Fming a group with the outputs GO1 and GO2 on a base unit It is also possible, e.g., to connect daisy-chained emergency stops to a base unit and f only this chain to act on other base units. The following example shows such an application. Only the inputs S12 and S14 on a base unit act on the outputs GO1 and GO2. In this way it is possible f the emergency stop chain to act on both base units, while the safety inputs S22 and S24 and all input modules in the group only act on base unit 1. Emergency stop chain S13 S11 S12 S14 GO1 GO2 GI1 GI2 GI 2 GI 1 In1 In2 In3 Base 1 Out In4 In5 Base 2 Out S23 S21 S22 S24 Safety switch Response times of the ESM-F system Figure 19: Fmation of a group with two base units. Example connection f daisy-chained e-stops. Note that the time from the signal change on an input to the contacts dropping out on an output module is at least 65 ms. The times in the diagram below are typical system times that may be exceeded in specific cases. Inputs/ outputs = switched on Input on the base unit Output on the base unit Output on the output module t 0 45 ms 65 ms t (ms) 29

30 Setup Warning! The device is only allowed to be placed in operation by authized personnel who are familiar with the crect setup of safety components. Proceed as follows: Ensure nobody can be placed in danger during setup. Pri to setup check whether all connections are crect (jumpers connected, external circuit crect) and the outer extension connects are fitted with terminal plugs. Switch on the power supply. If the base unit is setup f automatic starting, the LED illuminates and all input and output LEDs on the device illuminate. On devices with expanded diagnostic functions, the LEDs Rx and Tx flicker. If you start the base unit manually, the LED illuminates and all input LEDs on the device illuminate. On devices with expanded diagnostic functions, the LEDs Rx and Tx flicker. The output LEDs are not illuminated yet, as a start command has not yet been given. Press the start button (only necessary f manual start). Check the crect function of the safety circuits connected. In case of problems, see section Trouble shooting. Imptant! If you are using expansion modules safety groups, the status indication and the switching state of these modules will also be affected. Use the status table in the section Trouble shooting to check the overall function. 30

31 Trouble shooting Status table Status LEDs on the base units GO1 GI1 GO2 GI2 S13 S11 S12 S14 In1 1 2 In2 1 2 In B G Rx Tx S23 S21 S22 S24 O1 O2 OI OG A1 SO SI SA OV Out 1 Out 2 Feedb Out B ESM-F Basic O14 OY Y1 Y A2 ESM-F-BSN-2C2O2 ESM-F-BMN-2C2O2 LED In 1-1 In 1-2 In 2-1 In 2-2 In B In G Rx Tx Out 1 Out 2 Feedb Out B Significance Illuminates if operating voltage is present. Illuminates if the safety circuit on safety input 1, channel 1 is in the safe state. Illuminates if the safety circuit on safety input 1, channel 2 is in the safe state. Illuminates if the safety circuit on safety input 2, channel 1 is in the safe state. Illuminates if the safety circuit on safety input 2, channel 2 is in the safe state. Illuminates if all input modules connected are in the enable state. Illuminates if there is a group signal present on the inputs GI1 and GI2 GI1/GI2 and GO1/GO2 are fitted with a jumper and safety input 1, channel 1 and channel 2, is in the safe state Flickers if device is wking crectly. (Only devices with expanded diagnostic function) Flickers if device is wking crectly- (Only devices with expanded diagnostic function) Illuminates if safety relay 1 in the unit is closed. Illuminates if safety relay 2 in the unit is closed. Illuminates if the feedback loop is closed. Illuminates as long as the base unit is sending an enable signal to the output modules. S13 S11 S12 S14 S23 S21 S22 S24 In1 1 2 In2 1 2 Rx Tx ESM-F Input O1 O2 GO1 GO2 ESM-F-ISI-2C2 S13 S11 S12 S14 S23 S21 S22 S24 In1 1 2 In2 1 2 In3 1 2 Rx Tx ESM-F Input S33 S31 S32 S34 O1 O2 O3 ESM-F-I3I-3C2 ESM-F-ISI-6C1 ESM-F-IMI-3C2 ESM-F-ILI-3C2 Status LEDs on the input modules LED Significance Illuminates if operating voltage is present. In 1-1 Illuminates if the safety circuit on safety input 1, channel 1 is in the safe state. In 1-2 Illuminates if the safety circuit on safety input 1, channel 2 is in the safe state. In 2-1 Illuminates if the safety circuit on safety input 2, channel 1 is in the safe state. In 2-2 Illuminates if the safety circuit on safety input 2, channel 2 is in the safe state. In 3-1 Illuminates if the safety circuit on safety input 3, channel 1 is in the safe state. In 3-2 Illuminates if the safety circuit on safety input 3, channel 2 is in the safe state. Rx Flickers if device is wking crectly Tx Flickers if device is wking crectly Status LEDs on the output modules Y1 Y Y1 Y LED Significance Illuminates if operating voltage is present. Out 1 Out 2 Feedb ESM-F Output Out 1 Out 2 Feedb ESM-F Output Out 1 Out 2 Feedb Illuminates if safety relay 1 in the unit is closed. Illuminates if safety relay 2 in the unit is closed. Illuminates if the feedback loop is closed ESM-F-OSN-O Y1 Y O ESM-F-OSN-O3M Y1 Y O17 Feedb Feedb Out 1 2 ESM-F Output t Out 1 2 ESM-F Output ESM-F-OT05NO ESM-F-OTNO4 31

32 Err list Indication of the fault All LEDs off Feedb lit, all other LEDs are off In 1-1 flashing In 1-2 off In 1-1 off In 1-2 flashing In 2-1 flashing In 2-2 off In 2-1 off In 2-2 flashing In 3-1 flashing In 3-2 off In 3-1 off In 3-2 flashing In 1-1 and In 1-2 off In 2-1 and In 2-2 off In 3-1 and In 3-2 off In G off In B off Rx and/ TX off Description / cause No/inadequate supply voltage Total current consumption of the connected expansion modules is greater than 3A. no expansion connect connected Base unit only: only the right-hand side of the base unit was connected to an expansion connect. The left half is not being supplied with power. Synchronization time exceeded: f at least 500 ms channel 1 and channel 2 had different switching states. A channel on safety circuit 1 is faulty. Synchronization time exceeded: f at least 500 ms channel 1 and channel 2 had different switching states. A channel on safety circuit 2 is faulty. Synchronization time exceeded: f at least 500 ms channel 1 and channel 2 had different switching states. A channel on safety circuit 3 is faulty. Both channels of the safety circuit connected faulty. Contacts on the safety component are open (not a fault). Both channels of the safety circuit connected faulty. Contacts on the safety component are open (not a fault). Both channels of the safety circuit connected faulty. Contacts on the safety component are open (not a fault). No signal on terminals GI1 GI2. Enable signal from the higher level group has been disabled (not a fault). Not all input modules connected are in the enable state (not a fault if a safety component connected has been opened) left terminating plug not connected. Internal device fault Device does not have expanded diagnostics (not a fault). Rectification Check the power supply and the crect assembly of the expansion connects/terminal plugs. Check the number of expansion modules connected and divide the safety group into several groups if necessary. Check the crect assembly of the expansion connects/terminating plugs. Check f crect connection and the function of the safety switch connected to input 1. Check f crect connection and the function of the safety switch connected to input 2. Check f crect connection and the function of the safety switch connected to input 3. Check f crect connection and the function of the safety switch connected to input 1. Check f crect connection and the function of the safety switch connected to input 2. Check f crect connection and the function of the safety switch connected to input 3. Check whether the jumpers are fitted to terminals GO1/GI1 and GO2/GI2 check whether the group has been fmed crectly check the function of the higher level group. Check the crect connection and the function of the input modules connected check the crect assembly of the expansion connects/terminating plugs. Contact EUCHNER customer service. 32

33 Out 1 illuminated and Out 2 off Out 1 and Out 2 off Out B off Fault on the start button because: Start button was pressed too early after the application of the operating voltage. Start button was pressed during the activation of safety inputs. Start button faulty (contact welded, button sticking). Internal device fault Inputs group disabled (not a fault) Start button not pressed Fault on the inputs Fault on start button Inputs group disabled (not a fault). Fault on the inputs Feedb off Feedback loop open (not a fault, if Out 1 and/ Out 2 off). right terminating plug not connected. In 1-1 and In 2-2 flash with regular signal sequences Indication of an internal device fault (sequence of flashes interrupted by a fixed pause). Possible cause: Fault because off severe EMC interference Unit is faulty After the application of the operating voltage, wait at least 300 ms befe you press the start button. Check the crect function of the start button and replace if faulty. Contact EUCHNER customer service. Check the crect function of the higher level inputs and groups that act on the output module. Check the crect function of the higher level inputs and groups that act on the output module. Check the crect connection and the function of the components in the feedback loop. check the crect assembly of the expansion connects/terminating plugs. Switch system off and on If it was not possible to rectify the fault with a restart, contact EUCHNER customer service. 33

34 Inspection and service Warning! Loss of the safety function because of damage to the device. In case of damage the related module must be replaced. The replacement of individual parts in a module is not permitted. Regular inspection of the following is necessary to ensure trouble-free long-term operation: Check the switching function Check the secure fastening of the devices and the connections Check f soiling (e.g. the ventilation slots on the housing) No servicing is required. Repairs to the device are only allowed to be made by the manufacturer. Service In case of a need f service, contact: EUCHNER GmbH + Co. KG Kohlhammerstraße 16 D Leinfelden-Echterdingen Service telephone: +49 (0) 7 11 / info@euchner.de Internet: 34

35 Declaration of confmity As per the requirements of the Low voltage directive 73/23/EEC, the EMC directive 89/336/EEC and the Machinery directive 98/37/EC, we declare the confmity of the products listed below with the following European standards: a: EN Electromagnetic Compatibility (EMC). Generic emission standard. Part 1: Residential, commercial and light industry b: EN Electromagnetic Compatibility (EMC). Generic emission standard, Part 2: Industrial environment c: EN Safety of machinery. Safety related parts of control systems. General principles f design d: EN Safety of machinery. Electrical equipment f machines. Part 1: Specification f general requirements e: EN Low-voltage switchgear and controlgear assemblies. Part 1: Type-tested and partially type-tested assemblies f: EN Safety of power transfmers, power supply units and similar. General requirements and tests g: EN /0 Fire hazard testing. Part 2: Diffusion type and premixed type flame test methods h: EN Specification f low-voltage switchgear and controlgear. Part 1: General rules i: EN Specification f low-voltage switchgear and controlgear. Part 5-1: Control circuit devices and switching elements. Electromechanical control circuit devices j: EN Specification f low-voltage switchgear and controlgear. Part 7: Ancillary equipment. Terminal blocks f copper conducts k: EN 574 Safety of machinery. Two-hand control devices. Functional aspects. Principles f design The products are marked with the - marking as per the machinery directive. Product Series Confmity with EN standards Safety relay ESM-... a, b, c, d, e, f, g, h, i, j, k Safety module ESM-F-... a, b, c, d, e, f g, h, i, j The use of these products in a machine system does not guarantee the entire machine system complies with the European directives. Leinfelden, November 2005 Dipl.-Ing. Stefan Euchner Direct 35

36 Euchner GmbH + Co. KG Kohlhammerstraße 16 D Leinfelden-Echterdingen info@euchner.de Issue: /07 Title: System Manual Modular Safety System ESM-F Copyright: EUCHNER GmbH + Co. KG, 02/2007 Subject to technical modifications, all data supplied without liability. Me than safety.