S1 Minor (usually reversible) injury S2 Serious (normally irreversible) injury including death

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1 General data Application Classification of a machine in categories acc. to EN 954- The 98/3/EG machinery directive stipulates that every machine must comply with the applicable guidelines and standards. Measures must be taken to keep the risk to persons as small as possible. The first step is for the project engineer to perform a risk evaluation according to EN 5 "Guidelines for risk assessment". The ambient conditions of the machine have to be considered, for example. Then any overall risk must be evaluated. Risk evaluation must be performed in such a manner that the procedure and conclusions can be retraced. Possible selection of the categories acc. to EN 954- The dangers and possible technical measures for reducing risk must also be specified. After risk assessment, the according to which the safety s will be designed and implemented is specified with the aid of EN This defines the technical requirements for the configuration of the safety equipment. There are five categories (B,, 2, 3 and 4), whereby B (for Basic ) is the of the lowest risk and the one which defines the minimum demands made on the control system. Starting point for risk assessment of the safety related part of the control Category B S S2 F F2 P P2 P P2 Selection of the S Severity of the injury B, to 4: Categories for parts of controllers with relevance for safety Preferred categories for reference points Possible categories which demand additional measures Measures that may be excessive with respect to the particular risk S Minor (usually reversible) injury S2 Serious (normally irreversible) injury including death Summary of the requirements for categories acc. to EN 954- NSC_32 F Frequency and/or duration of the exposure to danger F From rarely to often and/or short duration of exposure F2 From frequently to constantly and/or long duration of exposure P Possibility to avoid the danger P Possible under certain conditions P2 Hardly possible Category (not to be applied in any specific hierarchy) B Summary of requirements System response Principles for achieving safety The safety related parts of controllers and/or their protective devices as well as their components must be designed, constructed, selected, assembled and combined in accordance with the applicable standards in such a way that they can resist the expected external influences. The requirements of B must be met. Well-proven components and well-proven safety principles must be implemented. 2 The requirements of B must be met and well-proven safety principles must be implemented. The safety functions must be tested at regular intervals by the machine control. 3 The requirements of B must be met and well-proven safety principles must be implemented. Parts with relevance for safety must be implemented such that a single fault in any of these components does not result in loss of the safety function, and whenever reasonably possible, the individual fault is detected. 4 The requirements of B must be met and well-proven safety principles must be implemented. Parts with relevance for safety must be implemented such that a single fault in any of these components does not result in loss of the safety function, and the individual fault is detected during or before the next activation of the safety function or, if this is not possible, an accumulation of faults will not result in loss of the safety function. The occurrence of a fault can result in loss of the safety function. The occurrence of a fault can result in loss of the safety function but the probability of it occurring is less than for Category B. The occurrence of a fault can result in loss of the safety function between tests. The loss of the safety function will be detected by the test. When the single fault occurs, the safety function is always maintained. Some but not all faults are detected. An accumulation of undetected faults may lead to loss of the safety function. When faults occur, the safety function is always maintained. The faults are detected early to prevent loss of the safety function. Mainly characterized by the selection of components Mainly characterized by the structure Siemens L 26 /6

2 General data Standards for "Safety of machines" EN 624- "Electrical equipment of industrial machines" EN 48 "EMERGENCY-STOP equipment, functional aspects, basic design principles" EN 54 "Two-hand switching" EN 954- "Safety-related parts of controls" EN 5 "Guidelines for risk assessment" EN 88 "Locking facilities in combination with isolating protective devices" IEC 658 "Functional safety of electrical/programmable safety related systems" categories Potential dangers posed by a machine must be eliminated as quickly as possible. As a rule, the "danger-free status" is standstill with respect to hazardous motions. All SIRIUS safety relays are de-energized in the event of danger or a fault, i.e. the machine drives are switched to standstill. The EN 624 standard requires that every machine must be equipped with the function of Category. functions of Categories and/or 2 must be implemented when this is necessary for the safety and/or functional requirements of the machine. There are 3 categories of functions: : Shutdown by immediate switch-off of the energy infeed to the machine drives. : Controlled shutdown, whereby the energy infeed to the machine drives is maintained during shutdown and is only switched off when standstill has been achieved. 2: Controlled shutdown, whereby the energy infeed to the machine drives is maintained. The devices support autostart or monitored start depending on their versions. /Manual start : The device switches on the enabling s automatically as soon as the switch-on conditions (sensor and feedback s closed) are satisfied. Manual start: If an ON pushbutton is installed in the feedback a manual start can be provided with the autostart function. Caution: Not permissible for EMERGENCY-STOP Category 4! Crossover protection Crossover protection is the ability of the safety relay to detect faults (e.g. through cable compression or ground faults) in the safety chain to be monitored and to suppress the enabling of the enabling s until the external fault has been rectified. EMERGENCY-STOP EMERGENCY-STOP devices must have priority over all other functions. The energy infeed to the machine drives that can cause dangerous situations must be switched off as quickly as possible without causing any further danger. Resetting of the drives must not result in restarting of the equipment. EMERGENCY-STOP must either function as a of Category or Category. Resetting of the command device must only be possible as a result of a manual action on the command device. Resetting of the command device must not initiate a restart command. Restarting of the machine must not be possible until all actuated operator controls have been reset deliberately and individually by hand (EN 48). The basic units of the SIRIUS safety relays can be used for EMERGENCY-STOP applications up to Category 4 of EN Category 3 or 4 of EN 954- or SIL 2/3 (Safety Integrity Level) acc. to IEC 658 must be achieved depending on the external and routing of the sensor leads. Protective door monitoring EN 88 distinguishes between interlocked, isolating protection devices and interlocked, isolating protective devices with tumbler. SIRIUS safety relays are also used in this case for EMERGENCY- STOP applications. Control systems for up to Category 4 of EN 954- or SIL 2/3 of IEC 658 are possible. Presses and punches The two-hand control unit is a device that requires both hands of the operator to be used simultaneously as a means of protecting the operator from danger. The devices are suitable for installation in control systems for eccentric, hydraulic and screw presses. They can be used up to Category 4 of EN Type III C according to EN 54 is possible specifically for presses. To switch on the enabling s the switch-on conditions (sensor and feedback s closed) must be satisfied. In addition the device must be started with an ON pushbutton. The device responds in this case to the negative edge of the ON signal. /68 Siemens L 26

3 with electronic enabling s Overview The SIRIUS safety pilot guides you quickly to the right device Type Connection Crossover protection 3TK28 4 basic unit 3TK28 4 standard unit 3TK28 42 standard unit tv 3TK28 45 multi-function unit Category acc. to EN 954- EMERGENCY- STOP Protective door Solid-state sensors Cascade input Safety mats -channel 2-channel B DC Type 3TK28 4 basic unit 3TK28 4 standard unit 3TK28 42 standard unit tv 3TK28 45 multi-function unit = available -- = not available floating STOP ) The outputs are only safe when an external contactor is used. Monitored start Switching capacity AC -5 at U =23 DC -3 DC at 24 U =24 Rated operational voltage AC AC DC voltage Control inputs AC AC DC ) A A A HL 2 A.5 A HL Siemens L 26 /69

4 with electronic enabling s Selection and ordering data voltages U s 24 DC and AC 5/6 Hz, 5, 23 floating Safety relays,, for EMERGENCY-STOP and protective doors acc. to EN 954- DT With screw terminals PU per unit ) ) 3 DC 24 A 3TK28 4-BB4 unit 2.8 Standard devices ) ) 4 DC 24 A 3TK28 4-BB4 unit 2.66 Standard devices tv -- --, A 3) -- 4 DC 24 A 3TK28 42-BB4 unit 2.68, B 3) A 3TK28 42-BB42 unit 2.66, C 3) A 3TK28 42-BB44 unit 2.66 Multi-function units, A 3) HL 4 DC 24 A 3TK28 45-BB4 unit 2.4, B 3) A 3TK28 45-BB42 unit A 3TK28 45-BB4 unit 2.45 ) The outputs are only safe in conjunction with external actuators with positively-driven. 2) Suitable for sensor input. 3) t v = Off-delay A = s, B = s, C = s. 4) An enabling can be used as a signaling. voltages U s 24 DC and AC 5/6 Hz, 5, 23 floating Safety relays,, for EMERGENCY-STOP and protective doors acc. to EN 954- ) The outputs are only safe in conjunction with external actuators with positively-driven. 2) An enabling can be used as a signaling. 3) t v = Off-delay A = s, B = s, C = s. DT With spring-loaded terminals PU ) ) 3 DC 24 B 3TK28 4-2BB4 unit 2.5 Standard devices ) 4 DC 24 A 3TK28 4-2BB4 unit 2.43 Standard devices tv -- --, A 3) -- 4 DC 24 B 3TK BB4 unit 2.43, B 3) A 3TK BB42 unit 2.46, C 3) B 3TK BB44 unit 2.49 Multi-function units, A 3) HL 4 DC 24 B 3TK BB4 unit 2.36, B 3) B 3TK BB42 unit B 3TK BB4 unit 2.36 / Siemens L 26

5 with relay enabling s Overview The SIRIUS safety pilot guides you quickly to the right device Type -channel connection 2-channel connection Crossover protection Category acc. to EN 954- EMER- GENCY- STOP Protective door B TK NO NC -- 3TK ) 2 NO TK NO TK NO TK NO 2 NC 3TK28 2 ) -- 2 NO + NC -- 2 NC, delayed 3TK28 28 ) 2 NO + 2 NC, delayed NC -- Expansion devices ( as for basic unit) 3TK NO Press control devices according acc. to EN 54 3TK NO +2 NC TK NO + NC = available -- = not available = corresponds to basic unit ) Only possible for instantaneous enabling. 2) The ON button is not monitored. Monitored start Siemens L 26 /

6 with relay enabling s Selection and ordering data voltages U s 24 DC and AC 5/6 Hz, 24 5, 23 acc. to EN 954- for EMERGENCY-STOP and protective doors 3TK28 2 to 3TK28 24 with screw-type connection 3TK28 25 with screw-type connection 3TK28 2 and 3TK28 28 with screw-type connection For multi-unit/reusable packaging, see Appendix. DT With screw terminals PU voltage U s 3 NO NC B,, 2, 3 AC/DC 24 } 3TK28 2-CB3 unit NO -- B,, 2, 3, 4 AC/DC 24 } 3TK28 22-CB3 unit NO -- B,, 2, 3, 4 AC/DC 24 } 3TK28 23-CB3 unit NO -- B,, 2, 3 AC/DC 24 } 3TK28 24-CB3 unit DC 24 } 3TK28 24-BB4 unit AC 5 A 3TK28 24-AJ2 unit AC 23 } 3TK28 24-AL2 unit / monitored start 3 NO 2 NC B,, 2, 3, 4 DC 24 } 3TK28 25-BB4 unit AC 24 } 3TK28 25-AB2 unit 2.42 AC 5 } 3TK28 25-AJ2 unit 2.59 AC 23 } 3TK28 25-AL2 unit 2.56 OFF-delay, t v = s 2NO + 2NO NC B,, 2, 3, 4 ) DC 24 } 3TK28 2-BB4 unit 2.49 AC 24 } 3TK28 2-AB2 unit AC 5 } 3TK28 2-AJ2 unit 2.65 AC 23 } 3TK28 2-AL2 unit 2.65 OFF-delay, t v = s 2NO + 2NO NC B,, 2, 3, 4 ) DC 24 } 3TK28 2-BB4 unit AC 24 B 3TK28 2-AB2 unit AC 5 B 3TK28 2-AJ2 unit 2.65 AC 23 A 3TK28 2-AL2 unit 2.65 OFF-delay, t v = s 2NO + 2NO NC B,, 2, 3, 4 ) DC 24 } 3TK28 28-BB4 unit AC 24 B 3TK28 28-AB2 unit 2.5 AC 5 A 3TK28 28-AJ2 unit 2.65 AC 23 A 3TK28 28-AL2 unit 2.65 OFF-delay, t v = s 2NO + 2NO NC B,, 2, 3, 4 ) DC 24 } 3TK28 28-BB4 unit AC 24 B 3TK28 28-AB2 unit 2.5 AC 5 B 3TK28 28-AJ2 unit 2.65 AC 23 A 3TK28 28-AL2 unit 2.65 ) Only applicable to the instantaneous enabling. /2 Siemens L 26

7 with relay enabling s voltages U s 24 DC and AC 5/6 Hz, , 23 acc. to EN 954- for EMERGENCY-STOP and protective doors For multi-unit/reusable packaging, see Appendix. DT With spring-loaded terminals PU 3 NO NC B,, 2, 3 AC/DC 24 } 3TK28 2-2CB3 unit NO -- B,, 2, 3, 4 AC/DC 24 A 3TK CB3 unit NO -- B,, 2, 3, 4 AC/DC 24 A 3TK CB3 unit NO -- B,, 2, 3 AC/DC 24 A 3TK CB3 unit 2.23 DC 24 } 3TK BB4 unit AC 5 B 3TK AJ2 unit AC 23 B 3TK AL2 unit 2.2 / monitored start 3 NO 2 NC B,, 2, 3, 4 DC 24 } 3TK BB4 unit 2.34 AC 24 B 3TK AB2 unit 2.35 AC 5 B 3TK AJ2 unit 2.42 AC 23 B 3TK AL2 unit 2.45 OFF-delay, t v = s 2 NO+2 NO NC B,, 2, 3, 4 ) DC 24 } 3TK28 2-2BB4 unit AC 24 B 3TK28 2-2AB2 unit AC 5 B 3TK28 2-2AJ2 unit 2.66 AC 23 B 3TK28 2-2AL2 unit 2.64 OFF-delay, t v = s 2 NO+2 NO NC B,, 2, 3, 4 ) DC 24 A 3TK28 2-2BB4 unit AC 24 B 3TK28 2-2AB2 unit AC 5 B 3TK28 2-2AJ2 unit 2.24 AC 23 B 3TK28 2-2AL2 unit 2.65 OFF-delay, t v = s 2 NO+2 NO NC B,, 2, 3, 4 ) DC 24 } 3TK BB4 unit 2.45 AC 24 B 3TK AB2 unit AC 5 B 3TK AJ2 unit 2.69 AC 23 B 3TK AL2 unit 2.62 OFF-delay, t v = s 2 NO+2 NO NC B,, 2, 3, 4 ) DC 24 A 3TK BB4 unit 2.45 AC 24 C 3TK AB2 unit AC 5 B 3TK AJ2 unit 2.24 AC 23 B 3TK AL2 unit 2.68 ) Only applicable to the instantaneous enabling. Siemens L 26 /3

8 with relay enabling s voltages U s 24 DC and AC 5/6 Hz, 24, 5, 23 Expansion units acc. to EN 954- for expansion of the for the safety relays ( enabling contact of the basic unit is required for connecting to the basic unit) 4 NO -- corresponds to basic unit DT With screw terminals PU AC/DC 24 } 3TK28 3-CB3 unit 2.26 AC 5 A 3TK28 3-AJ2 unit 2.36 AC 23 A 3TK28 3-AL2 unit TK28 3 Press control devices for use in presses and punches Two-hand control unit, two-channel 2 NO 2 NC 4 DC 24 } 3TK28 34-BB4 unit AC 24 } 3TK28 34-AB2 unit AC 5 } 3TK28 34-AJ2 unit 2.59 AC 23 } 3TK28 34-AL2 unit 2.59 Slowing down test apparatus 3 NO NC DC 24 B 3TK28 35-BB4 unit TK28 34 and 3TK28 35 For multi-unit/reusable packaging, see Appendix. voltages U s 24 DC and AC 5/6 Hz, 24, 5, 23 Expansion units Press control devices acc. to EN 954- For multi-unit/reusable packaging, see Appendix. for expansion of the for the safety relays ( enabling contact of the basic unit is required for connecting to the basic unit) 4 NO -- corresponds to basic unit DT With spring-loaded terminals PU AC/DC 24 } 3TK28 3-2CB3 unit AC 5 B 3TK28 3-2AJ2 unit 2.26 AC 23 B 3TK28 3-2AL2 unit 2.26 for use in presses and punches Two-hand control unit, two-channel 2 NO 2 NC 4 DC 24 A 3TK BB4 unit AC 24 B 3TK AB2 unit 2.36 AC 5 B 3TK AJ2 unit 2.42 AC 23 B 3TK AL2 unit 2.42 Slowing down test apparatus 3 NO NC AC 24 B 3TK AB2 unit Accessories ersion DT Sealable caps to secure against unauthorized adjustment, for 3TK28 2 and 3TK28 28 devices PU } 3RP9 2 5 units.4 Push-in lugs for screw mounting for 3TK28 2 to 3TK28 35 devices ( set = 2 units) } 3RP9 3 units.2 /4 Siemens L 26

9 with contactor relay enabling s Overview The SIRIUS safety pilot guides you quickly to the right device Type Connection Crossover protection Category acc. to EN 954- EMERGENCY- STOP Protective door Solid-state sensors Cascade input Safety mats -channel 2-channel B DC with contactor relays mounted on the front 3TK28 5 basic unit TK28 5 basic unit TK28 52 basic unit TK28 53 basic unit 3TK expansion unit 3TK expansion unit tv Type floating Monitored start Switching capacity Rated operational voltage voltage with contactor relays mounted on the front 3TK28 5 basic unit A A -- 3TK28 5 basic unit NC 6 A A -- 3TK28 52 basic unit NC 6 A A -- 3TK28 53 basic unit A A TK NC A A expansion unit 3TK A A expansion unit tv = available -- = not available = corresponds to basic unit AC -5 at U = 23 DC -3 at U =24 DC 24 AC 23 AC 6 DC 24 AC 5 AC 23 Control inputs DC 24 Siemens L 26 /5

10 3TK28 Safety Relays with contactor relay enabling s Selection and ordering data voltages U s 24 DC and AC 5/6 Hz, 5, 23 floating Safety relays,, with contactor relays, for EMERGENCY-STOP and protective doors acc. to EN 954- ) Suitable for sensor input. 2) For expansion of the for the 3TK28 4, 3TK28 42, 3TK28 45, 3TK28 5, 3TK28 5, 3TK28 52, 3TK28 53 standard and basic units. DT With screw terminals PU DC 24 A 3TK28 5-BB4 unit 2.89 AC 5 B 3TK28 5-AJ2 unit 2.65 AC 23 B 3TK28 5-AL2 unit NC 3 DC 24 B 3TK28 5-BB4 unit 2.82 AC 5 B 3TK28 5-AJ2 unit 2. AC 23 B 3TK28 5-AL2 unit NC 3 DC 24 A 3TK28 52-BB4 unit 2.99 AC 23 B 3TK28 52-AL2 unit ) DC 24 A 3TK28 53-BB4 unit 2.4 Expansion units 2) NC corresponds DC 24 B 3TK28 56-BB4 unit 2.85 to basic unit Expansion units tv 2) -- 3, A corresponds DC 24 B 3TK28 5-BB4 unit , B basic unit B 3TK28 5-BB42 unit , C B 3TK28 5-BB44 unit 2.65 /6 Siemens L 26

11 3TK28 Safety Relays with contactor relay enabling s voltages U s 24 DC and AC 5/6 Hz, 5, 23 floating Safety relays,, with contactor relays, for EMERGENCY-STOP and protective doors acc. to EN 954- DT With spring-loaded terminals PU DC 24 B 3TK28 5-2BB4 unit 2.82 AC 5 B 3TK28 5-2AJ2 unit 2.65 AC 23 B 3TK28 5-2AL2 unit NC 3 DC 24 B 3TK28 5-2BB4 unit 2.65 AC 5 B 3TK28 5-2AJ2 unit 2.65 AC 23 B 3TK28 5-2AL2 unit NC 3 DC 24 B 3TK BB4 unit AC 23 B 3TK AL2 unit ) DC 24 B 3TK BB4 unit 2.5 Expansion units 2) NC corresponds DC 24 B 3TK BB4 unit 2.5 to basic unit Expansion units tv 2) -- 3, A corresponds DC 24 B 3TK28 5-2BB4 unit , B to basic unit B 3TK28 5-2BB42 unit 2.6 3, C C 3TK28 5-2BB44 unit 2.65 ) Suitable for sensor input. 2) For expansion of the for the 3TK28 4, 3TK28 42, 3TK28 45, 3TK28 5, 3TK28 5, 3TK28 52, 3TK28 53 standard and basic units. Siemens L 26 /