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6.1 Switch Safely
The following circuit examples have been harmonized with the German Trade Association (BG) and have been approved. * Contactor circuits * SIGUARD safety combinations using contactors using safety relays Suitable for: * EMERGENCY OFF * Protective door monitoring functions * Press controls EMERGENCY OFF circuits for extremely simple machines EMERGENCY OFF switch The EMERGENCY OFF function may only be fed through an EMERGENCY OFF switch for extremely simple machines, depending on the result of a risk analysis. In this particular case, only Stop Category 0 is possible. Such an EMERGENCY OFF switch switches, contrary to usual EMERGENCY OFF pushbuttons, the main circuit (circuit diagram 6/1). An EMERGENCY OFF switch must be configured, so that * There is only one EMERGENCY OFF switch; * the EMERGENCY OFF switch is located in the supply to those circuits which can result in hazardous motion in the system. The complete power supply to all of the circuits does not have to be interrupted; * the EMERGENCY OFF switch must be able to interrupt the current of the largest motor when the motor stalls; * the sum of the currents of all of the loads which must be disconnected using the EMERGENCY OFF switch must be able to be safely interrupted.
An EMERGENCY OFF switch may * be manually actuated; * act on an undervoltage release via one or several EMERGENCY OFF control devices (circuit diagram 6/1); * be provided with overload- and/ or short-circuit releases (version as circuit-breaker);
* be simultaneously used as main switch, if it additionally fulfills the requirements for a main switch (however, a main switch must disconnect all circuits). An example for such an EMERGENCY OFF switch for extremely simple machines is illustrated in circuit diagram 6/2.
Manual drive mechanism
To loads, which must be shutdown for an EMERGENCY OFF "EMERGENCY OFF switch" Switch lock Release Mushroom-head pushbutton
To loads, which don't have to be/may not be disconnected for EMERGENCY OFF U< Main switch EMERGENCY OFF control device
Supply
Circuit diagram 6/1 EMERGENCY OFF switch with manual actuation or remote actuation via undervoltage release
"EMERGENCY OFF switch" To loads which don't have to be/may not be disconnected for EMERGENCY OFF
Control off
Off
On K1
K1
on K2
K2
Main switch
e.g. plant protective conductor Supply To loads which must be shutdown for EMERGENCY OFF
Circuit diagram 6/2 Example of a machine control with EMERGENCY OFF switch (this is only permissible with some restrictions)
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EMERGENCY OFF contactor Generally, a so-called EMERGENCY OFF contactor is not permitted. Such a contactor is only permissible in precisely defined exceptional cases: This contactor may only be used as an EMERGENCY-STOP contactor in the branch to be shutdown. Additional contactors in series are not permitted. This means that this concept is restricted for applications on extremely simple machines (refer to circuit diagram 6/3). An EMERGENCY OFF contactor must be configured, so that * each EMERGENCY OFF contactor must be immediately de-energized by the EMERGENCY OFF control device; * there are no additional contactors in series.
L1 Supply To loads which don't have to be/may not be disconnected for EMERGENCY OFF Main switch EMERGENCY OFF control device located in the control circuit To loads which must be shutdown for EMERGENCY OFF
Circuit diagram 6/3 Example of a machine control with 2 EMERGENCY OFF contactors, only permitted with some restrictions
F1 EMERGENCY OFF device, if required several in series
Enable signals
Safety circuits using individual contactors Configured using two auxiliary contactors Safety circuits of any complexity can be configured using auxiliary contactors. Up to several years ago, the circuit with two auxiliary contactors and overlapping auxiliary contacts (circuit diagram 6/4) was considered to be state-of-the-art. This circuit offers redundancy. However, due to the fact that the contacts are not positively driven, the two auxiliary contactors do not mutually monitor each other for correct functioning. This means, that if a contact welds, this fault is not detected and the circuit still continues to function. A subsequent fault in the second contactor could completely disable the combination. This would mean that the level of safety would no longer be guaranteed. Thus, today, this circuit is no longer used (circuit diagram 6/4).
Actuator "On" or "On" after EMERGENCY OFF K1
K1
K2
K1 - no positively-driven contacts - no self-monitoring
K2
K2
K1 N
K2
This circuit is no longer used.
Circuit diagram 6/4 This contactor combination consists of two auxiliary contactors with overlapping contacts
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Using three auxiliary contactors Today, circuits with three auxiliary contactors represent state-of-the-art technology. Three auxiliary contactors, with positively-driven contacts are used, as shown in circuit diagram 6/5. The three auxiliary contactors guarantee redundancy and function monitoring. The positively-driven contacts guarantee that the auxiliary contactors mutually monitor themselves. Faults are therefore detected and the circuit can no longer be closed after shutdown, therefore eliminating subsequent faults. With this circuit, using today's stateof-the-art technology, it can be assumed that if the auxiliary contactors incorrectly function this will not result in a hazardous status in the system.
Several auxiliary contactors are combined to form a safety circuit in the form of the 3TK28 contactor safety combinations. Naturally, the circuits
can also be implemented using individual contactors.
L+/L1
F1 EMERGENCY OFF device, if required several
Enable signals K1
Actuator "On" or control voltage "On" K2 K1
K1 K2 K3
K2
K3
K3
K1
K3
L-/N
K1
K2
K3
Circuit diagram 6/5 Contactor combination using three auxiliary contactors with self-monitoring, single-channel
Connecting several EMERGENCY OFF control devices In the previous circuit diagrams, only one EMERGENCY OFF device was shown. Generally, there are several EMERGENCY OFF control devices (e.g. at different locations) on a machine. The contacts of these EMERGENCY OFF control devices are then connected in series.
Circuit examples to monitor protective devices Circuits to monitor protective devices use position switches. Various possibilities of the different devices are shown in the examples for EMERGENCY OFF These circuit examples . will not be repeated here as the EMERGENCY OFF control device is only replaced by one or two position
switches per protective device. The number of position switches which are required for each protective door can be taken from Section 2 of the Manual.
Single-channel
Two-channel
EMERGENCY OFF control devices
EMERGENCY OFF control devices
Doors
Open Closed Closed Open
Circuit diagram 6/6 Several EMERGENCY OFF control devices
Circuit diagram 6/7 SIGUARD position switches used to monitor moving protective equipment
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6.2 3TK28 SIGUARD Contactor Safety Combinations
6
1 Enabling contacts 2 Signaling contacts 3 Signal transmitter 4 "Ready ON" For 3TK28 01-3TK28 04 and 3TK29: 5 "Ready" LED 6 "ON" LED
The internal circuit diagrams are valid for DC-operated devices. The ACoperated SIGUARD combinations essentially correspond to those for DC operation. Only the polarity protection diode V1 is eliminated and a bridge rectifier is located in front of every contactor. This means that ACoperated SIGUARD contactor safety combinations can also be used for DC voltages with some restrictions.
L+ X1
3 X2 X3
X4
4 X5
1 X6 13 23
2 25
U
R3
K3 K1
K1 K2 R2 K3 H2 K1 V1
K1 K2
K1 K2 K2 K2
K3 K3 V3 R1 K2 H1 5 6 14 V2
K3
K3
L -
24
(26)
Circuit diagram 6/8 Internal circuit diagram of 3TK28 01, 3TK28 02 contactor safety combination (DC operation) NC signaling contact for 3TK28 02. For 3TK 2801/02, terminals "X2, X4, X6" are at the top, for TK 2803, there is no terminal "X3"
L1/L+ N/L1 Enable 2 Signal F1 3 L1/L+ X1 (X2) (X3) (X4) X5 4 (X6) 13 1 2 3 EMERGENCY OFF signal transmitter 4 "Ready ON"
K1
K2
K3
N/L-
X2
X4
X6
14
Circuit diagram 6/9 Contactor safety combinations 3TK28 01 to 3TK2804 for EMERGENCY OFF circuits
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Immediately ready after the power returns (it is not necessary to open and close the protective device): The "Ready ON" f is not required (jumper X5-X6), if the resulting automatic reclosure (restart) does not represent potential danger.
L1/L+ N/LDoor Open Closed
1 Enable 2 Signal F1 3 Signal transmitter 3 4 X1 (X2) (X3) (X4) X5 (X6) 13 1 2 4 "Ready ON"
L1/L+
K1
K2
K3
N/L-
X2
X4
X6
14
Circuit diagram 6/10 Contactor safety combinations 3TK28 01 to 3TK28 04 to monitor moving protective devices. For 3TK 2801/02, terminals "X2, X4, X6" are at the top, for TK 2803, there is no terminal "X3" .
L1/L+ N/L1 Enable 2 Signal 3 F1 4 L1/L+ X1 (X2) (X3) (X4) X5 (X6) 13 1 2 3 Signal transmitter EMERGENCY OFF 4 "Ready ON"
K1
K2
K3
N/L-
X2
X4
X6
14
Circuit diagram 6/11 Contactor safety combinations 3TK28 01 to 3TK28 04 for an EMERGENCY OFF circuit. For 3TK28 01/02, terminals "X2, X4, X6" are at the top, for 3TK 2803, there is no terminal "X3" .
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3 L+ X1 X2 V1 U R3 K1 R2 H2 K3 K1 K1 K2 K1 K3 R1 K1 K2 K3 H1 K3 K1 K2 X3 X4 4 X5 X6 13 1 23 33 43 2 57 65 1 Enabling contacts 2 Signaling contacts 3 Signal transmitter 4 "Ready ON" 5 "Ready" LED 6 "ON" LED K2 K3
5
6
L-
14
24 34 44
58
66
Circuit diagram 6/12 Internal circuit diagram of a 3TK28 04 contactor safety combination (DC operation)
L+ V1
4 X1
3 X3 X5
1
2 1 Enabling contacts 2 Signaling contacts 3 Signal transmitter 4 "Ready ON" 5 "Ready" LED 6 "ON" LED For 3TK28 05: 5 "Line supply" LED 6 H2 = LED "Channel 2" H3 = LED "Channel 1" H2 + H3 = Enable 8 Terminal X2 is not connected-up
13 23 33 43 53 65
H1 R3 K2 R1 R5 H3 K3 D3 K1 K2
K3 K2
U
D1 K1 K1
K3 K1 K3
H2 K1 D2 K2 R2
5 L -
8 (X2) X4 X6
6
6 14 24 34 44 54 66
8 For 3TK28 06: Special circuit is possible for terminal X2
Circuit diagram 6/13 Internal circuit diagram of a 3TK28 05, 3TK28 06 contactor safety combination (DC operation); terminal X2 is only connected-up for the 3TK28 06 device
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L1/L+ N/L F1
"Ready ON"
L1 L2 L3
EMERGENCY OFF X3 X5 13 23 33 43 53 65
L1/L+ V1
X1
KM1
H1 R3 K2 R1 R5 H3 K3 D3 K1 K2
K3 K2
KM1
U
D1 K1 K1
K3 K1 K3
H2 K1 D2 K2 R2
M 3~
N/L-
X2
X4
X6
14 24 34 N/LKM1
44 54 66
Circuit diagram 6/14 Contactor safety combination 3TK28 06 for a single-channel EMERGENCY OFF circuit. This circuit can also be used for the 3TK28 05 (Cat. 2).
L1/L+ N/L F1
"Ready ON"
L1 L2 L3
EMERGENCY OFF X3 X5 13 23 33 43 53 65
L1/L+ V1
X1
KM1 KM2
H1 R3 K2 R1 R5 H3 K3 D3 K1 K2
K3 K2
KM1 KM2
U
D1 K1
K3 K1 K3
H2 K1 D2 K2 R2
M 3~
N/L-
X4
X6
14 24 34
44 54 66 KM2
N/L-
KM1
Circuit diagram 6/15 Contactor safety combination 3TK28 06 for a two-channel EMERGENCY OFF circuit. This circuit can also be used for the 3TK28 05 (Cat. 3).
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L1/L+ N/L F1
"Ready ON" EMERGENCY OFF
L1 L2 L3
L1/L+ V4
X1
X3
X5
13 23 33 43 53
65
KM1 KM2
H1 R3 K2 R1 R5 H3 K3 D3 K1 K2
K3 K2
KM1 KM2
U
D1 K1
K3 K1 K3
H2 K1 D2 K2 R2
M 3~
N/L-
X4
X6
14 24 34
44 54
66
KM2 N/LKM1
Circuit diagram 6/16 Contactor safety combination 3TK28 06 for a two-channel EMERGENCY OFF circuit with cross-circuit protection. This circuit can also be used for the 3TK28 05 (Cat. 4).
L+ V1
4 X1
3 X3 X5
1 13 23 33 43 53
2 65
5 77 87 97
K3 L1/L+ K3 R2 R1 H1 K2 U K1 V2 K1 K1 K3 R4 V4 H3 K2 R3 V3 H2 IN2 N/L Y2 Z2 IN1 N/L Y1 Z1 K3 K1 K2 K2 K1 Timer module Channel 2 tv = 0.5...30s L1/L+ Timer module K4 Channel 1 tv = 0.5...30s K5
Enabling contacts Signaling contacts Signal transmitter "Ready ON" Enable contacts, delayed 7 Jumper Y1-Z1 and Y2-Z2 to extend the delay time by 10x 8 A special circuit can be connected at terminal X2
1 2 3 4 5
L -
X2 8
X4
14 24 34 44 54
66
Y2
Z2 7
Y1
Z1
78 88 98
t v x 10
t v x 10
Circuit diagram 6/17 Internal circuit diagram of a 3TK28 07 contactor safety combination (DC operation)
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L1/L+ N/L F1 4 3 F2 1 L1/L+ X1 X3 X5 13 23 33 43 53 65 F2 2 77 87 97
L1 L2 L3 1 Enable, instantaneous 2 Motor OFF delayed , 3 Signal transmitter, EMERGENCY OFF 4 "Ready ON" 5 Motor control device 6 Braking trigger signal 7 Fault signal, motor control device 8 Mechanical brake K3 K2 K1 K4 K5 5 KM1
M 3~ 8 6 N/L X2 KM1 7 N/LKM1 X4 14 24 34 44 54 66 78 88 98
Circuit diagram 6/18 Contactor safety combination 3TK28 07 for controlled actuation of EMERGENCY OFF.
L1/L+ N/L F1 Door Open Closed L+ X1 X3 X5 1 13 23 33 43 53 65 1 Enabling signals 4 Ready ON
K3 4 K2 K1
L -
X2
X4
X6
14 24 34 44 54
66
Circuit diagram 6/19 Contactor safety combination 3TK28 06 to monitor moving protective devices
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L1/L+ N/L F1
Door Open Closed
L1 L2 Automatic restart is only permitted for protective monitoring in exceptional cases. If an automatic restart cannot result in a hazardous condition, then "Ready ON" is not required. X5 13 23 33 43 53 65 L3
L+
X1
X3
KM1 K3 KM2 KM1 K2 K1 KM2
M 3~
L X4 X6 14 24 34 44 54 66 KM2 N/LKM1
Circuit diagram 6/20 Contactor safety combination 3TK28 06 for two-channel and cross-circuit proof monitoring of moving protective devices with automatic restart
Classification in Categories according to EN 954-1 The classification of circuits into categories according to EN 954-1 has now been made clear using the previous examples.
The classification below, is valid when the wiring is correctly realized according to the published circuit diagrams, also under difficult ambient conditions, for example dirty industrial environments (pollution level 3). If special care is taken connecting-up the wiring, it may be possible to achieve a higher safety category, e.g.
using separate cables or routing the cable to EMERGENCY OFF contacts and position switches so that it is mechanically protected (e.g. in special cable ducts). Thus, Category 4 can be achieved without having a cross-circuit proof configuration, under the assumption, that the appropriate peripheral devices are used.
Category acc. to EN 954-1 Circuit version B, 1, 2 3 4 Single channel Two channel Two channel and cross-circuit proof
Possible equipment Possible with all basic- and expansion devices 3TK2805, 3TK28 06, 3TK28 07, also in conjunction with one or several expansion units 3TK28 05 and 3TK2806 also in conjunction with one or several expansion units
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Interface for expansion units The 3TK29 SIGUARD combination expansion units must always be used together with a basic 3TK28 unit. One expansion unit can be connected for each enabling contact in the basic unit. The signaling contact in the expansion unit must always be connected in series with "Ready ON" . The Category which a circuit with an expansion unit can achieve according to EN 954-1 depends on the Category of the basic unit with interface. If the expansion unit is located next to the basic unit in the cabinet, the connecting cables between the basic unit and expansion unit are so short, that a fault (electrical fault) can be completely ruled-out in these connecting cables.
A circuit with the 3TK28 06 and two expansion units to multiply the contacts of the 3TK28 07 is illustrated in circuit diagram 6/21. The 3TK29 . 3 expansion units can be used for drop-out delayed contacts of up to 8 seconds (circuit diagram 6/23). The delay time is set using different jumpers at connecting terminals Y2, Z1, Z2 and Z3.
L1/L+ N/L F1
Ready ON EMERGENCYSTOP
3TK28 06 (or 3TK28 05) with two-channel and cross-circuit-proof connection of the EMERGENCY OFF control devices can achieve Category 4 according to EN 954-1, also using one (or two) expansion unit(s).
If required, more than one expansion unit can be connected to a basic unit as shown here in the example. In this example, 5 expansion units can be connected.
L1/L+ V1
X1
X3
X5
13 23 33 43 53 65
X7
103 123 73 83 93 113 133
X7
103 123 73 83 93 113 133
H1 R1 R5
R3 K3 D3 K2 K1
K3 K2 K2 R3
R1
K3
R1
K3
U
K3 H3 H2 K1 D2 K2 R2
R3
U
K3 K4
R2 H1
K4
U
K3 K4
R2 H1
K4
D1 K1
K1
K3
K1 N/L X2 X4 X6 14 24 34 44 54 66 A1/ A2/ L+ LX8 74 84 94 114 134 A1/ A2/ 104 124 L+ LX8 74 84 94 114 134 104 124
Circuit diagram 6/21 Contactor safety combinations 3TK28 06 for two-channel and cross-circuit-proof connection of the EMERGENCY OFF control device and two 3TK29 07 expansion units. This circuit can also be realized using the 3TK28 05 unit.
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L1/L+ N/L F1 Ready ON L1/L + V1 X1
EMERGENCY OFF
3TK28 06 (or 3TK28 05) with two-channel and cross-circuit-proof connection of the EMERGENCY OFF control devices can achieve Category 4.
X3
X5
13 23 33 43 53 65 V1 V2 R5 R4 R7 R1
X7
77 87 97
H1 R1 R5
R3 K3 D3 K2 K1
K3 R3 K2 K2 H2 K1
K1
U
R2 + + C2 C3 + C4 + R6 K1 K2 H1 K2
U
K3 H3
D1 K1
K1
K3
D2 K2 R2
C1
K1 N/L X2 X4 X6 14 24 34 44 54 66 A1/L+ A2/LY2 Z1 Z2 Z3 X8 78 88 98
Circuit diagram 6/22 Contactor safety combination 3TK28 06 for two-channel and cross-circuit-proof connection of the EMERGENCY OFF control device and a 3TK29 . 3 expansion unit. This circuit can also be used with the 3TK28 05.
Expansion units
1 X7 V1 V2 R4 R3 R5 U R2 + C1 C2 + C3 + C4 + R6 K1 K2 H1 H1 K2 R7 R1 K1 R3 R1 K3 77 87 97 X7
1 73 83 93 103 113 123 133
U
K3
K4 R2 K4
6 A1/L+ A2/L Y2 Z1 Z2 Z3 X8 78 88 98 A1/L+ A2/L1 Enabling contacts 6 "ON" LED X8 74 84 94 104 114 124 134
1 Enabling contacts
Circuit diagram 6/23 Internal circuit diagram of a contactor safety combination delay module 3TK29 23, 43, 83 (DC operation)
Circuit diagram 6/24 Internal circuit diagram of a contactor safety combination supplementary module 3TK29 07 (DC operation)
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Press control devices Circuit examples for presses The two devices, two-hand control device 3TK28 11 and overtravel tester 3TK28 15 are used for press controls.
Two-hand control device 3TK28 11 The two-hand control device 3TK28 11 is a control which allows presses to be controlled using two hands. For presses, it must be ensured that both hands are required to control the presses. The two-hand control device fulfills Category 4 in accordance with EN 954-1 and achieves type 3 according to EN 60 204-1 (VDE 0113 Part 1) as well as type IIIc according to EN 574 for two-hand control systems. This means that both control devices of the 3SB33 SIGUARD two-hand control must be simultaneously actuated ( 0.5 s) with both hands and they have to be continually actuated while the press is in a hazardous condition. If one actuator device is released, then the control stops the hazard-ous motion. If the 0.5 s is exceeded, or if one of the control devices is released, then both control devices must be released before a restart can be initiated. It should also be observed that the switching currents for the control devices are 50 mA at 24 V DC. The 3SB3 SIGNUM(R) control devices, as well as the SIGUARD two-hand operator unit 3SB33G3 are suitable. It may be necessary to use gold-plated contacts. Control interlocking functions are switched in the feedback circuit.
3TK28 15 overtravel tester This unit is used to check overtravel for linearly operated presses, such as spindle, hydraulic and pneumatic presses. Each time that the power supply is switched-on at the two-hand control device 3TK28 11, the braking travel is checked using the 3TK28 15. 3TK28 15 must always be used in conjunction with the two-hand control unit 3TK28 11. For press control units using relays, refer to Pages 6/28 to 6/31.
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L1/L+ N/L 1 F1 S1 A1 3TK2811 T11 T12 T13 KM1 X1 KM2 X2 13 23 31 41 2 F2 F3 KM2 KM1
A2
T21
T22 S2
T23
14
24
32
42
1
Circuit diagram 6/25 Two-hand control device 3TK28 11
L1/L+ N/L -
F1 Powering-up a press * Power-up the pump (S4) X1 13 K3 S1 3 K4 X2 14 32 3TK2811 24 K4 S3 A1+ 3TK2815 3 7 K4 9 12 5 16 8 1 10 S5 H1 K3 7 K2 1 Two-hand pushbutton 2 Feedback 3 OFF 4 PE: Test limit switch, defines the overtravel 5 OT: Upper dead center 6 Hydraulic pump ON 7 UP (wards) K1 Hydraulic pump contactor 31 23 * Travel to upper dead center (S5) * Actuate the two-hand operation console (3TK2811), until S3 opens * Actuate the two-hand operation console a second time. After the two-hand operation console is released, the ram automatically travels to upper dead center.
4 K1 PE
5 OT S2 S4 6
A2-
4
6
11
13
14
15
K2 Ram up K3 Ram down, 1st channel K4 Ram down, 2nd channel
Circuit diagram 6/26 Overtravel tester 3TK28 15 and two-hand control device 3TK28 11
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6.3 3TK28 SIGUARD Relay Safety Combinations
Y33 Y34 A1 4 1 2 K1 K1
Y22 Y21 K2
13 23 A1/A2 Y33/34 3 K1 Y11/12 Y21/22 power supply "ready ON" Feedback circuit sensor (e.g. EMERGENCY OFF pushbutton) sensor (e.g. EMERGENCY OFF pushbutton two-channel) enable circuit enable circuit "POWER" LED "Channel 1" LED "Channel 2" LED PTC fuse
K1 C1 K1 K2 K2 V1 K2 A2 Y11 Y12 14 24
13/14 K2 23/24 1 2 3 4
Circuit diagram 6/27 Internal circuit diagram of the 3TK2823
Function description
Y33 Y34 A1 4 1 2 H1 C1 K1 H2 K1 K2 K2 V1 K2 A2 Y11 Y12 14 24 K2 K1 K1 3 K1 H3 Y22 Y21 K2 13 23 Power-on Connect the power; the "Power" LED is lit, EMERGENCY OFF closed, C1 is charged, press ON, C1 is charged, K1, V1 are energized, ...K2 starts, K1 + K2 latch, "Channel 1" and "Channel 2" LEDs are lit. ON monitoring ON is pressed fault! EMERGENCY OFF closed, V1 immediately starts K2, C1 is not charged K1 does not start. Only the "Channel 2" LED is lit Cross-circuit If EMERGENCY OFF 1 and EMERGENCY OFF 2 are short-circuited, a short-circuit current flows through the PTC fuse. The PTC goes into a high-ohmic state. None of the LEDs are lit.
Circuit diagram 6/28 Function description 3TK2823
Y2 A1 4 K1 1
Y1
13 23
(33) (41) A1/A2 Y1/Y2 power supply via EMERGENCY OFF pushbutton "ON" feedback circuit enable circuit enable circuit enable circuit signaling circuit "POWER" LED "Channel 1" LED "Channel 2" LED PTC fuse
K1 K2 K2 K1 13/14 23/24 33/34 41/42 3 K1 K2 K2 1 2 3 4 14 24 (34) (42)
2
A2
Circuit diagram 6/29 Internal circuit diagram of the 3TK2821/24
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The following circuit diagrams have been harmonized with the German Trade Association (BG) and also approved.
24 V AC/DC K1 K2 ON K1 EMERGENCY OFF A1 3TK2821/24 L/+
6.3.1 EMERGENCY OFF (EMERGENCY-STOP) circuits
Circuit diagrams
K3 Y1 Y2 13 23 (33) (41)
M
K2
M
A2
14 24 (34) (42) K1 K2 K3 H1 N/-
K3
Circuit diagram 6/30 3TK2821/24 for EMERGENCY OFF, Category 2, single-channel, with feedback circuit
M
N/-
24 V AC/DC
L/+
ON
3TK2821/24
EMERGENCY OFF
A1
Y1 Y2
13 23
(33)
(41)
K1
K1
K2 K2
M
A2 14 24 K1 K2 N/- N/- (34) (42) H1
Circuit diagram 6/31 3TK2821/24 for EMERGENCY OFF, Category 3 (4), two-channel, with feedback circuit
24 V AC/DC K1 ON K2 A1 Y11 Y12 3TK2823 Y33 Y34
L/+
13 23
EMERGENCY OFF
K1
K2 Y21 Y22 A2 14 24 K1 K2 N/- N/-
M
Circuit diagram 6/32 3TK2823 for EMERGENCY OFF, Category 4, two-channel, with feedback circuit, monitored start
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L/+ L/+ A1 Y10 Y11 Y12 Y21 Y22 ON K1 K2 K3 Y33 Y34 Y43 Y44 PE A2 14 24 34 42 K1 K2 K3 H1 PE N/- N/- 52 H2 3TK2825
EMERGENCY OFF
13 23 33 41
51
K1
K2
K3
M
M
M
Circuit diagram 6/33 3TK2825 EMERGENCY OFF Category 2, single-channel, according to EN 954-1, monitored start ,
L/+
L/+ A1 Y10 Y11 Y12 Y21 Y22 3TK2825 13 23 33 41 51
ON K1 K2
EMERGENCY OFF
K2
K1
M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 K1 K2 PE N/- N/- H1 52 H2
Circuit diagram 6/34 3TK2825 EMERGENCY OFF Category 4, two-channel, according to EN 954-1, monitored start ,
L/+
L/+ A1 Y10 Y11 Y12 Y21 Y22 3TK2827
EMERGENCY OFF
13 23 31
47 57
K2
K1
ON K1
M
K2
M
Y33 Y34
PE
A2
14 24 32 H1
48 58 K1 K2 N/-
PE N/-
Circuit diagram 6/35 3TK2827 EMERGENCY OFF Category 2, single-channel, according to EN 954-1, monitored start ,
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6
L/+ L/+ A1
EMERGENCY OFF
Y10 Y11 Y12 Y21 Y22 13 23 31
47 57
3TK2827
ON K1 K2
K1 K2
M
Y33 Y34 PE A2 14 24 32 H1 48 58 K1 K2
Circuit diagram 6/36 3TK2827 EMERGENCY OFF with shutdown, stop Category 1, for Category 3 according to EN 954-1, two-channel, with feedback circuit, monitored start
24 V AC/DC K1
PE N/- N/-
ON L/+
K5 A1 Y11 Y12 Y33 Y34 3TK2823 13 23 3TK2830 Y21 Y22 A2 14 24 K1 N/- N/- A2 14 24 34 44 52 K2 K3 K4 K5 A1 13 23 33 43 51
EMERGENCY OFF
Circuit diagram 6/37 3TK2823 expanded with 3TK2830 for EMERGENCY OFF Category 4 acc. , to EN 954-1, two-channel, with feedback circuit
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6/19
L/+ 24 V AC/DC
A1 Y10 Y11 Y12 Y21 ON K1
EMERGENCY OFF
Y22
13 23 33 41
51 3TK2830
A1 13 23 33 43 51
K5 K6 Y33 Y34 PE N/- N/- PE A2 14 24 34 42 K1 K2 52 N/- N/- A2 14 24 34 44 52 K3 K4 K5 K6
3TK2825
H1 H2
Circuit diagram 6/38 3TK2825 expanded by 3TK2830 for EMERGENCY OFF Category 4 acc. to EN 954-1, two-channel acc. to EN 954-1, monitored start ,
L/+ 24 V AC/DC
A1 Y10 Y11 Y12 Y21 ON K1 3TK2827
EMERGENCY OFF
Y22
13 23 31
47 57 3TK2830
A1 13 23 33 43 51
K7 Y33 Y34 PE N/- N/- PE A2 14 24 32 K1 K2 H1 48 58 K3 N/- N/- A2 14 24 34 44 52 K4 K5 K6 K7
Circuit diagram 6/39 3TK2827 expanded by 3TK2830 for EMERGENCY OFF Category 4, two-channel, monitored start ,
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6.3.2 Protective door monitoring
24 V AC/DC L/+ K1 K2 open closed A1 closed 3TK2821/24 K3 Y1 Y2 13 23 (33) (41) open
K1
K2
K3
M
M
M
Circuit diagram 6/40 3TK2821/24 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position switch), Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart
A2 N/- N/-
14 24 (34) (42) K1 K2 K3 H1
open 24 V AC/DC closed K1 K2 K3 A1 3TK2821/24 Y1 Y2
L/+
K1
M
13 23 (33) (41)
K2
open closed
M
Circuit diagram 6/41 3TK2821/24 for protective door monitoring with tumbler (2 protective doors are cascaded, each with 2 SIGUARD position switches with tumbler), Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart
A2
14 24 (34) (42) K1 K2 K3 H1 N/-
K3
M
N/-
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L/+ 24 V AC/DC
A1
3TK2821/24
K1 K2 Y1 Y2 13 23 (33) (41)
open
closed
K1
K2
M
A2 14 24 (34) (42) H1 K1 K2
open closed N/-
N/-
Circuit diagram 6/42 3TK2821/24 for protective door monitoring (2 protective doors are cascaded, each with 2 SIGUARD position switches), Category 3(4) acc. to EN 954-1, two-channel with feedback circuit, autostart, ( for Category 4 - the cable has to be routed so that it is especially protected)
24 V AC/DC L/+
K1 K2 A1 3TK2822 Y11 Y12 Y33 Y34 13 23
open closed
K1
K2
M
Y21 Y22 A2 14 24 K1 K2 N/-
N/-
Circuit diagram 6/43 3TK2822 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position switch), Category 4 acc. to EN 954-1, two-channel with feedback circuit, autostart
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L/+ L/+ closed K1 open A1 3TK2825 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51 K2 open closed K3 K1 K2 K3
M
Y33 Y34 Y43 Y44 PE A2 PE N/- N/- 14 24 34 42 52 K1 K2 K3 H1 H2
M
M
Circuit diagram 6/44 3TK2825 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position switch), autostart, Category 2 acc. to EN 954-1, single-channel, with feedback circuit
L/+
open closed L/+ A1 3TK2825 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
K1
K1
K2 K2
Y33 Y34 Y43 Y44 PE A2 PE N/- N/-
14 24 34 42 K1 K2 H1
52 H2
M
Circuit diagram 6/45 3TK2825 for protective door monitoring with 2 SIGUARD position switches, autostart, Category 4 acc. to EN 954-1, two-channel, with feedback circuit
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L/+
L/+ closed open
A1 3TK2828
Y10
Y11 Y12
Y21
Y22
13 23 31
47 57
K1
K2
K1 open closed K2 Y33 Y34 PE A2 14 24 32 H1 48 58 K1 K2 N/- PE N/-
M
M
Circuit diagram 6/46 3TK2828 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position switch), stop Category 1, Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart
L/+
L/+ A1 3TK2828 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57 K1 K2
K1 K2
open closed
Y33 Y34
PE
A2
14 24 32
48 58
M
H1
K1 K2 N/-
PE N/-
Circuit diagram 6/47 3TK2828 for protective door monitoring with 2 SIGUARD position switches, stop Category 1, Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart
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24 V AC/DC L/+ A1 3TK2825 K1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51 3TK2830 Y44 PE A2 14 24 34 42 K1 K2 PE N/ N/- H1 52 H2 N/- N/- A2 14 24 34 44 52 K3 K4 K5 K6 A1 13 23 33 43 51
K6 open closed Y33 Y34 Y43
Circuit diagram 6/48 3TK2825 expanded by 3TK2830 for protective door monitoring with 2 SIGUARD position switches, Category 4 acc. to EN 954-1, two-channel, with feedback circuit, autostart
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Protective door monitoring with contactless SIGUARD magnetically-operated switches Protective doors are monitored using an evaluation unit up to Cat. 3 acc. to EN 954-1 (circuit diagram 6/50). The evaluation unit can be operated, both with automatic restart as well as with monitored start. The start button is not necessarily required. Monitoring several protective doors with evaluation unit up to Cat. 3 acc. to EN 954-1 A maximum of eight SIGUARD magnetically-operated switches can be connected to the 3SE6808-6DB evaluation unit. If one of the eight magnetically-operated switches is actuated (the protective door is opened), then the unit stops. There is a PLC signaling output (switching to p) for each input. The fail-safe shutdown is realized using two relay safety outputs. If an input is not used, then the appropriate terminals of the NO contact must be jumpered. For limited safety requirements, the evaluation unit can also be used without a start button. For this particular application contact X1 must be supplied with 24 V DC (Y1 or external).
L1 0V +24 V DC
5 START
A1
A2
Y1
X1
13
23
I max.
100 mA
P1
K1
P2 K2
S13 sw/bk 13
S14 bl/bl 14
S21 br/br 21
S22 ws/wh 22
14
24
K3 K4
0V Enable
M 3~
SK3
Circuit diagram 6/49 SIGUARD magnetically-operated switch with evaluation unit 3SE6801-1CC for Category 3 acc. to EN 954-1
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Connecting example 3SE6808-6DB
Magnetically-operated switch 5 Magnetically-operated switch 6 Magnetically-operated switch 7 Magnetically-operated switch 8
+24 V 4AT +SPS Y+ L+ 13 23
Signaling outputs to the PLC S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 Y5 Y6 Y7 Y8
S13
S14
S21
S22
S13
S14
S21
S22
S13
S14
S21
S22
S13
S14
S21
S22
Y1
Y2 Y3 Y4 Signaling outputs to the PLC START
X4
L-
14
24
0V
Magnetically-operated switch 1 Magnetically-operated switch 2 Magnetically-operated switch 3 Magnetically-operated switch 4
(C)1998
Circuit diagram 6/50 A max. of 8 protective doors can be monitored using SIGUARD magnetically-operated switches and evaluation unit 3SE6808-6DB for Category 3 acc. to EN 954-1
Technical data of the evaluation unit for SIGUARD 3SE6808-6DB magnetically-operated switches
Connection cross-section: Mounting in an enclosure: Max. 2 x 2.5 mm2 with end sleeves, min. 1.5 mm2 Snapped onto 35 mm standard mounting rails acc. to DIN EN 50022 Terminals: IP 20 Enclosure: IP 40 Approx. 300 g Any, front panel visible when the cabinet is open 4 AT Supply voltage, acc. to IEC 38: Own power drain: Safety outputs: Fusing, output circuits: Limiting continuous current at the max. ambient temperature: Switching current, max.: Switching voltage, max.: Switching capacity: AC: DC voltage: Category: 24 V DC +10%/-10% 24 V DC nom. 6.5 W, max. 9.1 W 13-14, 23-24 4 AT 4A
Degree of protection acc. to DIN VDE 0470 Part 1: Weight: Mounting position: Fusing, power supply voltage:
8A 400 V ~ 50/60 Hz, 250 V AC 15-C 250 Max. 1500 VA Refer to the load limiting characteristic, SR4 safety relay 3 (acc. to EN 954-1)
Permissible ambient temperature: Operation: -10C/+55C Storage: -55C/+80C Overvoltage Category: Degree of pollution: Rated insulation voltage: 2 (2.5 kV) 2 250 V acc. to DIN VDE 0110 Part 1 (1997-04)
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6.3.3 Press control devices
Press control devices with contactors also refer to Pages 6/14 - 6/15
A1 3TK2834
Y11 Y12 Y21 Y22 Y23
13
23
31
41 Operating A1 voltage A2 Outputs 13, 14 23, 24 31, 32 41, 42 Inputs Y11, Y12 Y21, Y22, Y23 Y31, Y32, Y33 L/+ N/- Enable circuit 1 (NO contact) Enable circuit 2 (NO contact) NC contact NC contact Feedback circuit Pushbutton S1 Pushbutton S2 1 Power supply unit 2 PTC fuse 3 Control logic 4 Channel 1 5 Channel 2 6 Safety circuits
1
2 3 5 4 6
A2
Y31 Y32 Y33
14
24
32
42
Circuit diagram 6/51 Internal circuit diagram of the 3TK2834 two-hand control device
L/+ S1 K1 K2 A1 3TK2834 Y11 Y12 Y21 Y22 Y23
L/+
13
23
31
41 S1, S2 buttons on the two-hand operating console H1 Signaling lamps K1, K2 must be contactors with positively-driven contacts
K1
K2 M
A2
Y31 Y32 Y33
14
24
32
42
K1 N/- S2 N/-
K2
H1
Circuit diagram 6/52 3TK2834 two-hand control device, Category 4 acc. to EN 954-1
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A1 3TK2835 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41 Operating A1 voltage A2 Outputs 13, 14 23, 24 33, 34 41, 42 Inputs Y11, Y12, Y13, Y14 Y21, Y22 Y31, Y32, Y33, Y34 1 Power supply unit 2 PTC fuse 3 Control logic 4 Safety circuits A2 Y31 Y32 Y33 Y34 14 24 34 42 L/+ N/- Enable circuit (tool down) NO contact (tool up) NO contact (overtravel OK) NC contact (hydraulic pump on) Feedback circuit (K4) Position switch (S4) for test cams Upper dead center, switch (S3) 1 2 3 4
Circuit diagram 6/53 Internal circuit diagram of the 3TK2835 overtravel tester
S0 L/+
L/+
S1 K3 K4 A1 3TK2834 Y11 Y12 Y21 Y22 Y23 13 23 31 41 3TK2835 A1 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41 K1 S4 K4
S0 Main switch S1, S2 Button on the two-hand operating console S3 Postitioning switch at the upper dead center S4 Position switch for test cams S5 Hydraulic pump "ON" S6 Tool "UP" (manual operating) K1 Contactor for the hydraulic pump K2 Tool "UP" K3, K4 Tool "DOWN" H1 Signal lamp
A2
Y31 Y32 Y33 14
24
32
42 S3 S6
A2
Y31 Y32 Y33 Y34
14
24
34
42 S5
S2 N/- N/-
K4
K3
K2
H1
K1
Circuit diagram 6/54 3TK2834 two-hand control device in conjunction with a 3TK2835 overtravel tester to monitor the overtravel in linear hydraulic-, pneumatic- and spindle presses acc. to VBG 7 n 5.2 11, Category 4 acc. to EN 954-1
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Sequence after the press has been powered-up: 1. The hydraulic pump is poweredup with S5, the ram is moved up to upper dead center, if required, using S6. 2. Press S1, S2 at the two-hand operating console until the position switch for the test cams (S4) opens. 3. Release S1, S2. 4. Depress S1, S2 again: Signal lamp H1 lights-up (bright), if the overtravel is OK. 5. Release S1, S2: The ram returns to the upper dead center. 6. If the overtravel is OK, all of the outputs remain active until the control voltage is disconnected.
Fig. 6/1
LEDs
POWER RELEASE Overtravel OK Overtravel erronous or test still not executed
Operation
Fault situation If the cam actuates position switch S4, then the signal lamp H1 is not lit-up. The machine part, which is potentially hazardous, can then only be moved to the upper dead center using S6. This press can then no longer be used. Contact the technician to check the press.
A more detailed description of the function of the 3TK2834 two-hand control device is provided in the Instruction Manual, Order No. 3ZX1012-0TK28-7CA1, for the overtravel tester 3ZX1012-0TK28-6CA1.
A
Us S1, S2 3TK2834 23/24 (K4) S3 S4 S5 S6 3TK2835 13/14 (K3) 23/24 (K2) 33/34 (H1) 41/42 K1 1 2 3 4 5 6 7
B
C Overtravel OK
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Power (Vs) on S5 is pressed, K1 pulls-in (latches). S6 is pressed, K2 pulls-in (the ram moves upwards in the manual mode). The upper dead center is reached, S3 is actuated. S6 is released, K2 drops-out. S1 and S2 are pressed on the two-hand operating console, the two-hand control device 3TK2834 outputs an enable signal, K3 and K4 pull-in. The ram moves downwards, S3 is no longer actuated. Test cams are reached, S4 is actuated, K3 drops-out. The ram remains stationary, S1, S2 are released, K4 drops-out. S1, S2 are pressed, K4 pulls-in again, H1 lights up. S1, S2 are released, K4 drops-out. K2 pulls-in, the ram moves upwards. S4 is no longer actuated. Upper dead center is reached, S3 is actuated. S1 and S2 are pressed; K2 drops-out, K3 and K4 pull-in. The ram moves downwards, S3 is no longer actuated. S1, S2 are released, K3 and K4 open. K2 pulls-in. points 14 to 16 are repeated at each stroke of the press.
8
9 10 11 12 13 14 15 16
Fig. 6/2
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A
US S1, S2 3TK2834 23/24 (K4) S3 S4 S5 S6 3TK2835 13/14 (K3) 23/24 (K2) 33/34 (H1) 41/42 K1
1 2 3 4 5 6 7 8 9
B
D Overtravel too long
1 Power (Vs) on 2 S5 is pressed, K1 pulls-in (latches). 3 S6 is pressed, K2 pulls-in (the ram moves upwards in the manual mode). 4 The upper dead center is reached, S3 is actuated. 5 S6 is released, K2 drops-out. 6 S1 and S2 on the two-hand operating console are pressed, the 3TK2834 two-hand control device outputs enable signals, K3 and K4 pull-in. 7 The ram moves downwards, S3 is no longer actuated. 8 Test cams are reached, S4 is depressed, K3 drops-out. 9 The ram does not remain stationary, S4 is no longer actuated (is passed-over), K3 pulls-in. 10 S1 and S2 are released, K3 and K4 drop-out. 11 S1, S2 are actuated, K4 pulls-in again. Overtravel tester is inhibited.
10 11 12 13 14 15 16
Fig. 6/3
S3 S S S4
A
B
C
D!
Fig. 6/4 Function schematic of the press control. The permissible overtravel "s" corresponds to the length of the cam which actuates position switch S4. According to ZH 1/456, the press manufacturer must define "s" .
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6.4 Contactless Protective Devices
6.4.1 Circuit examples for SIGUARD light curtains
SIGUARD light curtains can be supplied externally from 24 V DC. All of the connecting cables must be screened. Standard evaluation for SIGUARD light curtains (3RG7817-1DB2) The system, as standard is operated with a monitored start, which requires a start button. For an automatic re-start, a jumper must be inserted between terminals T11 and X2. The muting evaluation unit can also be used to monitor SIGUARD light curtains, without actually using the muting function. Terminals AML and 53 must be jumpered to simulate a muting lamp (as this isn't required in this case). The NC contacts of external contactors must be connected in the feedback circuit between terminals ERK and ERK+. If one of the safety outputs at the light curtain opens, the evaluation unit shuts down. Refer to circuit diagram 6/59 for connecting-up the electronic outputs. Fault monitoring with muting function The use of the light curtain in the muting mode with four muting sensors with floating NO contact outputs is shown in circuit diagram 6/60.
L
N
Receiver
Sender
Power supply 24 V DC
- +
2 -
1 +
3
4
2 -
13 +
4
Jumper for the test function Feedback circuit
A1(+) Start T11 T24 X1 X3 K2 V7 + - K1 X2 K1 K2 K1 K3 K3 K1 K2 D1 K3 D2 K1 K1 K3 K2 K2 K2 X2 T12 T44 PE T22 13 23 41
3RG7817-1DB2 A2(-) 14 24 42
Safety outputs
Circuit diagram 6/55 Connecting-up the standard evaluation unit for SIGUARD light curtains
* It is mandatory to use a muting lamp (white) and this is monitored via the evaluation unit (terminal 53). * The start button cannot be bypassed. Automatic re-start is not possible. * Terminal 63 can have a maximum 1.5 A load. In order to avoid an overload condition, the receiver ground must be connected to terminal 63.
T11 T34 X1 X2
Evaluation unit
Circuit diagram 6/56 Automatic restart
Connection possibilities
Muting sensor with floating output Muting sensor with PNP output
GND VCC PNP
MSxN
Evaluation unit
Evaluation unit
Circuit diagram 6/57 Connecting different muting sensors
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MSxN
MSx+
MSx+
MSxP
MSxP
MSx-
MSx-
6
Receiver Sender
2 - 1 + 3 4 2 - 13 + 4
GND +24 V RESET
MS1+ 1 A1+ A1+ ESS+ ERK+ ERK MS2+ MS2N MS2P MS2- 13 23 33 53 63 MS1N MS1P MS1- BWS1N BWS1P
+24 V
Jumper for the test function
AML
PE
3RG7817-3FA2
ESS EST+ EST BWSE+ BWSE- MS4+ MS4N MS4P MS4- 14 24 34 54 64 A2- A2-
MS3+
MS3N
MS3P
MS3-
BWS2N BWS2P
START
1 Feedback circuit between terminal ERK and ERK+
Circuit diagram 6/58 Connecting-up the muting evaluation unit without using the muting function
MS1
R
MS4
Sender
Receiver
2 -
13 +
4
2 -
1 +
3
4
MS2
S
MS3 +24 V +24 V GND MS2 MS1
MS1+ MS1N MS1P MS1-
Jumper for the test function, optional
+24 V DC max. 1,5A ML
BWS1N BWS1P
RESET
Keyoperated switch
A1+
A1+
ESS+
ERK+
ERK
MS2+
MS2N
MS2P
MS2-
13
23
33
53
63
AML
PE
3RG7817-3FA2
ESS EST+ EST BWSE+ BWSE- MS4+ MS4N MS4P MS4- 14 24 34 54 64 A2- A2-
MS3+
MS3N
MS3P
MS3-
BWS2N BWS2P
START
MS4
MS3
Circuit diagram 6/59 Connecting-up the muting evaluation unit using the muting function
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Connecting-up the safety-related semiconductor outputs
Note The electronic safety-related outputs are destroyed by voltage spikes exceeding approx. 60 V. Thus, the motor contactors used must be provided with diode damping circuits, which act as arc quenching elements. The arc quenching elements must be connected in parallel with the loads, but not in parallel to the outputs. We recommend, as external contactors, Siemens auxiliary contactors with integrated diode, type 3RH11221JB40 or the combination consisting of the auxiliary contactor (without free-wheeling diode) 3RH1122-1BB40 and the 3RT1916-1DG00 diode. Using the key-operated switch
+24 V
K2 ext.
K2 ext.
14, 24 33 ERK Evaluation unit
ERK
Circuit diagram 6/60
Safety-related outputs 14, 24: Safety-related semiconductor outputs (p switching) with cyclic testing function. If the evaluation unit has been started, and the light curtain is not interrupted, these outputs switch through 24 V DC. The output is open when the evaluation units switched-off. 33: Safety-related semiconductor output (n switching) with cyclic testing function. If the evaluation unit has been started, and the light curtain is not interrupted, the output switches to ground.
Muting operation can be simulated using the key-actuated switch. This is necessary, if, when the muting sensors are actuated, the power supply of the muting evaluation unit fails. In this condition, the evaluation unit would always detect a fault, and it would no longer run-up at the start. The plant or system would not be able to be started If the key-operated switch is actuated, the evaluation unit switches-into the muting mode for max. 10 min so that the material being transported or conveyed can be removed from the muting zone. If a muting sensor is no longer actuated, the device stops and must be re-started.
6/34
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6.4.2 Circuit examples for SIGUARD light barriers
Evaluation unit and light barriers for Category 2 acc. to EN 954-1
Power supply voltage +24 V 0V +24 V (Internal) 3RG7821-7BG00 3RG7821-7CD00
Sender 1 Receiver 1
START
IN X2
OUT X3
0 V (Internal) X4 3RG7821-7BG00 3RG7821-7CD00
Sender 2 Receiver 2
A1
A2
X1
X5 BN
X6 WH
X7 BN
X8 WH
X9 BN
X10 WH
X11 BN
X12 WH
3RG7826-1CB1
Ext. feedback circuit
TEST +24 V (Internal) IN X13 X14 OUT X15 0V +24 V (Internal) (Internal) IN X16 X17 X18 0 V (Internal) OUT X19 X20
13
14
X21 +24 V (Internal)
X22
Y1 PNPOUT
X23
K1
Contactor
Circuit diagram 6/61
Safety Integrated Application Manual
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Evaluation unit and light barriers for Category 4 acc. to EN 954-1
3RG7821-7BG00 3RG7821-7CD00 Sender Receiver Sender Receiver
1243
1243
1243
1243
L1 S S +24 V DC A1 24V X1 T1 X2 Q1 X3 T2 X4 Q2 X5 X6 X7 X8 + - 13 23 39 41
RESTART
Cont.M
UB OUT
RESTART
Relay
3RG7827-1DE2
0V A2
T3 X9
Q3 X10
T4 X11
Q4 X12 X13
PM X14 Y1
Indic. Y2
UB OUT + - 14 24 34 42
0V
0V
1243
1243
1243
1243 K4 K5
Sender
Receiver
Sender
Receiver N
M 3~
Circuit diagram 6/62
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6.5 SIGUARD Switching Strips
6
Circuit examples with evaluation unit SIGUARD switching strips, together with the 3RG78 57-1BD evaluation unit, can be used as a safety system up to Category 3 acc. to EN 954-1. The evaluation electronics in the 22.5 mm enclosure is used to evaluate the sender/receiver signal and to monitor the complete system for faults and errors.
The power supply voltage of the evaluation unit is 24 V DC. 2 relay outputs are available as safety-related outputs. A semiconductor output (n-switching) can be used to issue a signal to a PLC. After the switching strip has been actuated, the device must be enabled using a manual start button, so that the system can restart.
Receiver
3RG7855-1R
Sender
Power supply 24 V DC
Signal output wh
3RG7857-1BD
Start button X2 X3
Safety-related outputs 13 23
gn
bn
A1(+)
X1
K1
K1
K2 12 V controller
K2 K1 K2
Safety-related signal processing
K1
K2
A2(-)
14 24 Safety-related outputs
Circuit diagram 6/63
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6.6 SIMATIC S5-95F - Safe Shutdown using Approved EMERGENCY OFF Function Modules
EMERGENCY OFF with SIMATIC S5-95F S5-95F can be used to implement EMERGENCY OFF circuits, as it fulfills the requirements of EN 954-1 and/or IEC 61508. Standard function modules have been written, and have been approved by the German Trade Association. These function modules either permit inputs and outputs to be assigned with a resolution of one bit (one input = one output), or input/output assignment, with a byte resolution. This means, that after evaluation, several EMERGENCY OFF pushbuttons can be used to shutdown a common EMERGENCY OFF circuit from the S5-95F with user-friendly display capability. Under certain prerequisites, it is permissible to activate/deactivate light barriers (muting). Connecting-up the individual functions The sensors (EMERGENCY OFF pushbuttons, light curtains etc.) can either be connected to the fail-safe onboard- or the fail-safe external I/O of the S5-95F In this case, for single. channel sensors, the signal cables are connected in parallel to the sub-units, or for two-channel sensors, each signal cable is connected to a sub-unit. In both cases, the signal is connected redundantly to the automation unit (PLC), however, from the perspective of the user program, one single input is addressed. If a cross-circuit test is required, then the sensor connecting cables are not fed from a constant 24 V supply voltage, but from an onboard digital output, configured using the COM 95F parameterizing software. This test output is then briefly switched-out for the test and the zero signal checked at the associated inputs.
START button PB EMERGENCY OFF button 1 EMERGENCY OFF button 2
FB START SEQUENCE CHAIN
START START Logic operation
EMERGENCY OFF NOT-AUSlogical operation Verknupfung
If the sequence chain has still not been started and there is a positive edge at the start and EMERGENCY OFF logic operation "1" and inverted feedback signal to the EMERGENCY OFF output, then EMERGENCY OFF output = "1"
output & Actuator
EMERGENCY OFF button
Feedback
FB STOP SEQUENCE CHAIN
Software interrupt Time interrupt
(OB3) for EMERGENCY OFF pushbutton at onboard I/O (OB13) for EMERGENCY OFF pushbutton an external I/O
Circuit diagram 6/64 Principle of identifying and shutting down EMERGENCY OFF sequence chains for fail-safe S5-95F PLC
The feedback contact of the contacts and the start button can be connected-up to both non-fail-safe as well as fail-safe inputs. Information regarding circuit diagram 6/65 The sensors can be logically combined with one another in a program module, and the result assigned to an intermediate flag, which in turn is permanently assigned to an EMERGENCY OFF output. In the most basic case, all of the inputs (NC contacts) are switched in series by the program, and assigned the flags. The start module, logically combines, in the cyclic program, the signals "intermediate flag, start button and checkback signal input" with one another. The EMERGENCY OFF output may only be energized, if the intermediate flag, i.e. the logical combination of the sensors, has a logical 1 signal, the checkback signal input of the shutdown element has a logical 0 signal, and a positive edge from the start button has been identified.
The parameterized stop module switches the set EMERGENCY OFF output off, as soon as the associated intermediate flag has a 0 signal. Depending on how the sensors are connected to the fail-safe onboard- or the fail-safe external I/O, this shutdown is realized in the organization block OB3 within a max. of 10 ms, or in the OB13 within a max. of 120 ms. The EMERGENCY OFF output can only be re-energized when the associated intermediate flag again has a logical 1 signal (e.g. the EMERGENCY OFF pushbutton which was pressed, has been released again), a positive edge is read-in at the start button and the checkback signal input has a 0 signal.
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O 32.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
I 0.1 O 32.2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
I 1.1
The following examples show how the ON/acknowledge button and an EMERGENCY OFF control device can be connected to the onboard I/O of the S5-95F . Rule The EMERGENCY OFF control devices must be connected to fail-safe inputs. EMERGENCY OFF control devices can be used both with failsafe onboard- as well as fail-safe external I/O. The ON/acknowledge button can be connected, both to the fail-safe onboard I/O, the fail-safe external I/O, as well as the non-fail-safe external I/O. Example 1 A circuit for indirectly controlling the EMERGENCY OFF stop device via two redundant auxiliary contactors and with checkback signals via two positively-driven auxiliary contacts via the external I/O is illustrated in Fig. 6/66. Example 2
EMERGENCY OFF device
K1
K2
K3 K1 L+ L- K2 K2 K1
Circuit diagram 6/65 Controlling redundant auxiliary contactors with checkback signals via positively-driven auxiliary contacts
DA 33.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DE 32.2
DE 33.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
DE 32.2
Fig. 6/67 shows how the ON/acknowledge button and an EMERGENCY OFF control device can be connected to the fail-safe onboard I/O.
DE 33.0
L+ L-
S1
S2a
S2b
L+
S1= ON/acknowledge button
S2= EMERGENCY OFF pushbutton
Circuit diagram 6/66 Connecting the ON/acknowledge button and the EMERGENCY OFF control devices with cross-circuit monitoring
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6.7 ET 200S SIGUARD
PM-X Master
PM-D F1 DS RS F-Kit PM-X
Power module SPS Direct starter Reversing starter Auxiliary contact block (for the feedback circuit) Connection modul Safety Category 1 2 3 4
PM-D F1
DS
DS
RS
Terminating module
Circuitbreaker
PROFIBUS-DP IM 151 L+ M A1+ A2- F-Kit F-Kit F-Kit
Feeder contactor KO
PM-D PM-DF1 F-Kit PM-X Feeder contactor
ON button EMERGENCY OFF button L1 L2 L3
M ~
M ~
M ~
Terminating module cover
Circuit diagram 6/67 EMERGENCY OFF with monitored start, Category 4
Explanation
L+ ON + ON - CH1 CH1 CH2 CH2 + - + - CON A1+
When commissioning the circuit, proceed as follows: * Connect auxiliary voltage V1 to terminals L+, M * Connect auxiliary voltage V2 to terminals CON A1+, CON A2* The EMERGENCY OFF circuits at terminals CH1+, CH1- and CH2+, CH2- must be closed * The system becomes operational as soon as the ON button, connected to terminals ON+, ON- is actuated. EMERGENCY OFF circuits and ON buttons are monitored for cross-circuit during operation.
ET 200S Bus M CON A2- OUT- OUT+
Cross-reference: Also refer to Part 2.31 ET 200S SIGUARD, Page 2/49, as well as the "SIMATIC ET 200S" Manual - Order No. GE S7 151-1AA00-8AA0
The basic configuration of a SIGUARD Power Module is shown in the circuit diagram using as an example PM-D F1, EMERGENCY OFF with monitored start
Circuit diagram 6/68 Block diagram of the SIGUARD Power Module PM-D F1
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25
Power module PM-DF1
U1 + 1/8 - 2/9 + 4/11 - 5/12
26 27 28 22 23
EMERGENCY OFF
K0
ON
U2
K0
K1
K2
K3
Feedback circuit
Q1 K1
Q2 K2
Q3 K3
K0 Feeder contactor
K1
K2 Direct starter
K3
M
M
M
Circuit diagram 6/69 Monitoring load feeders, EMERGENCY OFF, stop Category 0, monitored start, Category 4. The load feeders are monitored, as the contactor NC contacts (F kit) are switched as "feedback circuits" in series with the ON button.
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6.8 Controlling Drives
This section describes application examples using the SIMOVERT MASTERDRIVES drive system for applications with AC variable-speed drives.
The examples show how applications can be implemented. The solution required for the machine must be harmonized with the machine function. This results in individual parameterization or control commands for applications, Stop Category 1. The solutions shown are implemented using the SIMOVERT MASTERDRIVES and SIMODRIVE 611 drive systems.
The "SAFE STANDSTILL function can " be implemented with the devicespecific "SAFE OFF" functions or "Start inhibit" In this case, the appro. priate information must be observed in the product descriptions. SIMOVERT MASTERDRIVES Vector Control Catalog DA 65.10 SIMOVERT MASTERDRIVES Motion Control Catalog DA 65.11 SIMODRIVE 611 Catalog NC 60.1 and NC 60.2
6.8.1 Application examples for EMERGENCYSTOP stop Category 0
L1 L2 L3 PE
DC P 24 V DC M F1 Ready ON L1/L+ 3TK2806 X1 EMERGENCY OFF X3 X5 13 23 33 43 53 65 X533 1 Option K80 2 PV 4 P24 V 3 U1 V1 W1 K
K3 M K2 X101
1)
C XU
The checkback signals from protective equipment and devices are connected here e.g. protective doors, light curtains.
X: Digital input assigned to OFF2 P556i001 and i002 The checkback signals from protective equipment are connected here
N/L -
X2
X4
X6
14 24 34 44 54
66
SIMOVERT MASTERDRIVES Drive converter U2 V2 W2 M 3~
Circuit diagram 6/70 Stop Category 0, single-channel, with feedback circuit. Category 3 acc. to EN 954-1 function with motor which is coasting down
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L1 L2 L3 PE L/+ N/- DC P 24 V DC M K1
EMERGENCYSTOP
K1 ON A1 3TK2824 Y1 Y2 13 23
X533 Option K80 1 2 PV 4 P24 V 3
U1 V1 W1
M X101
C XU
1)
A2
14
24
Drive converter
SIMOVERT MASTERDRIVES U2 V2 W2 M 3~
The checkback signals from protective equipment are connected here e.g. protective doors, light curtains
X: Digital input, assigned to OFF2 P556i001 and i002 Cable is routed so that it is especialy protected
K1 N/-
Circuit diagram 6/71 Stop Category 0, two-channel, with feedback circuit. Category 3 acc. to EN 954-1. Function with motor which is coasting down
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6.8.2 Application examples for EMERGENCY-STOP stop Category 1
L1 L2 L3 PE
1)
K
The checkback signals from protective equipment are connected here e.g. protective doors, light curtains
Rectifier unit L+/C L-/D
Y: Digital input, assigned to OFF3 P559i001 and i002 X: Digital input, assigned to OFF2 P556i001 and i002
X533 Option K80 1 2 PV 4 P24 V 3
L+ (C)
L- (D)
X533 Option K80 1 2 PV 4 P24 V 3
L+ (C)
L- (D)
M X101 X101
M
C XU Y
C XU
Y
SIMOVERT MASTERDRIVES Inverter U2 V2 W2
Inverter
SIMOVERT MASTERDRIVES U2 V2 W2
M 3~
M 3~
DC 24 V DC M
ON Y10 A1 3TK2827 Y11 Y12 Y33 Y34 13 23 31 43 53 3TK2830 Y21 Y22 PE PE 14 24 32 44 54 A2 14 24 34 44 52 A1 13 23 33 43 51
EMERGENCYSTOP
A2
Circuit diagram 6/72 Stop Category 1, two-channel with feedback circuit. Category 3 acc. to EN 954-1. Function with controlled motor stop along the torque limit.
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L1 L2 L3 PE L/+ N/- DC 24 V DC M K1
K1 ON Y10 A1 3TK2827 Y11 Y12 Y33 Y34 13 23 31 43 53
X533 Option K80 1 2 PV 4 P24 V 3
U1 V1 W1
M X101
EMERGENCYSTOP
C XU Y
1)
The checkback signals from protective equipment are connected here e.g. protective doors, light curtains
Y21 Y22 PE
A2
14 24 32 H1
44 54 K1
Drive converter
SIMOVERT MASTERDRIVES U2 V2 W2 M 3~
X: Digital input, assigned to OFF2 P556i001 and i002 Y: Digital input, assigned to OFF3 P559i001 and i002
PE
N/-
Circuit diagram 6/73 Stop Category 1, two-channel, with feedback circuit. Category 3 acc. to EN 954-1. Function with controlled motor stop along the torque limit.
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