Components for safety applications Preventa safety modules

Transcription

1 Selection guide Applications Modules For Emergency Stop and limit switch monitoring (modules integrated in Micro PLCs) Conforming to standards Machine IEC 204-, EN 292, EN 48 assemblies EN Principles EN category 3, pr EN for design EN 088, pr IEC 6508-SIL 2 Number of safety outputs Number of dual or single contact safety inputs 2 N/O 4 N/C PLC diagnostics Input contacts Reset and feedback loop inputs Reading output control signal Supply monitoring Display 0 bit bit bit bit 0 LED Supply voltage c 24 V PLC type Micro Module type TSX DPZ 0D2A Pages 43307/4 2

2 For Emergency Stop and limit switch monitoring (modules integrated in Premium PLCs) IEC 204-, EN 292, EN 48 EN EN category 4 EN 088, pr IEC 6508-SIL 3 2 N/O 4 N/O 2 N/C 24 bit 2 bit bit bit 28 DEL c 24 V Premium TSX PAY 262 TSX PAY / /6

3 General Safety Manufacturing workshops and technical service installations in buildings are increasingly subject to more stringent safety requirements. Good equipment is safe equipment, which combines: - safety: of persons (risk limited to an acceptable level), - reliability of operation: of the production tool (machine always able to perform its function) Safety is achieved by: - simultaneously optimising safety and reliability of operation, - applying fundamental principles: redundancy, self-monitoring, - making reliability a design consideration (failure causing the machine to react in a specified way, positive safety), - ease of maintenance Safety and automated systems All dangerous areas must be identified and have restricted access, controlled in a secure manner, i.e. any breakdown or careless operation must result in the automation system failing to a non-dangerous position. It should be noted that the use of safety products alone does not necessarily mean that the machine conforms to the machinery directive. It is in fact correct operation, wiring, association with other devices and scheme used which make the entire machine safe. It is more important to think in terms of safety solutions rather than safety products. General structure of an automated machine Signalling Display Control Data processing Detection Sensor Safety device Preactuation Contactors - Directional valves Variable speed drives Machine guarding Operation Control system Operating part 3860_Ver6.0-EN.fm/2

4 Basic principles Objective Detection of initial fault. Ensure non-dangerous positioning (machine stops in safe state). Ensure the safety of personnel operating industrial machines. Basic principles Redundancy Consists of compensating for the failure of one component by the correct operation of another, based on the assumption that both will not fail simultaneously Redundancy Consists of compensating for the failure of one component by the correct operation of another, based on the assumption that both will not fail simultaneously + Self-monitoring Consists of automatically checking, at each operating cycle, the operation of any component which changes state. The next cycle can be inhibited or enabled. + Reliable operation Reliable operation + Safety If an initial fault is undetected, corrective action is not initiated and a second fault may occur thus compromising safety. An initial fault in the safety circuits is detected before a second fault can occur (next cycle inhibited). The use of a Preventa safety module with redundancy and self-monitoring functions allows a category 4 control system to be built in accordance with standard EN 954- (parts of control systems relating to safety). Definitions Redundancy function This function is achieved by providing dual circuits at the design stage, together with a check function which will only permit a control action when at least two output signals are identical. Self-monitoring function incorporate relays with mechanically linked N/O and N/C contacts. This technique ensures that all N/O and N/C contacts within each relay remain synchronised. The self-monitoring function is achieved by checking the correct operation of the linked contact relays which are energised during the current operating cycle. The method for detecting the failure of a N/O contact in a mechanically linked contact relay consists of checking the correct operation of its N/C contacts which are thus incorporated in the self-monitoring circuit. This is only possible if mechanically linked relay contacts are used. 3860_Ver6.0-EN.fm/3

5 Concept of interposing relays Operation of the control circuit without interposing relays The control signal from the protection device (emergency stop in the circuit on the left) acts directly on the power contactor of the device. Emergency stop stop KM In this type of scheme, there is still a risk of simple faults: - Em ergency Stop button auxiliary contact being shorted out, - KM contactor sticking in. When the operator presses an Emergency Stop button, the instruction is not processed, and another sequence can begin following the emergency stop, despite the presence of the fault. KM KM In this type of failure, the safety function () is no longer provided. Therefore, a reliable interposing relay system must be used. M () A safety function is a function whose non-execution or untimely execution results in immediate placing of the equipment in a non-hazardous condition. Operation of the control circuit with interposing relays Feedback loop KM6 KM5 KM5 KM5 Emergency stop KM6 KM6 Preventa safety module Redundancy KM5 KM6 M KM5 and KM6 contactors with mechanically linked contacts Independent safety circuits provide a reliable interposing relay function by overcoming a number of risks associated with: - control circuit fault (inputs), - power circuit fault (outputs), - safety module internal component fault. The safety function remains operative whenever any one of these faults occurs. For the use of mechanically linked contact relays CA2-DN22/DN3 and LC-D09/D8/D25, LP-D09/D8/D25, with contacts which can be used in the feedback loop, please consult your local representative or agent. 3860_Ver6.0-EN.fm/4

6 Safety solutions: Applications for protection systems and access doors Selection criteria Low risk Locking or interlocking device based on the principle of intrinsically safe design (tried and tested components and principles). High risk Locking or interlocking device based on the principle of redundancy and self-monitoring. The safety modules perform both functions. Machines with instant stopping. Locking (stopping time < access time) () XPS-FB XPS-FB Locking by actuator key Locking by actuator key and Activation in positive and negative activation in positive mode (combined) mode associated with illage à clé-languette associated with a safety module a safety module Activation in positive mode Activation in positive and negative (combined) mode High inertia machines with long stopping times. Interlocking (stopping time > access time) () XPS-FB XPS-VN XPS-FB Interlocking device with actuator key captive in the guard Interlocking device with operating Interlocking device with operating key captive in the guard key captive in the guard and zero speed detection XPS-VN XPS-FB Interlocking device with electromagnetic lock () Stopping time: time elapsed between actuation of the machine stop control and the moment the machine stops (risk eliminated). Access time: time required for a person to gain access to the hazardous zone (calculated on the basis of an approach speed). Other configurations Please consult your local representative or agent. 3860_Ver6.0-EN.fm/5

7 Electrical durability Curves showing electrical durability of safety contacts conforming to EN , table C2 XPS-AF, XPS-AK, XPS-AFL Switching current (A) 0 AC-5 230V DC-3 : 24V AC- : 230V DC- : 24V 0, Number of operating cycles XPS-AV, XPS-MP Switching current (A) 0 AC-5 : 230 V DC-3 : 24 V (< 0, Hz) DC-: 24 V AC- : 230 V 0, Number of operating cycles XPS-AL, XPS-AS, XPS-ASF, XPS-AT (time delay contacts), XPS-AX, XPS-TSA, XPS-TSW, XPS-BA, XPS-BC, XPS-CE, XPS-DA, XPS-FB, XPS-NS, XPS-OT, XPS-PVK, XPS-PVT, XPS-VN, GNK-L 0 Switching current (A) AC-5: 230V DC-3: 24V AC-: 230 V DC-: 24 V 0, Number of operating cycles XPS-AM, XPS-AMF, XPS-AP, XPS-APF, XPS-AT (instantaneous contacts), XPS-ECM, XPS-ECP Switching current (A) 0 DC-3 : 24 V AC-5 : 230 V DC-: 24 V AC- : 230 V 0, Number of operating cycles 3860_Ver6.0-EN.fm/6

8 Electrical durability Definition of tests Determining the electrical durability according to EN (table C2) Type of current Utilisation category -up Breaking Current Voltage Cos ϕ Current Voltage Cos ϕ a.c. supply AC-5 0 x Ie Ue 0.7 Ie Ue 0,4 Type of current Utilisation category -up Breaking Current Voltage T0.95 Current Voltage T0,95 d.c. supply DC-3 Ie Ue 50 ms Ie Ue 50 ms Ie: Operational current measured. Ue: Operational voltage measured. Cos ϕ: Power factor. T0,95: Time taken to reach 95 % of rated current. The tests are carried out with a frequency of 6 switching operations per minute and with no additional protection of the components connected to the safety outputs. The use of additional protection for the components connected to the safety outputs significantly increases the durability of the safety outputs. Determining the breaking capacity according to EN (table 4) Utilisa- -up Breaking Total Switching ops. Switching ops. Minimum tion Current Voltage Cos ϕ Current VoltageCos ϕ no. of per minute for per minute for duration of cat. switching switching ops. switching ops. switching ops. operation AC-5 0 x Ie Ue 0.3 Ie Ue ms Utilisa- -up Breaking Total Switching ops. Switching ops. Minimum tion Current Voltage T0.95 Current VoltageT0.95 no. of per minute for per minute for duration of cat. switching switching ops. switching ops. switching ops. operation DC-3 Ie Ue 50 ms Ie Ue 50 ms ms e: Operational current measured. Ue: Operational voltage measured. Cos ϕ: Power factor. T0.95: Time taken to reach 95 % of rated current. Comments : The maximum values for the breaking capacity of the safety outputs in the various utilisation categories are not fixed and depend on the power factor and on the switching frequency. The test definition for the breaking capacity and durability tables in European standard EN uses different values for the power factor and the switching frequency. The power factor (cos ϕ) in the breaking capacity table (0.3) is greater than that in the durability table (0.7) The switching frequency of the safety outputs is higher in the breaking capacity table (60 switching operations per minute for the first 000 switching operations) than in the durability table (6 switching operations per minute). Consequently, the maximum breaking capacity values determined using the breaking capacity table are lower than those in the durability table. 3860_Ver6.0-EN.fm/7

9 Operating principle for emergency stop and limit switch monitoring Operating principle Preventa XPS-AL, XPS-AX, XPS-AV, XPS-AT, XPS-AS/, XPS-AM/ and XPS-AP/ safety modules are used to monitor emergency stop circuits, conforming to standards EN 48 and EN , and also comply with the safety requirements for the electrical monitoring of limit switches used in conjunction with machine guards conforming to the standard EN 088. They provide protection for both the operator and the machine by immediately stopping the dangerous movement on receipt of a stop instruction from the operator, or on detection of a fault in the safety circuit itself. To assist diagnostics, the modules incorporate LEDs to indicate the state of the monitoring circuit Module XPS-AL Module XPS-AL incorporates 2 safety outputs. Module XPS-AX Module XPS-AX incorporates 3 safety outputs and N/C signalling output. Modules XPS-AV and XPS-AT (see page 38783/3) In addition to the three instantaneous opening safety outputs (stop category 0), modules XPS-AV and XPS-AT incorporate stop category time delay outputs (3 for XPS-AV and 2 for XPS-AT), which allow for controlled deceleration of the motor components until a complete stop is achieved (for example, motor braking by variable speed controller). The function for monitoring the button can be configured by wiring. The XPS-AV module also incorporates 3 solid state signalling outputs for signalling to the process PLC. The XPS-AT module also incorporates a N/C signalling output. Modules XPS-AS/, XPS-AM/, XPS-AP/ (see pages 3877/3 and 38774/3) These emergency stop monitoring modules also comply with the safety requirements for electrical monitoring of pushbuttons used for two-hand functions (EN 574, type III A). The function for monitoring the button can be configured by wiring. Safety modules XPS-ASF, XPS-AMF and XPS-APF are also suitable for monitoring safety mats and edges _Ver6.00-EN.fm/2

10 Characteristics for emergency stop and limit switch monitoring Characteristics Module type XPS-AL XPS-AX Product designed for use in safety related parts of control systems Category 3 Category 3 (conforming to EN 954-) Supply - voltage V " and $ 24, "5, " 230 " and $ 24 - voltage limits % ("Ã24 V) % (" 24 V) % ($ 24 V) % ($ 24 V) % (5 V) % (230 V) - frequency Hz 50/60 50/60 Consumption W < 2 ($ 24 V) < 2 ($ 24 V) VA < 4 (" 24 V) < 4 (" 24 V) < 7 (" 5 V) < 6 (" 230 V) Module fuse protection Adjustable time delay s button monitoring No No Control unit voltage Identical to supply voltage Identical to supply voltage (nominal supply voltage) - 24 V version V "Ã24 (approx. 60 ma), $Ã24 (approx. 80 ma) "Ã24 (approx. 60 ma), $Ã24 (approx. 80 ma) - 5 V version V "Ã5 (approx. 60 ma) V version V "Ã230 (approx. 25 ma) Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 23-24) 3 N/O (3-4, 23-24, 33-34) - number and type of additional N/C (4-42) circuits - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.25 A L/R = 50 ms 24 V/.25 A L/R = 50 ms - max. thermal current (Ithe) A max. total thermal current A output fuse protection conforming to A 4 gl or 6 fast acting 4 gl or 6 fast acting IEC EN (6 A fast acting only for outputs or 33-34) DIN VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time on input opening ms < 00 < 40 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC EN , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC EN , DIN VDE 00 parts and 2) voltage (Uimp.) LED display 2 2 Operating temperature C Storage temperature C Degree f protection conforming to IEC EN 529 Terminals IP 20 Enclosure IP 40 Connection Type Captive screw clamp terminals: without cable end x 4 mm2, with cable end 2 x 2.5 mm _Ver6.00-EN.fm/3

11 References for emergency stop and limit switch monitoring References Description Number of instantaneous opening safety circuits Additional outputs Supply Reference Weight kg XPS-AL Safety modules for emergency stop and limit switch monitoring 2 " and XPS-AL $ 24 V " 5 V XPS-AL " 230 V XPS-AL _ 3 " and XPS-AX $ 24 V XPS-AX 38770_Ver6.00-EN.fm/4

12 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AL Module XPS-AL associated with an emergency stop button Functional diagram for module XPS-AL L (+) F L (+) F ()S (2) S A2 A A2 A Y Y K XPS-AL XPS-AL () (2) K K K 4 24 Key 0 Supply voltage Emergency stop A Emergency stop A2 Feedback loop Y-Y2 Output 3-4 (N/O) Output (N/O) button Emergency stop Emergency not activated stop not activated activated activated N ( ) N ( ) () Emergency stop button with N/C contact (2) Emergency stop button with 2 N/C contacts (recommended application) Y-Y2: Feedback loop XPS-AX Module XPS-AX associated with an emergency stop button Functional diagram for module XPS-AX L (+) F K5 Supply voltage Emergency stop A Emergency stop A2 button Emergency stop Emergency not activated stop not activated activated activated S () ESC Feedback loop Y-Y2 A Y Y Output 3-4 (N/O) + K XPS-AX Logic A K K K5 K5 K5 Output (N/O) Output (N/O) Output 4-42 (N/C) Key 0 N ( ) K5 (3) L (+) F XPS-AL and XPS-AX Key to LEDs S (2) K5 ESC 2 A Y Y XPS-AX + Logic K K K K5 K5 K5 Supply voltage A-A2 2 State of K- (safety outputs closed) N ( ) A () Emergency stop button with N/C contact (2) Emergency stop button with 2 N/C contacts (recommended application) (3) Emergency stop signalling Y-Y2: Feedback loop ESC: External start conditions K5 (3) 38770_Ver6.00-EN.fm/5

13 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AT Module XPS-AT associated with an emergency stop pushbutton L (+) F ( ) (+) S A XPS-AT 5 V 230 V T + S B 2 2 A2 PE S33 Y K K K Logic Y2 Y3 Y4 Y5 K (2) () Stop category 0 Instantaneous opening safety outputs Stop category Time delay opening safety outputs N ( ) S: Emergency stop button with 2 N/C contacts (recommended application). Output 4-42 must not be used as a safety circuit. () With button monitoring (2) Without button monitoring Functional diagram for module XPS-AT with emergency stop button monitoring Supply voltage Begin Emergency stop not activated Emergency stop activated Supply voltage 75 ms t max. Guard closed Guard opens Input A S- Input A -2 button button 2 Feedback loop Y39-Y40 Output 3-4 (N/O) Output (N/O) Output (N/O) Output 4-42 (N/C) Output (N/O) Output (N/O) Key 0 Tv = 0 30 s Adjustable Tv = 0 30 s Adjustable With button monitoring (connection Y3-Y5) 2 Without button monitoring (connection Y3-Y4) 38783_Ver.00-EN.fm/8

14 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AT Example of a safety circuit combining an emergency stop module with a variable speed controller F T F3 F2 ( ) (+) S L L2 L V A S B Q 0 30 s U/T V/T2 W/T3 FW RV A2 PE S33 Y Y2 Y3 Y4 Y KM R K () KM2 PLC K (2) KM KM2 KM U V W M 3 PE KM2 () With button monitoring (2) Emergency stop signalling S: Emergency stop button with 2 N/C contacts (recommended application) XPS-AT Connection with emergency stop pushbutton ( ) (+) S (+) ( ) S S3 A S B XPS-AT Both input channels are supplied on the same polarity. S: Emergency stop pushbutton with 2 N/C contacts. (a short-circuit between the 2 inputs is not detected) XPS-AT Configuration with button monitoring (functional diagram for button, see page 38783/8) S33 Y Y2 Y3 Y4 Y5 Configuration without button monitoring (functional diagram for button 2, see page 38783/8) XPS-AT A2 PE () S33 Y Y2 Y3 Y4 (3) Auxiliary terminal (to be used to separate the feedback loop from the wiring to the button) XPS-AT Key to LEDs () Y5 A S B XPS-AT Connection of multiple emergency stop pushbuttons with 2 N/C contacts (recommended application). The 2 input channels are supplied on different polarity. A short-circuit between the 2 inputs is detected. Monitoring an emergency stop pushbutton with N/C contact S A S B XPS-AT ( ) (+) S: Emergency stop button with N/C contact Not all faults are detected: a short-circuit on the emergency stop pushbutton is not detected Supply voltage A-A2, internal electronic fuse status 2 (A) input state 3 2 (B) input state 4 Stop category outputs closed 38783_Ver.00-EN.fm/9

15 Operating principle, characteristics for emergency stop and limit switch monitoring Operating principle Preventa XPS-AV and XPS-AT safety modules are used to monitor emergency stop circuits, conforming to standards EN 48 and EN , and also comply with the safety requirements for the electrical monitoring of limit switches used in conjunction with machine guards conforming to the standard EN088. They provide protection for both the machine operator and the machine by immediately stopping the dangerous movement on receipt of a stop instruction from the operator, or on detection of a fault in the safety circuit itself. In addition to the three instantaneous opening safety outputs (stop category 0), the modules incorporate stop category time delay outputs (3 for XPS-AV and 2 for XPS-AT), which allow for controlled deceleration of the motor components until a complete stop is achieved (for example, motor braking by variable speed controller). At the end of the preset delay, the supply is disconnected by opening the time delay output circuits. For module XPS-AV, the time delay of the 3 output circuits is adjustable, in 5 preset values, between 0 and 300 seconds using selector keys. For module XPS-AT, the time delay of the 2 output circuits is adjustable between 0 and 30 seconds using a 2-position selector switch. The XPS-AV module also incorporates 3 solid state signalling outputs for signalling to the process PLC. To assist diagnostics, the modules incorporate LEDs to indicate the state of the monitoring circuit. The function for monitoring the button can be configured by wiring. Characteristics Module type XPS-AV3 and AV3P XPS-AT//// Product designed for use in safety related parts of control systems (conforming to EN 954-) Category 4 Category 4 (instantaneous safety outputs) Category 3 (time delay safety outputs) Supply V $ 24 " and $ 24, " 5, " voltage - voltage limits % % (24 V) % (5 V) % (230 V) - frequency Hz 50/60 Consumption W < 5 < 8 Module fuse protection Internal, electronic Internal, electronic Adjustable time delay s button monitoring Yes/No (configurable by terminal connection) Yes/No (configurable by terminal connection) Control unit voltage (at nominal supply voltage) Between terminals -2, S3-S32 or S- Between terminals S-, -2 or S-B - 24 V version V V and 230 V versions V 48 Calculation of wiring resistance RL between input terminals Ω 00 max. Maximum cable length: 2000 m U int - U min. RL max. = I min. Ue = true voltage applied to terminals A-A2 U int (terminals S-) = supply voltage Ue - 3 V (24 V version) U int between 42 V and 45 V, with typical value = 45 V (5 V, 230 V version) Calculated max. RL must be equal to or greater than the true value 38783_Ver.00-EN.fm/2

16 Characteristics (continued) for emergency stop and limit switch monitoring Characteristics (continued) Module type XPS-AV3 XPS-AV3P XPS-AT//// Synchronisation time between s For guard:.5 inputs For emergency stop: unlimited Approx (automatic start, terminals S33-Y2 and Y3-Y4 linked) Outputs - voltage reference Volt-free - number and type of instantaneous 3 N/O (03-04, 3-4, 23-24) 3 N/O (3-4, 23-24, 33-34) opening safety circuits - number and type of time delay 3 N/O (37-38, 47-48, 57-58) 2 N/O (57-58, 67-68) opening safety circuits - number and type of additional circuits 3 solid state N/C (4-42) - breaking capacity in AC-5 instantaneous outputs VA C300: inrush 800, maintained 80 B300: inrush 3600, maintained 360 time delay outputs VA C300: inrush 800, maintained 80 C300: inrush 800, maintained 80 - breaking capacity in DC-3 instantaneous outputs time delay outputs - breaking capacity of solid state 24 V/.25 A L/R = 50 ms 24 V/.25 A L/R = 50 ms 24 V/20 ma 24 V/.5 A L/R = 50 ms 24 V/.5 A L/R = 50 ms outputs - max. thermal current (the) instantaneous outputs time delay outputs - max. total thermal current A A 3.3 for all 3, or 6 for and 2 for 2, or 4 for 2 and 2 for 3.3 for all 3, or 6 for and 2 for 2, or 4 for 2 and 2 for output fuse protection conforming to IEC EN DIN VDE 0660 part 200 instantaneous outputs time delay outputs - minimum current A ma 4 gl or 6 fast acting 4 gl or 6 fast acting 0 6 gl 4 gl 0 - minimum voltage V 7 7 Electrical durability See page 3860/6 Response time on instantaneous opening inputs ms < 30 < 20 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC EN , DIN VDE 00 parts and 2) Rated impulse withstand voltage (Uimp.) LED display kv 4 (overvoltage category III, conforming to IEC EN , DIN VDE 00 parts and 2) 4 Operating temperature C Storage temperature C Degree of protection conforming to IEC EN 529Terminals Enclosure IP 20 IP 40 Connection Type Captive screw clamp terminals Captive screw clamp terminals, Captive screw clamp terminals separate removable block - -wire connection Without cable end Solid or flexible cable: mm 2 Solid or flexible cable: mm 2 Solid or flexible cable: x 4 mm 2 With cable end Without bezel, flexible cable: mm 2 Without bezel, flexible cable: mm 2 Flexible cable: 2 x 2.5 mm 2 With With bezel, flexible cable: With bezel, flexible cable: cable end mm mm 2-2-wire connection Without Solid or flexible cable: Solid cable: 0.2 mm 2 cable end mm 2 Flexible cable: mm 2 With Without bezel, flexible cable: Without bezel, flexible cable: cable end 0.25 mm mm 2 With cable end Double, with bezel, flexible cable: mm 2 Double, with bezel, flexible cable: mm 38783_Ver.00-EN.fm/3

17 References for emergency stop and limit switch monitoring References Description Type of Number Additional Supply Reference Weight connection of safety outputs terminal circuits block kg Safety Integrated 6 N/O 3 solid state $ 24 V XPS-AV modules for in module (3 N/O emergency time delay) stop and limit switch monitoring XPS-AV3 Separate, 6 N/O 3 solid state $ 24 V XPS-AV3P can be (3 N/O removed time delay) from module Integrated 5 N/O N/C " and XPS-AT in module (2 N/O $ 24 V time delay) XPS-AV3P " 5 V XPS-AT " 230 V XPS-AT XPS-AT//// 38783_Ver.00-EN.fm/4

18 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AV Module XPS-AV associated with an emergency stop pushbutton with N/C contact, automatic start or unmonitored start + 24 V + 24 V F K0 K02 ESC Emergency stop S 2 K S3 3 () To PLC 4 A S3 S S3 S32 S Y+ Y64 Y74 Y84 Logic channel Output Output 2 K Logic channel 2 Output Output 2 Fault K/ XPS-AV / A2 Y39 S33 2 S34 Y Time delay stop K0 (2) K02 K (3) 0 V 0 V () Link for automatic start. (2) Instantaneous opening safety outputs (stop category 0). (3) Time delay opening safety outputs (stop category ). ESC = External start conditions. Functional diagrams Automatic start Unmonitored start Power-up Emergency stop not activated Emergency stop S- Automatic start (without ESC) S3-S4 Linked input -2 Linked input S3-S32 Time delay interrupt Y39-Y40 N/O output 03-04/3-4/23-24 N/O output 37-38/47-48/57-58 Signalling output Y74 Emergency stop activated Emergency stop not activated Emergency stop activated Emergency stop S- button S3-S4 Linked input -2 Linked input S3-S32 Time delay interrupt Y39-Y40 N/O output 03-04/3-4/23-24 N/O output 37-38/47-48/57-58 Signalling output Y74 Power-up Emergency stop not activated Emergency stop activated Emergency stop not activated Emergency stop activated Signalling output Y84 Automatic start There is no start contact or it is shunted. Time delay Tv = 0 300s interrupted Unmonitored start The output is activated on closing of the start contact. Signalling output Y84 Tv = 0 300s Time delay interrupt Monitored start The start input is monitored so that there is no start-up in the event of the start contact being shunted or the start circuit being closed for more than 0 s. -up is triggered following activation of the start button (push-release function) on opening of the contact _Ver.00-EN.fm/5

19 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AV Module XPS-AV associated with an emergency stop button with 2 N/C contacts, monitored start + 24 V F S + 24 V To PLC Emergency stop 2 A S3 S S3 S32 S Y+ Y64 Y74 Y84 Logic channel Output Output 2 K Logic channel 2 Output Output 2 Fault K/ XPS-AV / A2 Y39 S33 2 S34 Y S3 3 4 Emergency stop 2 22 S K0 K02 K Time delay stop K0 K02 24 K () (2) 58 ESC 0 V 0 V () Instantaneous opening safety outputs (stop category 0). (2) Time delay opening safety outputs (stop category ). ESC = External start conditions. Functional diagram Monitored start Power-up Linked input S- Emergency stop (channel ) -2 Emergency stop (channel 2) S3-S32 button S33-S34 Time delay interrupt Y39-Y40 N/O output 03-04/3-4/23-24 N/O output 37-38/47-48/57-58 Signalling output Y74 Emergency stop not activated Emergency stop activated Emergency stop not activated Emergency stop activated Signalling output Y84 No start-up Tv = 0 300s Time delay interrupt Emergency stop monitoring function configuration -channel wiring 2 channel wiring, with short-circuit detection S S A S S3 S32 XPS-AV A S S3 S32 XPS-AV A2 2 A _Ver.00-EN.fm/6

20 Connections, functional diagrams for emergency stop and limit switch monitoring XPS-AV Monitoring of a movable guard associated with 2 limit switches Automatic start (diagram shown for guard closed) + 24 V F + 24 V K0 K02 K 2 S 3 ESC Guard closed To PLC 22 A S3 S S3 S32 S Y+ Y64 Y74 Y84 Logic channel Output Output 2 K Logic channel 2 Output Output 2 Fault K/ XPS-AV / A2 Y39 S33 2 S34 Y Guard closed Time delay stop K0 () (2) K02 K 0 V 0 V () Instantaneous opening safety outputs (stop category 0). (2) Time delay opening safety outputs (stop category ). ESC = External start conditions. Functional diagram Power-up Linked input S- Guard (channel ) -2 Guard (channel 2) S3-S32 Guard open S3-S4 Time delay interrupt Y39-Y40 N/O output 03-04/3-4/23-24 N/O output 37-38/47-48/57-58 Signalling output Y74 Guard closed Guard open Guard closed Guard open Guard closed Guard open Signalling output Y84 Tv = 0 300s Time delay interrupt Key to LEDs input state 2 2 input state 3 S32 input state 4 S34 input state 5 S4 input state 6 Y40 input state (time delay stop) 7 K/ state (N/O instantaneous opening safety outputs) 8 / state (N/O time delay opening safety outputs) 9 A-A2 supply voltage 0Fault Configuration mode 38783_Ver.00-EN.fm/7

21 Operating principle, characteristics for monitoring emergency stops, limit switches, safety mats and edges and security light barriers Operating principle Preventa XPS-AK safety modules are designed to conform with category 4 of standard EN They are used for: / Monitoring emergency stop circuits conforming to standards EN 48 and EN / Electrical monitoring of limit switches activated by protection devices, with optional selection of synchronisation time between signals / Monitoring 4-wire safety mats or edges / Monitoring type 4 light barriers conforming to EN 6496-, which have solid state safety outputs (for example, XUS-LC type barriers, see page30302/4) Housed in a compact enclosure, the modules have 3 safety outputs, a relay signalling output and 4 solid state signalling outputs for signalling to the process PLC. Preventa XPS-AK////P safety modules have removable terminal blocks, which facilitate machine maintenance. To aid diagnostics, the modules have 4 LEDs on the front face which provide information on the monitoring circuit status. The function for monitoring the button can be configured by wiring. Characteristics Module type XPS-A/44 XPS-A/44P Product designed for use in safety related parts of control systems (conforming to EN 954-) Category 4 Supply - voltage V " and $ 24, " 0 and $ 24, " 20 and $ 24, " 230 and $ 24 - voltage limits % - frequency Hz 50/60 Consumption VA 5 (version 24 V), 6 (versions 0, 20 and 230 V) Module fuse protection Internal, electronic button monitoring Yes/No (configurable terminal connection) Control unit voltage and current (between terminals $ 24 V/30 ma approx. (at nominal supply voltage) -2 and S3-S32) Maximum wiring resistance RL between terminals -2, S3-S32 Ω 28 Synchronisation time between s Automatic start: 2 or 4 depending on wiring inputs A and B Manual start (start button between S33 and S34): unlimited (terminals -2, S3-S32) Outputs - voltage reference Volt-free - number and type of safety circuits 3 N/O (3-4, 23-24, 33-34) - number and type of additional circuits N/C (4-42) + 4 solid state - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - solid state output breaking capacity 24 V/20 ma, 48 V/0 ma - max. thermal current (Ithe) A 6 - max. total thermal current A 8 - output fuse protection A 4 gl or 6 fast acting, conforming to IEC , DIN VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time on input opening ms 40 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand voltage (Uimp.) kv 4 (overvoltage category III, conforming to IEC , DIN VDE 00 parts and 2) LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals Captive screw clamp terminals, separate removable block --wire connection Without cable end Solid or flexible cable: mm2 Solid or flexible cable: mm2 With cable end Without bezel, flexible cable: mm2 Without bezel, flexible cable: mm2 With cable end With bezel, flexible cable: mm2 With bezel, flexible cable: mm2-2-wire connection Without cable end Solid or flexible cable: mm 2 Solid cable: 0.2 mm 2, flexible cable: mm 2 With cable end Without bezel, flexible cable: 0.25 mm2 Without bezel, flexible cable: 0.25 mm2 With cable end Double, with bezel, flexible cable: mm 2 Double, with bezel, flexible cable: mm _Ver3.00-EN.fm/2

22 References for monitoring emergency stops, limit switches, safety mats and edges and security light barriers References Description Type of No. of Additional Solid Supply Reference Weigh t connection safety outputs state terminal circuits outputs block to PLC kg XPS-A/44 Safety Integrated 3 4 " 24 V XPS-A modules for in module $ 24 V monitoring emergency stops, limit switches safety mats and edges and security light " 0 V XPS-A barriers " 20 V XPS-A $ 24 V " 230 V XPS-A $ 24 V Separate, 3 4 " 24 V XPS-A44P can be $ 24 V removed from module " 0 V XPS-A644P $ 24 V XPS-A/44P " 20 V XPS-A544P $ 24 V " 230 V XPS-A744P $ 24 V 38782_Ver3.00-EN.fm/3

23 Connections for monitoring emergency stops, limit switches, safety mats and edges and security light barriers XPS-AK Emergency stop monitoring function configuration -channel wiring 2-channel wiring Emergency stop button with a single N/C contact Emergency stop button with 2 N/C contacts, Emergency stop button with 2 N/C contacts, without short-circuit detection with short-circuit detection (recommended application). S S S A B S S3 S32 XPS-AK A B S S3 S32 XPS-AK A B S S3 S32 XPS-AK A2 B2 2 A2 B2 2 A2 B2 2 Not all faults are detected: a short-circuit on the emergency stop pushbutton is not detected The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. Connection of multiple emergency stop buttons configurations with 2 N/C contacts (recommended application). Automatic start With start button monitoring A B S S3 S32 XPS-AK A B S3 S4 XPS-AK A B S3 S4 XPS-AK A2 B2 2 A2 B2 S33 S34 A2 B2 S33 S34 S S3 The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. Proximity sensor monitoring Sensors with PNP outputs Without short-circuit detection Sensors with NPN and PNP outputs With short-circuit detection Safety mat and edge monitoring S + + PNP PNP + PNP A B S S3 S32 A B S S3 S32 A B S S3 S32 XPS-AK XPS-AK XPS-AK A2 B2 2 A2 B2 2 A2 B2 2 NPN + 0 V 0 V 38782_Ver3.00-EN.fm/4

24 Connections for monitoring emergency stops, limit switches, safety mats and edges and security light barriers XPS-AK Monitoring of a movable guard associated with 2 limit switches with contact each (limit switch with N/O contact, limit switch 2 with N/C contact). Automatic start, without synchronisation time monitoring Guard closed Manual start via button Guard closed S S A B S S3 S32 S3 S4 A B S S3 S32 S3 S4 XPS-AK XPS-AK A2 B2 2 A2 B2 2 S33 S34 Monitoring of a movable guard associated with 2 limit switches and automatic start (diagram shows guard open) S A B S XPS-AK A2 B2 2 S3 S32 S3 S4 S33 S34 Functional diagram for outputs S Outputs 2 s 4 s Module XPS-AK associated with an emergency stop button with 2 N/C contacts L F S To PLC (+24 V) Input B A B S S3 S32 S3 S Y64 Y74 + XPS-AK Logic K Input A K/ Input B Fuse () A2 B2 2 S33 S ( ) Input A S Y3 Y32 Y54 To PLC ESC N Supply connection depending on voltage: ESC: External start conditions " on terminals A/A2, or $ 24 V on terminals B/B2 ()Operating status of internal electronic fuse 38782_Ver3.00-EN.fm/5

25 Connections for monitoring emergency stops, limit switches, safety mats and edges and security light barriers XPS-AK Module XPS-AK for monitoring electro-sensitive protection equipment (ESPE) +24 V F +24 V 0 V OSSD ESPE outputs OSSD2 To PLC A B S S3 S32 S3 S XPS-AK A Logic B K 33 4 Input A K/ Y64 Input B Y74 Fusible () A2 B2 2 S33 S Y3 Y32 Y54 S ESC (2) To PLC ESC: External start conditions () Operating status of internal electronic fuse (2) ESPE indicator light deactivated 0 V Example of safety circuit combining module XPS-AK for limit switch monitoring and a PLC L (+) F Guard closed S Input B A B S S3 S32 S3 S K + Logic XPS-AK 33 4 Input A K/ Y64 Input B Fuse () Y74 A2 B2 2 S33 S Input A Y3 Y32 Y54 S ESC Inputs V A PLC Outputs A N ( ) ESC: External start conditions () Operating status of internal electronic fuse 38782_Ver3.00-EN.fm/6

26 Functional diagrams for monitoring emergency stops, limit switches, safety mats and edges and security light barriers XPS-AK Functional diagrams Limit switch monitoring function with automatic start Input A -2 Input B S3-S32 Input S3-S4 N/O Output 3-4/ 23-24/ N/O Output 4-42 N/C Supply voltage Guard opens 2nd switch st switch Guard opens Limit switch monitoring function with automatic start and synchronisation of time monitoring Supply st Guard st voltage switch opens switch Guard 2nd 2nd opens switch switch Input A -2 Input B S3-S32 Input S3-S4 N/O Output 3-4/ 23-24/ N/O Output 4-42 N/C Output (K + ) Y3-Y32 Output (K + ) Y3-Y32 Output (Power) Y3-Y54 Output (Input A) Y3-Y64 Output (Input B) Y3-Y74 Key 0 Output (Power) Y3-Y54 Output (Input A) Y3-Y64 Output (Input B) Y3-Y74 Key 0 t = t = 2s t = 4s Emergency stop monitoring or limit switch monitoring function Supply voltage Emergency stop or limit switch activated Light barrier monitoring function (ESPE) with solid state outputs Supply voltage Light barrier Deactivated Activated Input A -2 Input A -2 Input B S3-S32 button S33-S34 N/O Output 3-4/ 23-24/ N/O Input B OSSD (ESPE) S32 Input OSSD2 (ESPE) button S33-S34 N/O Output 4-42 N/C Output (K + ) Y3-Y32 Output 3-4/ 23-24/ N/O Output 4-42 N/C Output (Power) Y3-Y54 Output (Input A) Y3-Y64 Output (Input B) Y3-Y74 Key 0 Output (K + ) Y3-Y32 Output (Power) Y3-Y54 Output (Input A) Y3-Y64 Output (Input B) Y3-Y74 Key 0 Safety mat and edge monitoring function with monitored start Input S- Input A -2 Supply voltage Walk on mat Leave mat Walk on mat Key to LEDs 2 34 Input B S3-S32 button S33-S34 N/O Output 3-4/ 23-24/ N/O Output 4-42 N/C Output (K + ) Y3-Y32 A-A2 supply voltage, fuse status 2 Input 2 (A) 3 Input S32 (B) 4 K/ status (N/O safety outputs closed) Output (Power) Y3-Y54 Output (Input A) Y3-Y64 Output (Input B) Y3-Y74 Key _Ver3.00-EN.fm/7

27 Operating principle, characteristics for emergency stop, limit switch and two-hand control monitoring Operating principle (see page) Characteristics Type XPS-AS XPS-AM XPS-AP Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V a and c 24 or 48, a 5, a voltage limits a % (24 V, 48 V) c % (24 V, 48 V) a % (5 V) a % (230 V) - frequency Hz 50/60 Consumption VA 24 V < 6 < 6 < 8 48 V < 9 < 9 < 5 V/230 V < 6 < 7 < 8 Module fuse protection Internal, electronic Control unit voltage V 24 (24 V version), 48 (48 V, 5 V, 230 V versions) between S-, -2 or S-B Minimum voltage and current between terminals S-, -2 or S-B (inputs A and B) U min./i min V (20 C) version 6 V/70 ma 6 V/60 ma 6 V/00 ma U min./i min V (20 C) version 35 V/25 ma 35 V/25 ma 35 V/45 ma U min./i min. - 5 V/230 V (20 C) vers. 4 V/25 ma 4 V/25 ma 4 V/45 ma Calculation of wiring resistance RL between terminals S-, -2 or S-B as a function of the internal supply voltage U int (terminals S-) Ω Ue = true voltage applied to terminals A-A2 U int = supply voltage Ue - 3 V (24 V, 48 V version) U int between 42 V and 45 V, with typical value = 45 V (5 V, 230 V version) RL max. must not exceed 50 Ω Synchronisation time between ms Approx. 300 inputs A and B automatic start, linked terminals S33-S34 Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 23-24) 3 N/O (3-4, 23-24, 33-34) 6 N/O (3-4, 23-24, 33-34, 43-44, 53-54, 63-64) - number and type of additional circuits N/C (4-42) N/C (7-72) - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 B300: inrush 3600, maintained breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - max. thermal current (Ithe) A output fuse protection A 6 fast acting, 4 gg 6 gg conforming to IEC , DIN VDE 0660 part minimum current ma 0 - minimum voltage V 7 - max. total thermal current A Electrical durability See page 3860/6 Response time on input opening ms < 40 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2) voltage (Uimp) LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2.5 mm Ver4.00-EN.fm/2

28 References for emergency stop, limit switch and two-hand control monitoring References Description No. of safety Additional Supply Reference Weight circuits outputs kg Safety modules 2 a and XPS-AS for emergency stop, c 24 V limit switch and two-hand control monitoring a and XPS-AS c 48 V XPS-AS a 5 V XPS-AS a 230 V XPS-AS (N/C) a and XPS-AM c 24 V a and XPS-AM c 48 V XPS-AM a 5 V XPS-AM a 230 V XPS-AM (N/C) a and XPS-AP c 24 V a and XPS-AP c 48 V XPS-AP a 5 V XPS-AP a 230 V XPS-AP Ver4.00-EN.fm/

29 Connections, functional diagrams for emergency stop, limit switch and two-hand control monitoring XPS-AS Module XPS-AS associated with an Emergency Stop button with Functional diagrams 2 N/C contacts Emergency Stop function Input A (S-) Input B (-2) Feedback loop Y-Y2 button -S34 (N/O) Output 3-4 (N/O) Supply voltage button not activated Emergency stop not activated button activated Emergency stop activated Logic Output (N/O) Key 0 ESC: External start conditions Y-Y2: Feedback loop () Automatic start Key to LEDs Guard function with automatic start Supply st 2nd Guard voltage switch switch opening Guard Guard closed Input A (S-) open Input B (-2) Feedback loop Y-Y2 Link S33-S34 Output 3-4 (N/O) Output (N/O) A-A2 supply voltage, fuse state 2 Input (A) 3 Input 2 (B) 4 K/ state (N/O safety outputs off) Key 0 approx. 300 ms Type III A two-hand control monitoring conforming to EN 574 Two-hand control function Supply voltage Button Button 2 Button deactivated Input A (S-) Input B (-2) Feedback loop Y-Y2 Link S33-S34 Output 3-4 (N/O) Output (N/O) approx. 300 ms Response time Key 0 S and : pushbuttons. Must not be used for (presses) which require a type III C module (XPS-BC) conforming to EN Ver4.00-EN.fm/4

30 Connections, functional diagrams for emergency stop, limit switch and two-hand control monitoring XPS-AM Module XPS-AM associated with an Emergency Stop button with Functional diagrams 2 N/C contacts Emergency Stop function Supply voltage button not activated Emergency stop not activated button activated Emergency stop activated Input A (S-) Input B (-2) Feedback loop Y-Y2 button -S34 (N/O) Logic Output 3-4 (N/O) Output (N/O) Output (N/O) Signalling output 4-42 (N/C) Key 0 () Automatic start (2) Emergency Stop signalling ESC: External start conditions Y-Y2: Feedback loop Key to LEDs Guard function with automatic start Input A (S-) Input B (-2) Feedback loop Y-Y2 Link S33-S34 Supply st 2nd Guard voltage switch switch open Guard Guard closed open Output 3-4 (N/O) A-A2 supply voltage, fuse state 2 Input (A) 3 Input 2 (B) 4 K/ state (N/O safety outputs closed) Output (N/O) Output (N/O) Signalling output 4-42 (N/C) Key 0 approx. 300 ms 3877 Ver4.00-EN.fm/

31 Connections, functional diagrams for emergency stop, limit switch and two-hand control monitoring XPS-AP Module XPS-AP associated with an Emergency Stop button with 2 N/C contacts Logic () Automatic start (2) Emergency Stop signalling ESC: External start conditions Y-Y2: Feedback loop Key to LEDs Functional diagrams Emergency stop function A-A2 supply voltage, fuse state 2 Input (A) 3 Input 2 (B) 4 K/ state (N/O safety outputs closed) Input A (S-) Input B (-2) Feedback loop Y-Y2 button -S34 (N/O) Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 7-72 (N/C) Supply voltage button not activated Emergency stop not activated button activated Emergency stop activated Key 0 Guard with automatic function Supply st 2nd Guard voltage switch switch opening Guard Guard closed Input A (S-) open Input B (-2) Feedback loop Y-Y2 Link S33-S34 Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 7-72 (N/C) Key 0 approx. 300 ms 877 Ver4.00-EN.fm/6

32 Connections for emergency stop, limit switch and two-hand control monitoring XPS-AS/AM/AP Emergency Stop monitoring configuration -channel wiring 2-channel wiring Emergency Stop button with N/C contact. Not all faults are detected: a short-circuit on the Emergency Stop button is not detected. Emergency Stop button with 2 N/C contacts (recommended application). The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. Emergency Stop button with 2 N/C contacts. Both input channels are connected to the same polarity. A short-circuit between the 2 inputs is not detected. 2-channel wiring Type III A two-hand control monitoring, conforming to EN 574 Connection to multiple Emergency Stop buttons with 2 N/C contacts (recommended application). The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. NOTE: A high resistance short between channels may not be detected. S and : pushbuttons. Must not be used for (presses) requiring type III C modules (XPS-BC) conforming to standard EN 574. See page 38790/3. Monitoring of a guard associated with a limit switch with 2 N/C contacts Monitoring of a movable guard associated with 2 limit switches with contact each (limit switch with N/O contact, limit switch 2 with N/C contact) Guard closed Guard closed Single limit switch lock for a movable guard with manual or automatic reset after closing. In automatic reset mode (), synchronisation time between the two inputs is monitored. In manual reset mode, input synchronisation time is unlimited. () Manual reset after closing, no synchronisation check of limit switches. (2) Manual reset after closing with limit switch synchronisation check. (3) Automatic reset after closing with limit switch synchronisation check Ver4.00-EN.fm/

33 Operating principle, characteristics for emergency stop, limit switch, two-hand control, safety mat and edge monitoring Operating principle (see page 38770/2) Characteristics Type XPS-ASF XPS-AMF XPS-APF Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply -voltage V " and $ 24 or 48, " 5, " voltage limits " % (24 V, 48 V) $ % (24 V, 48 V) " % (5 V) " % (230 V) - frequency Hz 50/60 Maximum consumption connected to safety mat or edge 24 V VA < 9 48 V VA < 2 5 V/230 V VA < 0 Module fuse protection Internal, electronic Control unit voltage V 24 (24 V version), 48 (48 V, 5 V, 230 V versions) between S-, -2 or S-B Minimum voltage and current between terminals S-, -2 or S-B (inputs A and B) U min./i min V (20 C) version 6 V/70 ma 6 V/60 ma 6 V/00 ma U min./i min V (20 C) version 35 V/25 ma 35 V/25 ma 35 V/45 ma U min./i min. - 5 V/230 V (20 C) vers. 4 V/25 ma 4 V/25 ma 4 V/45 ma Calculation of wiring resistance RL Ω between terminals S-, -2 L maxi = U int - U mini I mini or S-B as a function of the internal Ue = true voltage applied to terminals A-A2 supply voltage U int = supply voltage Ue - 3 V (24 V, 48 V version) U int (terminals S-) U int between 42 V and 45 V, with typical value = 45 V (5 V, 230 V version) RL max. must not exceed 50 Ω Maximum resistance of Ω 50 safety mat and edge between terminals S3-S32, S4-S42 Synchronisation time between ms Approx. 300 inputs A and B automatic start, linked terminals S33-S34 and Y3-Y4 Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 23-24) 3 N/O (3-4, 23-24, 33-34) 6 N/O (3-4, 23-24, 33-34, 43-44, 53-54, 63-64) - number and type of additional circuits 2 solid state N/C (4-42) + 2 solid state N/C (7-72) + 2 solid state - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 B300: inrush 3600, maintained breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - breaking capacity of solid state outputs 24 V/20 ma, 48 V/0 ma - max. thermal current (Ithe) A output fuse protection A 6 fast acting, 4 gl 6 gl conforming to IEC , DIN VDE 0660 part minimum current (volt-free contact) ma 0 - minimum voltage (volt-free contact) V 7 - max. total thermal current A Electrical durability See page 3860/6 Response time on input opening ms < 40 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2) voltage (Uimp) LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2.5 mm _Ver4.00-EN.fm/2

34 References for emergency stop, limit switch, two-hand control, safety mat and edge monitoring References Description Number of Additional Solid Supply Reference Weight safety outputs state circuits outputs for PLC kg Safety modules 2 2 " and XPS-ASF for emergency $ 24 V stop, limit switch, two-hand control, safety mat and edge monitoring " and XPS-ASF $ 48 V XPS-ASF " 5 V XPS-ASF " 230 V XPS-ASF " and XPS-AMF $ 24 V " and XPS-AMF $ 48 V XPS-AMF " 5 V XPS-AMF " 230 V XPS-AMF " and XPS-APF $ 24 V " and XPS-APF $ 48 V XPS-APF " 5 V XPS-APF " 230 V XPS-APF _Ver4.00-EN.fm/3

35 Connections, functional diagram for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-ASF Module XPS-ASF associated with an Emergency Stop button with 2 N/C contacts L (+) F S A (3) B ESC To PLC A S /S3 2 S32 B Y Y Y34 T + XPS-ASF K A/A2 K/ 5 V 230 V Logic Logique K Fusible Fuse (2) A2 PE S33/S4 S42 (3) Y3 Y4 () S3 A B S Y33/Y43 Y44 To PLC N ( ) () Without button monitoring (Y3-Y4 linked) ESC: External start conditions (2) Internal electronic fuse operating state Y-Y2: Feedback loop (3) If no safety mats or edges are connected, S3: Safety mat or edge terminals S33/4-S42 and /3-S32 must be linked Functional diagram for XPS-ASF Emergency Stop function Input A (S-) Input B (-2) Link S3-S32 Link S4-S42 Feedback loop Y-Y2 button -S34 (N/O) button -S34 (N/O) Output 3-4 (N/O) Output (N/O) Solid state output Y33-Y34 (fuse) Solid state output Y43-Y44 (K/) Key 0 L (+) Supply Emergency stop Emergency stop voltage not activated activated () With button monitoring (Y3-Y4 open) (2) Without button monitoring (Y3-Y4 linked) Module XPS-ASF connected to multiple Emergency Stop buttons and PLC () (2) F F2 F3 S S3 ESC (2) A A2 5 V 230 V T + S B 2 /S3 S32 Y Y2 3 Logic XPS-ASF K PE S33/S4 S42 Y3 Y4 S34 4 K S4 (3) N ( ) 2 3 () Internal electronic fuse operating state ESC: External start conditions (2) Other circuits controlled by the XPS-ASF module Y-Y2: Feedback loop (3) Automatic start The PLC outputs are controlled by the XPS-ASF safety module Y34 A/A2 K/ Inputs A Fuse () Y33/Y43 Y44 PLC Outputs 2 3 A2 8774_Ver4.00-EN.fm/4

36 Connections, functional diagrams for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-ASF Example of safety circuit using module XPS-ASF for limit switch and/or safety mat and PLC monitoring functions L (+) F Guard closed S (5) A A2 5 V 230 V T + S A B B 2 /S3 S32 Y Y2 3 K PE S33/S4 S42 Y3 Y4 S34 4 (5) () Logic XPS-ASF A B K 23 Y34 A/A2 K/ Fuse (3) 24 Y33/Y43 Y44 Inputs A S3 (4) (2) Outputs Programmable logic controller (PLC) 2 3 A2 2 N ( ) () Without button monitoring (Y3-Y4 linked) (2) Safety mat or edge (3) Internal electronic fuse operating state (4) Automatic start (5) If no safety mats or edges are connected, terminals S33/4-S42 and /3-S32 must be linked Functional diagrams for module XPS-ASF Guard function with automatic start and safety mat Safety mat or edge function Supply voltage () (2) (3) (4) (5) (6) (7) (8) (9) Input A (S-) Input A (S-) linked Input B (-2) Input B (-2) linked Safety mat/edge Safety mat/edge channel (S3-S32) channel (S3-S32) Safety mat/edge Safety mat/edge channel 2 (S4-S42) channel 2 (S4-S42) Feedback loop Feedback loop Y-Y2 Y-Y2 Link S33-S34 button (-S34) Link Y3-Y4 button (-S34) Output 3-4 (N/O) Output 3-4 (N/O) Output (N/O) Output (N/O) Solid state output Solid state output Y33-Y34 (fuse) Y33-Y34 (fuse) Solid state output Solid state output Y43-Y44 (K/) Y43-Y44 (K/) Key 0 approx. Key ms () Supply voltage (6) Guard opening () With button monitoring (Y3-Y4 open) (2) Guard open (7) Guard closing (2) Without button monitoring (Y3-Y4 linked) (3) st switch (8) Walk on mat (4) 2 nd switch (9) Clear mat (5) Guard closed () (2) Safety mat/edge activated Safety mat/edge deactivated 38774_Ver4.00-EN.fm/5

37 Connections, functional diagrams for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-AMF Module XPS-AMF for Emergency Stop and/or safety mat monitoring function L (+) F S S3 (2) (2) To PLC A XPS-AMF S 2 S3 S32 S4 S42 B Y54 N ( ) A2 5 V 230 V T + PE S33 Y3 () Y4 Logic K S34 Y K Y ESC (4) (5) 4 A/A2 Fuse (3) Y53/Y63 () Without button monitoring (Y3-Y4 linked) (4) Automatic start (2) If no safety mats or edges are connected, (5) Emergency Stop signalling terminals S3-S32 and S4-S42 must be linked S3: Safety mat or edge (3) Internal electronic fuse operating state ESC: External start conditions K/ Y64 To PLC Functional diagram Emergency stop function Supply Emergency stop Emergency stop voltage not activated activated Input A (S-) Input B (-2) Link S3-S32 Link S4-S42 Feedback loop Y-Y2 button -S34 (N/O) button -S34 (N/O) Output 3-4 (N/O) Output (N/O) Output (N/O) Signalling output 4-42 (N/C) Solid state output Y53-Y54 (fuse) Solid state output Y63-Y64 (K/) Key 0 () With button monitoring (Y3-Y4 open) (2) Without button monitoring (Y3-Y4 linked) () (2) Key to LEDs A-A2 supply voltage. Fuse state Safety mat/edge not activated 2 input state (A) 32 input state (B) 4K/ state (N/O safety outputs closed) Functional diagram Safety mat or edge function Supply Safety mat/ Safety mat/ Input A (S-) voltage edge activated edge deactivated linked Input B (-2) linked Safety mat/edge channel (S3-S32) Safety mat/edge channel 2 (S4-S42) Feedback loop Y-Y2 button -S34 button -S34 Output 3-4 (N/O) Output (N/O) Output (N/O) Signalling output 4-42 (N/C) Solid state output Y53-Y54 (fuse) Solid state output Y63-Y64 (K/) Key 0 () (2) () With button monitoring (Y3-Y4 open) (2) Without button monitoring (Y3-Y4 linked) 8774_Ver4.00-EN.fm/6

38 Connections, functional diagrams for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-APF Module XPS-APF for Emergency Stop and/or safety mat monitoring function L (+) F ESC S (4) To PLC A XPS-APF S 2 B S33 S34 Y Y Y84 T + K A/A2 K/ 5 V 230 V Logic K Fuse (3) A2 PE S3 S32 S4 S42 S3 (2) (2) Y3 Y4 () (5) Y83/Y93 Y94 To PLC N ( ) () Without button monitoring (Y3-Y4 linked) (5) Emergency Stop signalling (2) If no safety mats or edges are connected, ESC: External start conditions terminals S3-S32 and S4-S42 must be linked Y-Y2: Feedback loop (3) Internal electronic fuse operating state S3: Safety mat or edge (4) Automatic start Functional diagrams Emergency stop function Guard function with automatic start and safety mat Input A (S-) Input B (-2) Link S3-S32 Link S4-S42 Feedback loop Y-Y2 button -S34 (N/O) button -S34 (N/O) Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 7-72 (N/C) Solid state output Y83-Y84 (fuse) Solid state output Y93-Y94 (K/) Key 0 Supply Emergency stop Emergency stop voltage not activated activated () (2) () (2) (3) (4) (5) (6) (7) (8) (9) Input A (S-) Input B (-2) Safety mat/edge channel (S3-S32) Safety mat/edge channel 2 (S4-S42) Feedback loop Y-Y2 Link S33-S34 Link Y3-Y4 Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 7-72 (N/C) Solid state output Y83-Y84 (fuse) Solid state output Y93-Y94 (K/) Key 0 approx. 300 ms () With button monitoring (Y3-Y4 open) () Supply voltage (6) Guard opening (2) Without button monitoring (Y3-Y4 linked) (2) Guard open (7) Guard closed (3) st switch (8) Walk on mat (4) 2 nd switch (9) Clear mat (5) Guard closed Key to LEDs A-A2 supply voltage. Fuse state. Safety mat or edge deactivated 2 input state (A) 3 2 input state (B) 4 K/ state (N/O safety contacts closed) 38774_Ver4.00-EN.fm/7

39 Connections for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-ASF/AMF/APF Configuration for emergency stop monitoring Single-channel wiring (+) S ( ) A S B XPS-ASF/AMF/APF Emergency Stop button with single N/C contact. Not all faults are detected: a short-circuit on the Emergency Stop pushbutton is not detected. 2-channel wiring (+) S ( ) (+) ( ) S A S B XPS-ASF/AMF/APF (+) S ( ) A S B XPS-ASF/AMF/APF Emergency Stop button with 2 N/C contacts (recommended application). The two input channels are supplied with different polarities. A short-circuit between the two inputs is detected. Emergency Stop button with 2 N/C contacts. Both input channels are supplied with the same polarity. A short-circuit between the two inputs is not detected. S3 A S B XPS-ASF/AMF/APF Connection of several Emergency Stop buttons with 2 N/C contacts (recommended application). The two input channels are supplied with different polarities. A short-circuit between the two inputs is detected. NOTE: A high resistance short between channels may not be detected. XPS-ASF/AMF/APF Configuration with automatic and manual reset XPS-ASF/AMF/APF A2 PE S33 S34 Y3 Y XPS-ASF/AMF/APF A2 PE S34 Y3 Y XPS-ASF/AMF/APF A2 PE S34 Y3 Y Push-release function: Automatic start Without button monitoring, With button monitoring and manual reset manual reset 8774_Ver4.00-EN.fm/8

40 Connections, functional diagram for emergency stop, limit switch, two-hand control, safety mat and edge monitoring XPS-ASF/AMF/APF Type III A two-hand control monitoring conforming to EN 574 L (+) F S Functional diagram for module XPS-ASF Two-hand control function Supply voltage Button Button 2 Button deactivated To PLC Input A (S-) Input B (-2) A S B Y XPS-ASF/AMF/APF Y Y34 A/A2 K/ Feedback loop Y-Y2 Link S33-S34 N ( ) () Fuse A2 PE S3 S32 S4 S42 Y3 Y4 S33 S Y33/43 Y44 To PLC + 24 V a Link Y3-Y4 Link S3-S32 Link S4-S42 Output 3-4 (N/O) S and : pushbuttons Must not be used for (presses) which require a type III C module (XPS-BC) conforming to EN 574. See page 38790/3. () Internal electronic fuse operating state. Output (N/O) Solid state output Y33/43-34 Solid state output Y33/43-34 Key 0 approx. 300 ms (0.5 s max.) Response time 38774_Ver4.00-EN.fm/9

41 Operating principle, characteristics for increasing the number of safety contacts Operating principle Characteristics XPS-EC/ safety modules, for increasing the number of safety contacts, are available as attachments for Preventa XPS base models (emergency stop, limit switch, two-hand control, etc.). They are used to increase the number of safety output contacts of the base modules. Type XPS-ECM XPS-ECP Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V " and $ 24, " 5, " voltage limits % (" 24 V) % ($ 24 V) % (" 5 V) % (" 230 V) - frequency Hz 50/60 Consumption 24 V VA < 5 5 V/230 V VA < 6 Module fuse protection Internal, electronic Outputs - voltage reference Volt-free - number and type of safety circuits 4 N/O (3-4, 23-24, 33-34, 43-44) 8 N/O (3-4, 23-24, 33-34, 43-44, 53-54, 63-64, 73-74, 83-84) - no. and type of additional safety circuits N/C (4-42) + solid state N/C (9-92) + solid state - breaking capacity in AC-5 VA B300 : inrush 3600, maintained breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - solid state output breaking capacity 24 V/20 ma, 48 V/0 ma - max. thermal current (Ithe) A 6 - max. total thermal current A output fuse protection A 6 gg conforming to IEC , VDE 0660 part minimum current (volt-free contact) ma 0 - minimum voltage (volt-free contact) V 7 Electrical durability See page 3860/6 Response time on ms < 20 input opening Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 3 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals : without cable end x 4 mm 2, with cable end 2 x 2.5 mm _Ver3.00-EN.fm/2

42 References for increasing the number of safety contacts References Description Number Additional Solid Supply Reference Weight of safety outputs state circuits outputs for PLC kg Safety modules 4 " and XPS-ECM for increasing $ 24 V the number of safety contacts used with XPS base modules XPS-ECM " 5 V XPS-ECM " 230 V XPS-ECM " and XPS-ECP $ 24 V XPS-ECP " 5 V XPS-ECP " 230 V XPS-ECP _Ver3.00-EN.fm/3

43 Connections, functional diagram for increasing the number of safety contacts XPS-ECM Connections L (+) F 3 23 XPS Base module 4 24 Y2 Y () A U K B U2 Y 3 XPS-ECM Y63 T + K A/A2 N ( ) 5 V 230 V A2 PE K Y Safety outputs 52 Signalling output Fuse (2) Y64 To PLC () When installing base modules and modules for increasing the number of safety contacts into different electrical enclosures, run separate cables for terminals U-3 and U-23. (2) Operating statuss of internal electronic fuse. Functional diagram for module XPS-ECM Supply voltage Channel closes Channel 2 closes Channel Channel 2 opens opens Input A (U-K) Input B (U2-) Feedback loop Y-Y2 Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 5-52 (N/C) Solid state output A/A2 (fuse) Key _Ver3.00-EN.fm/4

44 Connections, functional diagram for increasing the number of safety contacts XPS-ECP Connections L (+) F 3 23 XPS Base module 4 24 Y2 Y () A U K B U2 Y 3 XPS-ECP Y03 T + K A/A2 N ( ) 5 V 230 V A2 PE K Y Safety outputs Signalling output Fuse (2) Y04 To PLC () When installing base modules and modules for increasing the number of safety contacts into different electrical enclosures, run separate cables for terminals U-3 and U-23. (2) Operating status of internal electronic fuse. Functional diagram of module XPS-ECP Supply voltage Channel Channel 2 closes closes Channel opens Channel 2 opens Input A (U-K) Input B (U2-) Feedback loop Y-Y2 Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Signalling output 9-92 (N/C) Solid state out put A/A2 (fuse) Key _Ver3.00-EN.fm/5

45 Operating principle for electrical monitoring of limit switches combined in pairs Operating principle Preventa safety module XPS-FB meets the safety requirements for monitoring the operation of 2 limit switches used on guards for the protection of personnel (e.g. grilles, protective covers, mechanical shielding, etc.). It is also possible to monitor the operation of two photo-electric detectors with relay output (e.g. access to robotised areas). To do this, each detector must be fitted with a N/O contact and a N/C contact or an N/C + N/O changeover contact. The contacts must not, however, be of the make before break type. Module XPS-FB monitors correct operation of the limit switches connected to it when the guard moves. It automatically detects any operating or electrical wiring fault in the limit switches. Detection of a fault (shorting, change of contact state during operation, etc.) causes immediate opening of the safety contacts in the module and subsequent stopping of the machine s dangerous movement. After the module has been energised, the guard must be opened and closed again to check that the limit switches are properly connected and no faults are present. This function can be simulated by means of the reset button. With the feedback loop closed, the safety circuits of the module are actuated after closing the guard and (optional) operation of the button. The feedback loop allows self-monitoring of any contactor or control relay used to increase the number of output contacts and/or to increase the breaking capacity. Any contactor or control relay used for this purpose must incorporate mechanically linked contacts. The function of the button on module XPS-FB is determined by the terminal connections. When terminals Y3-Y5 are linked, the button is included in the monitoring circuit and the safety outputs are activated on the falling edge of the output signal when the button is released. When terminals Y3-Y4 are linked, the safety outputs are activated immediately after the button is pressed. This configuration allows the safety modules to function automatically as soon as the safety guard is closed, provided that the button is shorted. High risk Locking or interlocking device based on the principle of redundancy and self-monitoring. The safety modules perform both functions. Machines with instant stopping. Locking (stopping time < access time) () XPS-FB XPS-FB Locking by actuator key and activation in positive mode associated with a safety module Activation in positive and negative (combined) mode associated with a safety module High inertia machines with long stopping times. Interlocking (stopping time >access time) () XPS-FB XPS-VN XPS-FB XPS-VN XPS-FB Interlocking device with actuator Interlocking device with actuator Interlocking device with electrokey captive in guard key captive in guard and zero magnetic lock speed detection () Stopping time: Time elapsed between actuation of the machine stop control and the moment the machine stops (risk eliminated). Access time: Time required for a person to access the hazardous zone (calculated on the basis of an approach speed). 8780_Ver5.00-EN.fm/2

46 Characteristics for electrical monitoring of limit switches combined in pairs Characteristics Type XPS-FB Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V " and $ 24 or 48, "5, " voltage limits " % (24 V, 48 V) $ % (24 V, 48 V) " % (5 V) " % (230 V) - frequency Hz 50/60 Consumption VA < 8 Module fuse protection Inputs Internal, electronic S: N/C + N/O, : N/C + N/O Synchronisation time s Approx..5 button monitoring Yes/No (configurable by terminal connections) Control unit voltage between /S3-S, 2/3-24 V version V V/5 V/230 V version V 48 Minimum voltage and current between terminals /S3-S, 2/3- U min./i min V (20 C) version 7.5 V/40 ma U min./i min V (20 C) version 35 V/40 ma U min./i min. - 5 V/230 V (20 C) 38 V/40 ma version Calculation of wiring resistance RL between terminals /S3-S, 2/3- as a function of the internal supply voltage U int (terminals -2) Ω Ue = true voltage applied to terminals A-A2 U int = supply voltage Ue -.5 V (24 V, 48 V version) U int between 42 V and 45 V, with typical value = 45 V (5 V, 230 V version) RL max. must not exceed 50 Ω Outputs - voltage reference Volt-free - number and type of safety circuits 3 N/O (3-4, 23-24, 33-34) - number and type of additional circuits N/C (4-42), 2 solid state (Y53-Y54, Y63-Y64) - breaking capacity in AC-5 C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - breaking capacity of solid state outputs ma 50 (48 V) - max. thermal current (Ithe) A output fuse protection A 4 gg conforming to IEC , VDE 0660 part minimum current (volt-free contact) ma 0 - minimum voltage (volt-free contact) V 7 Electrical durability See page 3860/6 Response time ms < 20 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 3 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 RL max. = U int - U min. I min. Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2.5 mm _Ver5.00-EN.fm/3

47 References, connections, functional diagram for electrical monitoring of limit switches combined in pairs Description Number of Solid state Supply Reference Weight safety outputs for circuits signalling to PLC kg Safety modules 3 2 $ and XPS-FB for electrical " 24 V monitoring of limit switches combined in $ and XPS-FB pairs " 48 V " 5 V XPS-FB XPS-FB " 230 V XPS-FB XPS-FB Guard locking on all machines L (+) F A 5 V 230 V Lim. sw. S (N/O) Lim. sw. S (N/C) Lim. sw. (N/C) Lim. sw. (N/O) button S3 (N/O) button S3 (N/O) Feedback loop Y-Y2 S T + S3 S Y Y2 S33 S34 3 K S3 Logic A2 PE 3 2 S43 S44 Y3 Y4 Y5 4 2 K (4) XPS-FB K K- state () To PLC S4 Fuse OK Test (2) N ( ) Y-Y2: Feedback loop Output (4-42) must not be used as a safety circuit. It can be used for non-hazardous machinery movements. S, : Limit switch (guard closed) S4 : Test pushbutton (simulation of opening and closing of moving guard) Simulation (opening Functional diagram for module XPS-FB and closing of Guard guard by open test button) Supply Guard Guard voltage closed open Supply voltage A/A2 Fuse (3) Y53 Y54 Lim. sw. S (N/O) Lim. sw. S (N/C) Lim. sw. (N/C) Lim. sw. (N/O) button S3 (N/O) Test button S4 (N/O) Feedback loop Y-Y2 K/ Y63 Y64 Key to LEDs 2 3 Supply voltage A-A2 2 Feedback loop Y-Y2 + guard closed 3 K- state (N/O safety outputs closed) () With button monitoring (2) Without button monitoring (3) Operating state of internal electronic fuse (4) Automatic start Begin guard opening Guard open Begin guard closing Guard closed Begin guard opening Guard closed Output 3-4 (N/O) Output 3-4 (N/O) Output (N/O) Output (N/O) Output (N/O) Output (N/O) Output 4-42 (N/C) Output 4-42 (N/C) Output Y53-Y54 Output Y53-Y54 Output Y63-Y64 T T max. approx..5 s Key 0 With button monitoring (Y3-Y5 connection) 2 Without button monitoring (Y3-Y4 connection) T2 Response time Output Y63-Y64 T2 Response time T T max. approx..5 s T2 Response time 8780_Ver5.00-EN.fm/4

48 Connections for electrical monitoring of limit switches combined in pairs XPS-FB Guard locking on an injection press conforming to standard EN 20 L (+) F S K5 S3 K5 S4 A 5 V 230 V T + S3 S Y Y2 S33 S34 3 K XPS-FB K Logic Y53 Y63 A/A2 Fuse (2) K/ K A2 PE 3 2 S43 S44 Y3 Y4 Y () K5 K5 Y54 Y64 K/ state (N/O safety outputs closed) To PLC Fuse OK N ( ) K5 S-: Limit switches (guard closed position) S4: Hydraulic switch (guard closed position) () With button monitoring (2) Operating state of the internal electronic fuse Monitoring of 2 photo-electric detectors with module XPS-FB L (+) F Reset S (2) B BK BK OG (3) RD (5) BN BU BU Photo-electric detector B2 BK BK OG (3) RD (5) BN BU BU Photo-electric detector 2 Reset S K5 (2) () A S S3 Y3 Y4 Y Y53 Y63 XPS-FB A/A2 K Fuse (4) K/ A2 PE K5 Y Y2 S33 S34 S43 S N ( ) () With button monitoring. (2) Reset button S: N/C contact + N/O contact. (3) To avoid interference between the 2 photo-electric detectors, bilateral installation of the detectors is recommended ( transmitter on each side and receiver on each side) so that the direction of the beams of photo-electric detectors and 2 are reversed. (4) Operating state of the internal electronic fuse. (5) Contact represented with beam broken. K5 K5 K5 Y54 Y64 K/ state (N/O safety outputs closed) To PLC Fuse OK 38780_Ver5.00-EN.fm/5

49 Operating principle, characteristics for electrical monitoring of two-hand control stations Operating principle Two-hand control stations are designed to provide protection against hand injury. They require machine operators to keep their hands clear of the dangerous motion area. The use of two-hand control is an individual protective measure, which can safely protect only one operator. Separate two-hand control stations must be provided for each operator in a multiple-worker environment. Preventa XPS-BA and XPS-BC safety modules for two-hand control comply with the - requirements of European standard EN 574 for two-hand control systems. The control stations must be designed and installed such that they cannot be activated involuntarily or easily rendered inoperative. Depending on the application, the requirements of type C standards specific to the machinery involved must be met (additional personal protection methods may have to be considered). To initiate a dangerous movement, both operators (two-hand control pushbuttons) must be activated within an interval 0.5 s (synchronous activation). If one of the two pushbuttons is released during a dangerous operation, the control sequence is cancelled. Resumption of the dangerous operation is possible only if both pushbuttons are returned to their initial position and reactivated within the required time interval. The safety distance between the control units and the hazardous area must be sufficient to ensure that when only one operator is released, the hazardous area cannot be reached before the dangerous movement has been completed or stopped. Characteristics Type XPS-BA XPS-BC Product designed for use in safety related parts of control systems Category Category 4 (conforming to EN 954-) Supply - voltage V 7 24, " 5, " 230 $ 24, " 24, " 5, " voltage limits % ($ 24 V), % (" 24 V), % ($ 24 V), % (" 24 V), % (" 5 V), % (" 230 V) % (" 5 V), % (" 230 V) - frequency Hz 50/60 Consumption VA < 20 (apparent power) < 6 Module fuse protection Internal, electronic Inputs S: N/C + N/O, : N/C + N/O Two-hand control type III A III C conforming to EN 574 Synchronisation time (maximum) s 0,5 Control unit voltage - $ 24 V version V " 24 V, 5 V, 230 V version V Minimum voltage and current between terminals T-T2, T-T3 between terminals T-T3, T2-T23 U min/i min - $ 24 V (20 C) version 8 V/30 ma 8 V/40 ma U min/i min - " 24 V/5 V/ 230 V 8 V/30 ma 30 V/50 ma (20 C) version Calculation of wiring resistance RL Ω (for XPS-BC only) between terminals T-T3, T2-T23 as a function of the internal supply voltage U int (terminals T3-T23) I min. Ue = true voltage applied to terminals A-A2 U int = supply voltage Ue - V (24 V version) (5 V, 230 V version ) RL max must not exceed 50 Ω U int between 30.5 V et 35 V, with typical value = 35 V Outputs - voltage reference Volt-free - number and type of safety circuits N/O (-4) 2 N/O (3-4, 23-24) - number and type of additional circuits N/C (-2) N/C (3-32) - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - maximum thermal current (Ithe) A output fuse production A 4 gg or 6 fast acting 4 gg conforming to IEC , VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time ms < 25 < 30 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2) voltage (Uimp) LED display 2 3 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 RL max. = U int - U min. Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2,5 mm _Ver5.00-EN.fm/2

50 Selection, references for electrical monitoring of two-hand control stations Selection Standard EN 574 defines the selection of two-hand control stations according to the control system category. The following table details the three types of two-hand control conforming to EN 574. For each type, it lists the operating characteristics and minimum requirements. Requirements of standard EN 574 Type I Type II Type III A B C Use of both hands (simultaneous action) Link between input and output signals Output signal inhibited Prevention of accidental operation Tamper-proof Output signal reinitialised Synchronous action (specified time limit) Use of proven components (Category conforming to EN 954-) XPS-BA// XPS-AS// XPS-AM// XPS-AP// Redundancy with partial error detection (Category 3 conforming to EN 954-) XPS-BC Redundancy + Self-monitoring (Category 4 conforming to EN 954-) XPS-BC Two-hand control station XY2-SB// Meets the requirements of standard EN 574 Conforming to standard EN 954- References Description Type Supply Reference Weight conforming to EN 574 kg Safety modules III A 7 24 V XPS-BA for electrical monitoring of two-hand control stations " 5 V XPS-BA XPS-BA " 230 V XPS-BA III C $ 24 V XPS-BC " 24 V XPS-BC " 5 V XPS-BC XPS-BC " 230 V XPS-BC _Ver5.00-EN.fm/3

51 Connections, functional diagrams for electrical monitoring of two-hand control stations XPS-BA Module XPS-BA associated with a two-hand control station Type III A conforming to EN 574 L (+) N ( ) F A T T T2 T3 + T S Logic XPS-BA A2 2 4 K Signalling output Safety output Functional diagram for module XPS-BA 0 Supply voltage Supply A-A2 Input T-T2 (N/C) Input T-T3 (N/O) Safety output -4 (N/O) Signalling output -2 (N/C) Key Two-hand control deactivated Button Button 2 max. 500 ms Two-hand control activated Two-hand control deactivated max. 25 ms Response time S and : pushbuttons. Must not be used for (presses) which require a type III C module (XPS-BC) Key to LEDs 2 Supply voltage A-A2 2 K state (N/O safety output -4 closed) XPS-BC Module XPS-BC associated with a two-hand control station Type III C conforming to EN 574 Functional diagram for module XPS-BC L (+) F A T3 T2 T Y Y A2 XPS-BC S T K Logic ESC K T22 T23 T K Two-hand control deactivated Mushroom head S (N/C) Mushroom head S (N/O) Mushroom head (N/C) Mushroom head (N/O) Feedback loop Output 3-4 (N/O) Output (N/O) Output 3-32 (N/C-) Button Button 2 Two-hand control activated Two-hand control non active N ( ) Key 0 max. 500 ms max. 30 ms Response time ESC: External start conditions. Y-Y2: Feedback loop. Output (3-32) must not be used as a safety circuit. It can be used for non-dangerous machine movements. Key to LEDs 2 3 Supply voltage A-A2, S- LED indicates that buttons S and are correctly connected 2 Feedback loop Y-Y2 3 K- state (N/O safety outputs closed) 38790_Ver5.00-EN.fm/4

52 Connections for electrical monitoring of two-hand control stations XPS-BC Module XPS-BC associated with a two-hand control station and foot switch (must only be applied to suitable ) L (+) S4 F 02 S3 S A T XPS-BC T3 T2 T2 T23 T N ( ) A2 Y Y S4 selector switch: 0 = Stop = Control station 2 = Foot switch S-: Two-hand control station pushbuttons S3: Foot switch Modules XPS-BC associated with 2 two-hand control stations L (+) F A T S XPS-BC T T2 T2 T23 T X When operator is absent: replace terminal block X with X3 and physically remove the two-hand control station. When operator 2 is absent: replace terminal block X2 with X3 and physically remove the two-hand control station. A2 Y Y X3 S X A T XPS-BC T3 T2 T2 T23 T N ( ) A2 Y Y S selector switch: = Operator 2 = Operator 2 3 = Operator and operator 2 S-, -2: Two-hand control station pushbuttons 38790_Ver5.00-EN.fm/5

53 Operating principle for zero speed detection Operating principle XPS-VN zero speed detection modules are used to detect the stop condition of electric motors. Their most common include:- providing the unlock signal for electrically interlocked sliding or removable machine guards, controlling rotation direction signals for reversing motors and engaging locking brakes after a motor has come to a standstill. As electric motors run down, a remanent voltage is produced in the windings of the motor due to residual magnetism. This voltage is proportional to the speed of the motor and, therefore, decreases as the motor comes to a standstill. This remanent voltage is measured in a redundant manner so as to detect the stop condition of the motor. The cabling between the motor windings and the inputs of the XPS-VN module is also monitored to prevent a cabling breakage or fault being seen as a stopped motor. A transformer should not be used to connect the motor to terminals Z, Z2 and Z3 since there is no monitoring of the connection with the motor winding via the resistor monitoring. XPS-VN safety modules are suitable for detecting the stop condition of all types of a.c. or d.c. motor driven machines which, when the motor runs down, produce a remanent voltage in the windings due to residual magnetism. These machines can be controlled by electronic devices, such as variable speed drives or d.c. injection brakes. The input filters for standard XPS-VN modules are designed for a frequency of up to 50 Hz. For motors operating at a frequency higher than 50 Hz, which therefore produce a high-frequency remanent voltage, special modules XPS-VN////HS should be used. XPS-VN safety modules have two potentiometers mounted on the front face of the module which allow independent adjustment of the switching threshold for each input circuit. This allows adjustment for different types of motors and application requirements. To assist diagnostics, XPS-VN modules incorporate 4 LED indicators and 2 solid state outputs to provide information on the status of the zero speed detection circuit. 8777_Ver3.00-EN.fm/2

54 Characteristics, references for zero speed detection Characteristics Type XPS-VN Product designed for use in safety Category 3 related parts of control systems (conforming to EN 954-) Supply - voltage V $ 24, "5, " voltage limits % ($ 24 V) % ("5 V) % (" 230 V) - frequency Hz 50/60 (5 V, 230 V) Consumption W < 4 ($ 24 V) VA < 8 ("5 V, " 230 V) Module fuse protection Internal, electronic Frequency of motor power supply Hz 50 Hz (XPS-VN//42), > 50 Hz (XPS-VN//42HS) Inputs - max. voltage between terminals V 500 rms Z - Z2 - Z3 - detection threshold V (adjustable) Outputs - voltage reference Volt-free - number and type of safety circuits N/O (3-4), N/C (2-22) - number and type of additional circuits 2 solid state - breaking capacity in AC-5 C300 (inrush: 800 VA/maintained: 80 VA) - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms (contact 3-4) 24 V/.2 A - L/R = 50 ms (contact 2-22) - breaking capacity of solid state outputs 24 V/20 ma, 48 V/0 ma - max. thermal current (Ithe) A output fuse protection conforming to A 4 gg IEC , DIN VDE 0660 part minimum current (volt-free contact) ma 0 - minimum voltage (volt-free contact) V 7 Electrical durability See page 3860/6 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand voltage (Uimp) kv 4 (overvoltage category III, conforming to IEC , DIN VDE 00 parts and 2) LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 50 Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2.5 mm 2 References Description Number Solid state Supply Frequency Reference Weight of safety outputs of motor circuits for PLC power kg Safety 2 2 $ 24 V 50 Hz XPS-VN modules for zero speed > 50 Hz XPS-VN42HS detection " 5 V 50 Hz XPS-VN XPS-VN > 50 Hz XPS-VN3442HS " 230 V 50 Hz XPS-VN > 50 Hz XPS-VN3742HS _Ver3.00-EN.fm/3

55 Schemes, connections for zero speed detection XPS-VN Wiring scheme L (+) F2 F F F 3-phase motor M U V W PE + 24 V FM M 3 F F A Z Z2 Z3 3 2 Y33/Y43 F XPS-VN U V W 5 V 230 V Logic K A/A2 Zero speed M 3 A Z Z2 Z3 3 2 XPS-VN Logic 2 F = 2 A A Y34 Y44 () (2) N ( ) To PLC () Disengagement in event of stop (2) Motor running F = 2 A d.c. motor + 3-phase motor with variable speed controller KM F F KM Variable speed controller F F A B F M A Z Z2 Z3 3 2 XPS-VN U V M 3 W A Z Z2 Z3 3 2 XPS-VN F = 2 A 3-phase motor with star delta starting F = 2 A KM KM2 KM3 KM: High speed rotation KM2: Low speed rotation KM3: Star FM F F F W PE W2 V U M 3 U2 V2 A Z Z2 Z3 3 2 XPS-VN F = 2 A The star contactor (KM3) must be closed after the motor is de-energised, in order to allow detection of zero speed. 8777_Ver3.00-EN.fm/4

56 Schemes, connections for zero speed detection XPS-VN Functional diagram for module XPS-VN Key to LEDs Supply A-A2 Input - channel Z-Z2 Supply voltage Motor start Motor stop instruction Error in channel (e.g. cable break) Detection Repair of motor standstill Reset Input - 2 channels Z3-Z2 Output 3-4 (N/O) Output 2-22 (N/C) Solid state output Y33-Y34 (A/A2) Solid state output Y43-Y44 (zero speed) Supply voltage A-A2 2 Stop detected by channel 3 Stop detected by channel 2 4 Stop detected by both channels within time window Key 0 The voltages at terminals Z, Z2 and Z3 are indicated solely for the purposes of schematic diagram representation. Module XPS-VN associated with a star-delta motor starter and guard switch XCS-E L 230 V L2 L3 FM2 FM F2 F3 T F4 S0 Y S3 Stop KM2 KM KM3 S KM2 S4 A 3 2 Y33/Y43 A XPS-VN A/A2 Zero speed FM A2 Z Z2 Z Y34 Y44 F KM KM KM2 PE W V U PE M 3 W2 U2 V2 Y KM2 KM KM3 KM2 KM3 KM N M 38777_Ver3.00-EN.fm/5

57 Schemes, connections for zero speed detection XPS-VN Association of modules XPS-VN and XPS-AK L F4 Guard closed + 24 V F5 L L2 S S4 Stop S5 Motor starter L3 Y Inputs V F2 K Guard unlocking Outputs F PLC 0 V 0 V 0 V A B 2 S S3 S Y3 F3 3 5 XPS-AK K/ A/A2 fuse Input A Input B F F F K A2 B2 S3 S4 S33 S34 K S3 Validation K Y32 Y54 Y64 Y74 PE PE Z Z2 Z3 A 3 2 XPS-VN A/A2 Y33/Y43 Zero speed U V W PE M 3 A Y34 Y44 M Y K N S + Y: Guard switch with solenoid locking on de-energisation, type XCS-E or XCS-L Pulse on de-energisation relay type DAN-Z 8777_Ver3.00-EN.fm/6

58 Schemes, connections for zero speed detection XPS-VN Association of modules XPS-VN and XPS-FB L F4 Guard closed + 24 V F5 L L2 L3 S0 Emergency stop S Inputs S4 Stop S5 Motor starter A(+) F2 S6 Y Outputs PLC A2 ( ) K Guard unlocking F3 0 V 0 V F3 3 5 A S S3 Y3 Y4 Y Y53 Y63 A/A2 A2 fuse K/ XPS-FB F F F K A2 PE Y Y2 S43 S44 S33 S34 K S7 S3 Simulation Validation Y54 Y64 Z Z2 Z3 A 3 2 Y33/Y43 PE PE A XPS-VN A/A2 Zero speed U V W PE M 3 M A2 Y 4 22 Y34 Y44 K K N S + Y: Guard switch with solenoid locking on de-energisation, type XCS-E or XCS-L Pulse on de-energisation relay type DAN-Z 38777_Ver3.00-EN.fm/7

59 Operating principle, characteristics for lift control Operating principle Door unlocking zone Landing indicator (stop reference point) Car doors Car + 0,2 m 0,2 m Landing doors When the car is parked at a landing, with the doors open, some lifts automatically correct their level (isolevelling) in relation to the landing in order to compensate for any differences generated by modification of the load in the car. During this operation, European standard EN-8 recommends that the presence of the car be checked within an area of ±0.2 mm around the landing (door unlocking zone), by means of a safety circuit which will cause the car to stop if it moves out of the specified zone. The use of an XPS-DA safety module which checks the presence of the car in the specified zone at two points meets this requirement. The module is fitted with two safety outputs and two solid state outputs for signalling functions. Four LEDs on the front face of the module provide visual indication of the state of the safety circuit. Landing The position of the car in relation to the landing is detected by two limit switches in the lift shaft. It is also possible to use non-contact sensors (magnetic sensors with reed contact). When the car reaches the preset position and when it is within the permissible tolerances in relation to the landing, the two safety circuits in safety module XPS-DA close and allow isolevelling of the car with the doors open. Any change in one of the input signals (car outside the specified zone) or detection of a fault (break in the wiring, short-circuit...) causes immediate opening of the safety outputs in module XPS-DA and therefore stopping of the car. Characteristics Type XPS-DA Products designed for use in safety related parts of control systems Category 4 (conforming to EN 954-0) Supply - voltage V " and $ 24, "5, " voltage limits " % (24 V), $ % (24 V), " % (5 V), " % (230 V) - frequency Hz 50/60 Maximum consumption 24 V VA < 9 5 V/230 V VA < 0 Module fuse protection Internal, electronic Control unit voltage V 24 (24 V version), 48 (5 V, 230 V versions) between S-, -2 Protection of the control Via limitation of the maximum current in case of short-circuits (<85 ma) unit contacts Minimum voltage and current between terminals S-, -2 (inputs A and B) U min/i min - 24 V version (20 C) 6 V/70 ma U min/i min - 5 V/230 V version (20 C) 4 V/25 ma Calculation of wiring resistance RL Ω between terminals S-, -2 RL maxi = U int - U mini I mini as a function of the internal Ue = true voltage applied to terminals A-A2 supply voltage U int U int = supply voltage Ue - 3 V (24 V version) (terminals S-) U int between 42 V and 45 V, with typical value = 45 V (5 V, 230 V version) RL max must not exceed 50 Ω Synchronisation time between ms approx. 300 inputs A and B, automatic start, linked terminals S33-S34 and Y3-Y4 Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 23-24) - number and type of additional circuits 2 solid state - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - solid state output breaking capacity 24 V/20 ma - maximum thermal current (Ithe) A output fuse protection conforming A 6 fast acting, 4 gg to IEC , DIN VDE 0660 part minimum current (volt-free contact) ma 0 - minimum voltage (volt-free contact) V 7 - max. total thermal current A 5 Electrical durability See page 3860/6 Response time ms < 40 on input opening Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2) voltage (Uimp) LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 50 Connection Type Captive screw clamp terminals: without cable end x 4 mm 2, with cable end 2 x 2.5 mm _Ver3.00-EN.fm/2

60 References, schemes for lift control References Description Number Solid state Supply Reference Weight of safety outputs for circuits signalling to PLC kg Safety modules 2 2 " and $ 24 V XPS-DA for lift control " 5 V XPS-DA XPS-DA " 230 V XPS-DA Schemes XPS-DA Module XPS-DA associated with a lift control system L (+) F S () Inputs Lift control system (2) (2) Outputs 2 3 S3 (3) + 24 V A A2 S B 2 S34 3 XPS-DA PE Y Y2 Y3 Y A/A2 (4) Fuse Y33/Y43 K/ 24 Y34 Y44 (4) (5) () Limit switch S (car position) (2) Limit switch (car position) (3) Enable instruction given by the lift control system (4) Operating state of internal electronic fuse (5) Output sates (only permissible for functions not relating to safety) (6) Feedback loop (7) Without signal monitoring (Y3-Y4 linked) N ( ) (6) (7) Link active Functional diagram for module XPS-DA Key to LEDs Supply A-A2 First limit switch S Second limit switch signal S3 () signal S3 (2) Feedback loop Y-Y2 Safety output 3-4 (N/O) Safety output (N/O) Solid state output Y33/43-Y44 (K/) Solid state output Y33/43-Y34 (fuse) Supply First Second voltage limit limit signal switch switch Car outside door unlocking zone Supply voltage A-A2. Fuse state 2 Input (A) 3 Input 2 (B) 4 K/ state (N/O safety outputs closed) Key 0 () With start signal monitoring Y3-Y4 open. (2) Without start signal monitoring Y3-Y4 linked _Ver3.00-EN.fm/3

61 Operating principle for automatic overtravel monitoring on linear presses Safety module GNK-L is used for automatic monitoring of overtravel on all types of linear presses : hydraulic, pneumatic and mechanical. It has been developed for monitoring the overtravel, before the start of production, on presses fitted with either a two-hand control unit or security light barrier. This module must be connected to 2 limit switches : - limit switch, which detects top dead centre, - limit switch S3, which detects the presence of normal overtravel during the test cycle performed after switch-on (before production starts). To allow the slide to reach a high speed, limit switch S3 must be located approximately in the middle of the tools full stroke. The permissible overtravel corresponds to the length S of the linear cam, which operates limit switch S3. Length S is normally determined by the linear press manufacturer, based on the least favourable conditions (maximum tool weight, operating rate and stroke, high oil temperature, etc.). Safety module GNK-L operates only during the first press cycle after switch-on : the test cycle. First case : Normal overtravel Machine idle 2 of cycle : 3 Braking as soon as the cam reaches S3 tool downstroke Tool The length of cam S determines the maximum permissible overtravel distance. Overtravel does not exceed length S. In this case, the tool stops at the position described under 3 as long as the instruction provided by the control station is valid. A new instruction must be given to enable subsequent cycles. Safety module GNK-L will repeat the correct overtravel test when the machine is next switched-on. Second case : Abnormal overtravel due to wear, hydraulic leak, unsuitable load, etc. Machine idle 2 of cycle : 3 Braking as soon as 4 Excess tool downstroke the cam reaches S3 overtravel During the test cycle, overtravel exceeds length S. In this case, the tool is in the position described under 3. Limit switch S3 is deactivated and the tool moves down, then stays at bottom dead centre, the position described under 4. The slide cannot move back up, even if a new instruction is given from the control station. It can be returned to top dead centre only by pressing the manual UP button. The next cycle is inhibited. Maintenance will be required before a further test cycle is initiated. Production cannot resume until a further test cycle is performed successfully (normal overtravel) Ver5.00-EN.fm/2

62 Characteristics for automatic overtravel monitoring on linear presses Characteristics Type GNK-L Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V a and c 24, a 20, a voltage limits % (24 V) % (20, 230 V) - frequency Hz 50/60 (20 V), 50 (230 V) Consumption VA < 6 Outputs - voltage reference Volt-free - number and type of safety circuits N/O (8-3) closing movement, 2 N/O (0-5, -4) + N/C (2-4) - number and type of additional circuits - breaking capacity in AC-5 VA C300 : inrush 800, maintained 80 - breaking capacity in DC-3 24 V/2 A - L/R = 50 ms - max. thermal current (Ithe) A output fuse protection A 2 gg conforming to IEC , VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time ms < 20 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 8 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Polycarbonate Type Plug-in enclosure Number of terminals 20 Connection Type Captive screw clamp terminals : without cable end 2 x 2.5 mm 2, with cable end 2 x.5 mm 2, min. Ø 0.5 mm Ver5.00-EN.fm/

63 References for automatic overtravel monitoring on linear presses References Description Display Supply Reference Weight kg Safety modules 8 LEDs a and c 24 V GNK-L24VACDC for automatic overtravel monitoring on linear presses GNK-L a 20 V GNK-L20VAC a 230 V GNK-L230VAC Ver5.00-EN.fm/4

64 Connections, functional diagram for automatic overtravel monitoring on linear presses GNK-L Module GNK-L associated with a linear press whose tools are stopped in the down position (bottom dead centre) Two-hand control station or PSE Functional diagram of module GNK-L in the case of normal overtravel during the first test cycle Contact (N/C) Contact (N/O) Limit switch (N/C) Limit switch (N/O) Limit switch S3 (N/C) Output 8-3 (N/O) Output 0-5 (N/O) For hydraulic pump PSE : Presence sensing equipment S : Hydraulic pump stop : TDC limit switch S3 : TEST limit switch S4 : Hydraulic pump start S5 : Mode selector 0 : Stop : Adjust mode 2 : Normal mode S6 : Raise tool to top dead centre in adjust mode Downstrokstroke channel 3 Down- Upstroke Output -4 (N/O) channel channel 2 Output 2-4 (N/C) Key 0 () Slide at top dead centre. (2) First cycle instruction by pressing pushbutton. (3) Stop cycle as soon as S3 limit switch is reached. (4) st release of both pushbuttons. (5) Second cycle instruction by pressing pushbutton. (6) 2 nd release of the pushbuttons. (7) Slide upstroke to top dead centre. Key to LEDs Control of safety circuit solenoids (slide downstroke to bottom dead centre). Supply voltage to terminals A/A2 2 Internal c voltage OK 3 Internal fuse OK 4 Overtravel OK 5 Test switch S3 not activated 6 Energising instruction (channel 2) activated 7 Test in progress 8 Energising instruction (channel 2) deactivated when S3 reached Control of non dangerous movement solenoid (slide upstroke to top dead centre) Ver5.00-EN.fm/

65 Operating principle Preventa safety module for dynamic valve monitoring on linear presses Operating principle The XPS-PVT safety module is a dedicated module for monitoring hydraulic safety system valves, which control the movements of dangerous machinery. The operating principle of this module is explained in the circuit diagram of a hydraulic safety system for linear presses (see below). This hydraulic safety system features a 3-position piston which controls the up and down stroke of the operating cylinder. The circuit is equipped with a safety valve, to complete the redundant system. This circuit must be activated to enable the up and down stroke of the cylinder. If either of the two pistons becomes defective (for example, due to a broken spring or to oil contamination), and the valve piston shifts from its normal position toward the open position, the XPS-PVT module will detect it and prevent resumption of the piston stroke. Proximity sensors integrated into the valve to detect the valve positions and connected to the XPS-PVT module must be damped when the valve coils are in the de-energised state (position zero). The sensor circuits of the XPS-PVT module are designed to allow connection of NPN and PNP proximity sensors or sensing components. Either 2-wire or 3-wire types can be used. The diagram on page 38740/4 shows how to connect proximity sensors. Hydraulic safety system circuit operating on a linear press. Monitoring of valves in position 0. Closing + Opening Pressure relief valve Closing Opening Pump Pressure relief valve () 3-position hydraulic valve. (2) 2-position hydraulic valve Ver3.00-EN.fm/2

66 Characteristics, reference Preventa safety module for dynamic valve monitoring on linear presses Characteristics Type XPS-PVT Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V c 24 - voltage limits % Consumption W < 6 Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 33-34) + N/C (2-22) - number and type of additional circuits - wiping time ms 00 (minimum value) - breaking capacity in AC-5 VA C300 : inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - max. thermal current (Ithe) A output fuse protection conforming to A 4 gg IEC , VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time ms < 5 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 8 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Polycarbonate Type Plug-in enclosure Number of terminals 20 Connection Type Captive screw clamp terminals : without cable end 2 x 2.5 mm2, with cable end 2 x.5 mm2, min. Ø 0.5 mm Reference Description Display Supply Reference Weight kg Safety modules 8 LEDs c 24 V XPS-PVT for dynamic monitoring of hydraulic valves on linear presses XPS-PVT Ver3.00-EN.fm/

67 Connections Preventa safety module for dynamic valve monitoring on linear presses XPS-PVT Electrical connection diagram for module XPS-PVT Valve Y Valve Y2 Valve Y3 Close Open Close + open Logic Channel Channel 2 Potentially hazardous closing movement (tripping relay) Open Auxiliary Close Open contactor Close + open () Two-hand control or security light barrier outputs 8740 Ver3.00-EN.fm/4

68 Functional diagram Preventa safety module for dynamic valve monitoring on linear presses XPS-PVT Functional diagram of module XPS-PVT Supply ON Commence close command Test deactivated Slide at bottom dead centre Commence open command Test deactivated Slide at top dead centre Supply A-A2 Commence closing, input B Commence opening, input C Closing valve sensor, input -2 Opening valve sensor, input 3-4 Safety valve sensor, closing + opening, input 5-6 Feedback loop output, 2-22 (N/C) Close test, 3-6 (N/O) Enable closing, 3-4 (N/O) Open test, (N/O) Enable opening, (N/O) Key 0 t 00 ms min. t2 00 ms min. Key to LEDs Close instruction 2 Test closure 3 Open instruction 4 Test opening 5 Opening valve (Y2) in position 0 6 Enable close 7 Safety valve (Y3) activated 8 Closing valve (Y) in position Ver3.00-EN.fm/

69 Operating principle, characteristics for dynamic monitoring of double-bodied solenoid valves Operating principle Safety module XPS-PVK is specially designed for dynamic monitoring of the safety valves in eccentric presses, conforming to European standard EN 692. This standard establishes the specifications related to safety control systems for presses equipped with friction clutches. To meet the requirements of this standard, the clutch/brake control must be monitored dynamically. This function is provided by a double-bodied solenoid valve (safety valve for presses) which performs the functions of two valves mounted in one body. The position of the two valve pistons can be monitored by proximity sensors, mechanical limit switches or pressure switches. Module XPS-PVK checks for the correct operation of the double-bodied safety valves at 3 points in the cycle. / at top dead centre: checks the rest position of the two valves. / Take-on point (transfer function): checks that the two valves are in the activated (energised) position. / Press stop trigger point: checks that the two valves return to the rest position. Return must be simultaneous for both valves within a defined time period. Characteristics To set up an automatic disconnect of the XPS-PVK module at the first machine stroke, a N/C auxiliary contact mounted on the main control contactor or on another contactor/relay, activated at the same time, can be wired to terminals 7 and 8 in parallel with the RESET button. If a fault is detected during the cycle, the XPS-PVK module will stop the slide stroke and will also inhibit the start of another cycle. Type XPS-PVK Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V $ 24, " 5, " voltage limits % ($ 24 V) % (" 5 V) % (" 230 V) - frequency Hz 50/60 Consumption $ 24 V W < 9 " V VA < 6 Outputs - voltage reference Volt-free - number and type of safety circuits N/O (3-4) transfer function + N/C (2-22) feedback loop - number and type of additional circuits 4 solid state outputs - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - max. thermal current (Ithe) A solid state output power 24 V/20 ma, 48 V/0 ma - output fuse protection A 4 gg conforming to IEC , VDE 0660 part minimum current (volt-free contacts) ma 0 - minimum voltage (volt-free contacts) V 7 Response time ms < 40 Electrical durability See page 3860/6 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 8 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Polycarbonate Type Plug-in enclosure Number of terminals 32 Connection Type Captive screw clamp terminals: without cable end 2 x 2.5 mm2, with cable end 2 x.5 mm2, min. Ø 0.5 mm 8760_Ver5.00-EN.fm/2

70 References, Connections for dynamic monitoring of double-bodied solenoid valves References Description Display Sypply Reference Weight kg Safety modules 8 LEDs $ 24 V XPS-PVK for dynamic monitoring of double-bodied solenoid valves " 5 V XPS-PV XPS-PVK " 230 V XPS-PV Connections XPS-PVK Monitoring of a press safety valve by an XPS-PVK module Key to LEDs Safety noise damper Valve body Valve body 2 Double-bodied safety valve Compressed air supply To clutch and brake Main contactor auxiliary contact Reset S3 S + A + A A XPS-PVK Pressure switch for valve body Pressure switch for valve body 2 Condition for execution of the transfer function 3 2 Outputs Feedback loop circuit relating to clutch control $ internal supply no. 2 $ internal supply no. 2 3 Valve no. blocked 4 Valve no. 2 blocked 5 Ready for monitoring 6 Disconnect synchronised 7 Reset 8 Valves and 2 energised 38760_Ver5.00-EN.fm/3

71 Connections, functional diagram for dynamic monitoring of double-bodied solenoid valves XPS-PVK Functional diagram of the XPS-PVK module Supply voltage Reset button activated Reset button deactivated Valve activated Cycle start Maintain function activated Maintain function deactivated Valve deactivated Valve sensor activated Valve 2 sensor activated End of cycle top dead centre Supply A-A2 Safety valve and 2 Sensor valve body Sensor valve body 2 Reset 7-8 Solid state output Y+ / Y34 Solid state output Y+ / Y44 Solid state output Y+ / Y54 Solid state output Y+ / Y64 Transfer output 3-4 (N/O) Feedback loop 2-22 (N/C) Key 0 t approx. 00 ms Connection of XPS-PVK module with 3-wire (or 2-wire) proximity sensors 3-wire sensors 2-wire sensors Main contactor auxiliary contact Reset Sensor valve body S PNP + A Sensor valve body 2 PNP + A Main contactor auxiliary contact Reset Sensor valve body S PNP Sensor valve body 2 PNP + A + A S3 S3 A XPS-PVK 3 2 A XPS-PVK 3 2 A A _Ver5.00-EN.fm/4

72 Connections for dynamic monitoring of double-bodied solenoid valves XPS-PVK Connection of an XPS-PVK module with an eccentric press safety valve L (+) F P B 2 4 To valve body PNP B Ð + Reset S A KM Main contactor auxiliary contact Condition for executing the transfer function Part of clutch control feedback loop circuit a/c () 24 V c a/c + Ð + XPS-PVK (2) (3) Ð 24 V c A2 PE Y+ Y34 Y44 Y54 Y Part of clutch control feedback loop circuit PNP B2 + Ð Supply + 2 Valve Valve 2 Synchronous disconnect Condition for executing the transfer function N (Ð) P B2 4 To valve body 2 2 () Internal power supply no. (2) Internal power supply no. 2 (3) For a $ 24 V version: integrated $/$ adaptor To PLC 38760_Ver5.00-EN.fm/5

73 Operating principle for safety stop with automatic overtravel monitoring and control Operating principle Safety module XPS-OT is used on eccentric presses to monitor overtravel and ensure that the press slide stops in a non-dangerous position, that is, top dead centre (TDC) during normal (non-emergency) operation. Use of this module, designed in accordance with standard EN 692 relating to mechanical press safety, makes it possible to create a redundant, self-monitoring control system. The two essential functions of this safety module are : / Trigger the end of cycle stop sequences slightly before top dead centre (at point A) so as to reach a standstill stop at TDC. After TDC, the permissible overtravel is approximately 0. The safety module immediately detects any overtravel. Overtravel is indicative of braking device deterioration. In this case, jog mode must be used to move the slide back to TDC. The next cycle will be inhibited to allow maintenance to be performed on the braking device (cam ). / Take over control monitoring during the dangerous part of the cycle (slide downstroke). Any stop instruction issued between TDC (0 ) and point C (approximately 50 after TDC) causes an immediate stop of the press. This approximate value of 50 corresponds to the 8 mm tool closure dimension (safety point). When a stop instruction is issued after this point, the press completes the cycle and comes to a complete stop at TDC (cam 2). Control of the dangerous part of the cycle (generally the slide downstroke) is usually achieved from a two-hand control station associated with safety module (type XPS-BC) monitoring this station to qualify as a Category 4 control system according to standard EN Overtravel monitoring is performed on each cycle by safety module XPS-OT. Press Control cams Permissible overtravel A N 300 (usually slide upstroke) zone S TDC 0 0 B C N 50 Dangerous zone (usually slide downstroke) zone (usually Dangerous slide downstroke) approx. 0 S B Cam Cam 2 C2 Permissible overtravel OTS LS UN LS A2 A zone approx. 300 Safe zone Safe zone Top Dead Center BDC approx. 50 TDC Stop and overtravel monitoring (usually slide upstroke) Restart + Stop Bottom Dead Center 8 mm max. S A B C OTS UN Permissible overtravel Stop instruction trip point Point at which permissible overtravel is exceeded (a stop instruction issued after point B will lock up the press) Takeover point, beyond which the press will complete its cycle up to TDC TDC Top dead centre, actual stopping zone BDC Bottom dead centre Cam operation Cam is associated with the OTS limit switch (LS), cam 2 with the UN limit switch (the limit switches must be located on different cams for safety reasons). The OTS limit switch is deactivated at TDC, at which point the UN limit switch is activated. Point A of cam is located approximately 300 from TDC and, when reached, the press comes to a standstill: A is the press stop trigger point. Point B, located approximately 0 after TDC, constitutes the end of cam : If B is exceeded during stopping, the overtravel is abnormally long, the press locks up and the next cycle is inhibited. Point A2 of cam 2 functions like point A on cam (contact state of the UN limit switch reversed in relation to the contact state of the OTS limit switch). Point C2, located approximately 50 after TDC, corresponds to the 8 mm tool closing dimension. Stop instructions issued after C2 is reached are not executed until point A2 is reached. 8773_Ver4.00-EN.fm/2

74 Characteristics for safety stop with automatic overtravel monitoring and control Characteristics Type XPS-OT Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V " 5, " voltage limits % (5 V), % (230 V) - frequency Hz 50/60 Consumption VA < 2 Module fuse protection Internal, electronic Outputs voltage reference Volt-free - number and type of safety circuits 3 N/O (-2, -3, -4) - number and type of additional circuits 4 solid state outputs - breaking capacity in AC-5 VA C300 : inrush 800, maintained80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - solid state outputs breaking capacity 24 V/20 ma, 48 V/0 ma - max. thermal current (Ithe) A output fuse protection A 4 gg conforming to IEC , VDE 0660 part minimum current (volt-free contacts) ma 0 - minimum voltage (volt-free contacts) V 7 Electrical durability See page 3860/6 Response time ms < 20 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Polycarbonate Type Plug-in enclosure Number of terminals 42 Connection Type Captive screw clamp terminals : without cable end 2 x 2.5 mm2, with cable end 2 x.5 mm2, min. Ø 0.5 mm 38773_Ver4.00-EN.fm/3

75 References for safety stop with automatic overtravel monitoring and control References Description Display Supply Reference Weight kg XPS-OT Safety modules 4 LEDs " 5 V XPS-OT for safety stop with automatic overtravel monitoring and control " 230 V XPS-OT _Ver4.00-EN.fm/4

76 Connections, functional diagram for safety stop with automatic overtravel monitoring and control XPS-OT Connections F Cam enclosure Maintained + TDC stop S UN 22 2 TDC stop + overtravel OTS Safety valve signals Dynamic valve monitoring + 24 V A Z Z2 25 Z3 Z4 Y3 Y23 Y33 Y43 + XPS-OT Muting A/A2 Fuse OTS UN Logic N A2 PE ( ) (Continuous only) Two-hand control station XY2-SB CONT. S3 3 4 Feedback loop S4 Y K Y2 XPS-BC Two-hand control () The 2 coils of the safety valve must be wired separately. K S5 Operating modes 0 = Stop = Adjust 2 = Jog 02 Channel Channel 2 Maintained K H Inputs PLC Outputs K PSV Y4 Y24 Y34 Y () K Safety valve Functional diagram of module XPS-OT Close signal input 9-0 Limit switch OTS 5-6 Limit switch UN 3-4 Safety output -2 Safety output -3 Output -4 Solid state output Y3-Y4 Solid state output Y23-Y24 Solid state output Y33-Y34 Solid state output Y43-Y44 Internal signal Z3-Z4 Supply voltage TDC stop instruction Cycle start End of start instruction Dangerous movement Stop instructio Maintained Braking End of cycle TDC stop Key to LEDs Voltage present on terminals A/A2 2 Close instruction 3 OTS limit switch activated 4 UN limit switch activated Output Input Z-Z2 (XPS-PVK 2-22) Input Z3-Z4 (XPS-PVK 3-4) Angle of rotation Key 0 t t = 300 ms max. or limited to Z-Z2 Permissible overtravel ca cycle 38773_Ver4.00-EN.fm/5

77 Operating principle, characteristics for amplifier relay Operating principle The XPS-NS module is designed for reliable detection and amplification of signals generated by : - c 24 V proximity sensors (2-wire, 3-wire NPN or 3-wire PNP types), - magnetic sensors, - limit switches. The amplifier generates output signals which can be used in mechanically linked contact relays in safety circuits. Applications include : solenoid valve proximity sensors for eccentric press clutch/brake functions, magnetic sensors or limit switches mounted on protective guards, etc. By applying a nominal voltage to terminals A/A2, two separate c 24 V supplies are generated, terminals A+ = (+) / A = ( ) and terminals B+ = (+) / B = ( ), the latter being interconnected such that an internal short-circuit is generated if the proximity sensors are improperly connected. In turn, the short-circuits, are displayed by the corresponding LED POWER SUPPLY or POWER SUPPLY 2. Two other LEDs indicate the status of their corresponding proximity sensor. Each output relay (linked contacts) contains a N/O volt-free contact and a N/C volt-free contact. A monitoring circuit connected to terminals 5-52 comprises 2 N/C contacts in series for each of the two output relays. Possible sensor or limit switch connections and their combinations are shown in the electrical connections diagram on page 38772/3. Caution : If S and are 2 proximity sensors placed close to each other, 2 different types of sensor should be used to avoid interference. For example : S : 2-wire, : 3-wire NPN. Characteristics Type Product designed for use in safety related parts of control systems (conforming to EN 954-) XPS-NS Can be applied in category 4 safety related parts of control systems Supply - voltage V a 5, a voltage limits % (5 V), % (230 V) - frequency Hz 50/60 Consumption VA < 8 Module fuse protection A Internal, electronic Outputs - voltage reference Volt-free - number and type of safety circuits 2 N/O (3-4, 43-44) + 2 N/C (2-22, 3-32) - number and type of additional circuits N/C - breaking capacity in AC-5 VA C300 : inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - max. thermal current (Ithe) A output fuse protection A 4 gg conforming to IEC , VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 voltage (Uimp) overvoltage category III, conforming to IEC 947-, DIN VDE 00 parts and 2 LED display 4 Operating temperature C Storage temperature C Degree of protection Terminals IP 0 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals : without cable end 2 x 2.5 mm2, with cable end 2 x.5 mm2, min. Ø 0.5 mm 8772 Ver3.00-EN.fm/2

78 References, connections, functional diagram for amplifier relay References Description Display Supply Reference Weight kg Safety modules 4 LEDs a 5 V XPS-NS for amplifier relay a 230 V XPS-NS Connections XPS-NS Association of the XPS-NS modules and sensors 3-wire c 24 V Type PNP Type NPN 2-wire c 24 V + Switching Limit switch + Switching S proximity sensor outputs proximity sensor outputs Functional diagram of module XPS-NS S/ deactivated S activated S/ deactivated S/ activated S/ deactivated Prox. sens. S (N/O) Prox. sens. (N/O) Output 3-4 (N/O) Output 2-22 (N/C) Output (N/O) Output 3-32 (N/C) Output 5-52 (N/C) Key Ver3.00-EN.fm/

79 Dimensions, mounting XPS-AL, XPS-AX, XPS-BA AM-DP200 rail mounting ,5 XPS-AF////, XPS-AFL//// AM-DP200 rail mounting XPS-AF////P, XPS-AFL////P AM-DP200 rail mounting 4 22, ,5 XPS-AT, XPS-AM, XPS-AMF, XPS-AP, XPS-APF, XPS-ECM, XPS-ECP, XPS-FB, XPS-NS, XPS-VN AM-DP200 rail mounting XPS-AK////, XPS-AV////, XPS-MP//// AM-DP200 rail mounting XPS-AK////P, XPS-AV////P, XPS-MP////P AM-DP200 rail mounting _Ver5.0-EN.fm/2

80 Dimensions, mounting XPS-AS, XPS-ASF, XPS-BC, XPS-DA, XPS-CE AM-DP200 rail mounting GNK-L, XPS-PVT AM-DP200 rail mounting XPS-PVK AM-DP200 rail mounting XPS-OT AM-DP200 rail mounting 38730_Ver5.0-EN.fm/3

81 Operating principle, characteristics for emergency stop, limit switch and security light barrier monitoring Operating principle Preventa XPS-AF safety modules are designed to conform with category 4 of standard EN 954-, and safety modules XPS-AFL are designed to conform with category 3. They are used for: / Monitoring emergency stop circuits conforming to standards EN 48 and EN / Electrical monitoring of limit switches activated by protection devices conforming to the standard EN 088. In addition, Preventa XPS-AFL safety modules can be used for monitoring type 4 security light barriers conforming to EN which have solid state safety outputs (for example, XUS-LC type barriers, see page 30302/4). Housed in a compact enclosure, the modules have 3 safety outputs. Preventa XPS-AF////P safety modules have removable terminal blocks, which facilitate machine maintenance. To aid diagnostics, the modules have 3 LEDs on the front face which provide information on the monitoring circuit status. The function for monitoring the button can be configured by wiring. Characteristics Module type XPS-AF530 XPS-AFL530 XPS-AF530P XPS-AFL530P Product designed for use in safety related parts of control systems (conforming to EN 954-) Category 4 Category 3 Category 4 Category 3 Supply - voltage V " and $ 24 - voltage limits % - frequency Hz 50/60 Consumption VA 6 Module fuse protection Internal, electronic button monitoring Yes/No (configurable by terminal connection) Control unit voltage and current $ 24 V/30 ma approx. (at nominal supply voltage) Maximum wiring resistance RL Ω 90 Synchronisation time between inputs A and B Unlimited Outputs - voltage reference Volt-free - number and type of safety circuits 3 N/O (3-4, 23-24, 33-34) - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.5 A - L/R = 50 ms - max. thermal current (Ithe) A 6 - max. total thermal current A 8 - output fuse protection A 4 gl or 6 fast acting, conforming to IEC EN , DIN VDE 0660 part minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time on input opening ms 40 Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC EN , DIN VDE 00 parts and 2) Rated impulse withstand voltage (Uimp.) kv 4 (overvoltage category III, conforming to IEC EN , DIN VDE 00 parts and 2) LED display 3 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC EN 529 Enclosure IP 40 Connection Type Captive screw clamp terminals Captive screw clamp terminals, separate removable block - -wire connection Without cable end Solid or flexible cable: mm 2 Solid or flexible cable: mm 2 With cable end Without bezel, flexible cable: mm 2 Without bezel, flexible cable: mm 2 With cable end With bezel, flexible cable: mm 2 With bezel, flexible cable: mm 2-2-wire connection Without cable end Solid or flexible cable: mm 2 Solid cable: 0.2 mm 2, flexible cable: mm 2 With cable end Without bezel, flexible cable: 0.25 mm 2 Without bezel, flexible cable: 0.25 mm 2 With cable end Double, with bezel, flexible cable: mm 2 Double, with bezel, flexible cable: mm _Ver3.00-EN.fm/2

82 References for emergency stop, limit switch and security light barrier monitoring References Description Type of No. of Supply Reference Weight connection safety terminal block circuits kg Safety Integrated 3 " and XPS-AF modules for in module $ 24 V emergency stop and limit switch monitoring XPS-AF Separate, 3 " and XPS-AF530P can be $ 24 V removed from module XPS-AF530P Safety Integrated 3 " and XPS-AFL modules for in module $ 24 V emergency stop, limit switch and security light barrier monitoring XPS-AFL Separate, 3 " and XPS-AFL530P can be $ 24 V removed from module XPS-AFL530P 3878_Ver3.00-EN.fm/3

83 Connections, functional diagrams for emergency stop, limit switch and security light barrier monitoring XPS-AF Module XPS-AF associated with an emergency stop button with 2 N/C contacts L (+) N ( ) F A S33 S34 S () With start button monitoring (2) Without start button monitoring ESC: External start conditions T XPS-AF A2 S ESC () (2) Logic S K Functional diagrams Emergency stop function Input A (S-) Input B (-2) button S33-S34 N/O button S33-S39 N/O Output 3-4 N/O Output N/O Output N/O Key 0 Supply Emergency stop Emergency stop voltage not activated activated () With start button monitoring (2) Without start button monitoring Guard function with automatic start Supply st 2nd Guard Voltage switch switch opens Guard Guard closed Input A (S-) Input B (-2) Link at S33-S39 Output 3-4 N/O Output N/O Output N/O t = Key 0 () (2) Module XPS-AF with connection of multiple emergency stop buttons, combined with a PLC L (+) F F2 F3 S4 ESC A S33 S34 S T K Logic XPS-AF A Inputs PLC A2 Outputs COM COM () A2 S S N ( ) S3 Safety outputs closed 2 3 ESC: External start conditions () Other circuits controlled by module XPS-AF Key to LEDs 2 3 A-A2 supply voltage, fuse status 2 K relay energised 3 relay energised 3878_Ver3.00-EN.fm/4

84 Connections for emergency stop, limit switch and security light barrier monitoring XPS-AF Emergency stop monitoring function configuration -channel wiring A S33 S34 S XPS-AF A2 S Emergency stop button with a single N/C contact. Not all faults are detected: a short-circuit on the emergency stop pushbutton is not detected. 2-channel wiring XPS-AF A2 S S XPS-AF A2 S S S3 Emergency stop button with 2 N/C contacts (recommended application). The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. Connection of multiple emergency stop buttons with 2 N/C contacts (recommended application). The 2 input channels are connected to different polarities. A short-circuit between the 2 inputs is detected. Monitoring of a movable guard associated with 2 limit switches with contact each (limit switch with N/O contact, limit switch 2 with N/C contact) XPS-AF A2 S S Guard closed XPS-AF Configuration with automatic or manual reset A S33 S34 S XPS-AF A S33 S34 S XPS-AF A S33 S34 S XPS-AF Function: push-release. Automatic start Without start button monitoring, With start button monitoring, manual reset manual reset 3878_Ver3.00-EN.fm/5

85 Connections, functional diagrams for emergency stop, limit switch and security light barrier monitoring XPS-AFL Module XPS-AFL associated with an emergency stop button with 2 N/C contacts L (+) Functional diagrams Emergency stop function Supply voltage Emergency stop not activated Emergency stop activated F ESC () (2) A S33 S34 S Input A (S-) Input B (S-2) button S33-S34 N/O button S33-S39 N/O Output 3-4 N/O Output N/O Output N/O Key 0 () (2) A2 T XPS-AFL Logic S S K () With start button monitoring (2) Without start button monitoring Guard function with automatic start Supply voltage Guard open st switch 2 nd switch Guard closed Guard open S Input A (S-) Output B (S-2) N ( ) Link at S33-S39 Output 3-4 N/O Output N/O () With start button monitoring (2) Without start button monitoring ESC: External start conditions Output N/O Key 0 t = Emergency stop monitoring function configuration -channel wiring Emergency stop button with a single N/C contact 2-channel wiring Emergency stop button with 2 N/C contacts XPS-AFL A2 S S S XPS-AFL A2 S S S A short-circuit on the emergency stop pushbutton is not detected A short-circuit between the 2 inputs is not detected 2-channel wiring Connection of multiple emergency stop buttons XPS-AFL A2 S S S S3 A short-circuit between the 2 inputs is not detected 3878_Ver3.00-EN.fm/6

86 Connections for emergency stop, limit switch and security light barrier monitoring XPS-AFL Monitoring of a movable guard associated with 2 limit switches with contact each (limit switch with N/O contact, limit switch 2 with N/C contact) No detection of short-circuits Monitoring of electro-sensitive protection equipment (ESPE) 0 DC-3 : 24 V (< 0, Hz) DC-: 24 V XPS-AFL AC-5 : 230 V A2 S S S AC- : 230 V 0, Guard closed Key to LEDs A-A2 supply voltage, fuse status 2 K relay energised 3 relay energised _Ver3.00-EN.fm/7

87 Presentation, characteristics - monitors XPS-MP Operating principle - monitors XPS-MP are designed to conform with category 4 of the standard EN They enable two independent safety functions (selected from a choice of 5 pre-defined configurations) to be performed using the same product. Configuration selection is easily made using 3 buttons on the front face of the module. The 5 preprogrammed safety functions provide a solution for the majority of safety up to level 4 conforming to the standard EN 954-, for example: monitoring emergency stop, limit switches, safety mats and edges, agreement control with handle, monitoring type 4 security light barriers conforming to EN which have relay outputs (for example, XUS-LA type barriers, see page 30302/3) and monitoring contactless magnetic switches. XPS-MP monitors incorporate 6 safety outputs (3 per function) and 3 solid state signalling outputs for signalling to the process PLC. To aid diagnostics, the modules have LEDs on the front face which provide information on the monitoring circuit status. They also indicate and assist selection of the 2 required configurations. Configuration Synchronisation time Type of start () test Notes Automatic or unmonitored Monitored Functions disabled 0 Factory setting Emergency stop monitoring, -channel wiring (category 2) Emergency stop monitoring, 2-channel wiring, or guard monitoring (category 4) Guard monitoring for injector press or blowing machine (category 4) Agreement control with handle (3 position limit switch) (category 4) Safety mats and edges monitoring (category 3) Relay output security light barrier monitoring (category 4) Magnetic switch monitoring (category 4) X 2 X 3 Unlimited X X 4 Unlimited X X 5.5 s X X 6.5 s X X 7 Unlimited X 8 Unlimited X 9.5 s X X Uses both safety outputs (2) 0 X X The start button acts as start-up preparation X Mats with circuit making 2 X contacts s X X 4.5 s X Magnetic switches with s X contacts N/O and N/C () Automatic start: there is no start contact or it is shunted. Unmonitored start: the output is activated on closing of the start contact. Monitored start: the start input is monitored so that there is no start-up in the event of the start contact being shunted or the start circuit being closed for more than 0 seconds. -up is triggered following activation of the start button (push-release function) on opening of the contact. (2) Tool zone guard with 3rd limit switch. Additional rear guard (optional) with automatic start. The opening of the guard cuts all outputs. Characteristics Module type XPS-MP23 XPS-MP23P Product designed for use in safety Category 4 related parts of control systems (conforming to EN 954-) Supply - voltage V $ 24 - voltage limits % Consumption W 5 Module fuse protection Internal, electronic button monitoring Yes/No (depending on configuration selected) Control unit voltage V 24 (at nominal supply voltage) Between input terminals C-I, C2-I2, C3-I3, C4-I4, C5-I5 or C6-I6 Calculation of wiring resistance RL between input terminals Ω 00 max. Maximum cable length: 2000 m Synchronisation time between inputs s 0.5,.5 or unlimited, depending on configuration selected 38784_Ver.00-EN.fm/2

88 Characteristics (continued) References - monitors XPS-MP Characteristics (continued) Module type XPS-MP23 XPS-MP23P Outputs - voltage reference Volt-free - number and type of safety circuits 3 N/O per function (6 N/O total) (3-4, 23-24, 33-34, 43-44, 53-54, 63-64) - number and type of additional circuits 3 solid state - breaking capacity in AC-5 VA C300: inrush 800, maintained 80 - breaking capacity in DC-3 24 V/.25 A L/R = 50 ms - breaking capacity of solid state 24 V/20 ma outputs - max. thermal current (Ithe) for each group of 3 outputs - max. total thermal current A 20 - output fuse protection 4 gl or 6 fast acting (conforming to IEC , DIN VDE 0660 part 200) - minimum current ma 0 - minimum voltage V 7 Electrical durability See page 3860/6 Response time on input opening ms < 30 A 3.3 for all 3 outputs, or 6 for output and 2 for the other 2 outputs, or 2 for output and 4 for the other 2 outputs Rated insulation voltage (Ui) V 300 (degree of pollution 2 conforming to IEC , DIN VDE 00 parts and 2) Rated impulse withstand kv 4 (overvoltage category III, conforming to IEC , DIN VDE 00 parts and 2) voltage (Uimp.) LED display 2 Operating temperature C Storage temperature C Degree of protection Terminals IP 20 conforming to IEC 529 Enclosure IP 40 Connection Type Captive screw clamp terminals Captive screw clamp terminals, separate removable block - -wire connection W/out cable end Solid or flexible cable: mm 2 Solid or flexible cable: mm 2 With cable end Without bezel, flexible cable: mm2 Without bezel, flexible cable: mm2 With cable end With bezel, flexible cable: mm2 With bezel, flexible cable: mm2-2-wire connection W/out cable end Solid or flexible cable: mm 2 Solid cable: 0.2 mm 2. Flexible cable: mm 2 With cable end Without bezel, flexible cable: 0.25 mm2 Without bezel, flexible cable: 0.25 mm2 With cable end Double, with bezel, flexible cable: mm2 Double, with bezel, flexible cable mm References Description Type of connection terminal block Number of safety circuits Additional outputs Supply Reference Weight kg Modules for 2 independent safety functions Integrated in module 3 N/O per 3 solid function state (6 N/O total) $ 24 V XPS-MP XPS-MP Separate, can be removed from module 3 N/O per function (6 N/O total) 3 solid state $ 24 V XPS-MP23P XPS-MP23P 38784_Ver.00-EN.fm/3