ABB Safety Handbook

Safety
Handbook
1 SAC 103 201 H 0201
Contents
Safety handbook
Product overview Regulations and Standards
General information Machine safety Process industry Furnaces 8 10 21 26 4
Push buttons
EMERGENCY OFF control devices Signal towers and Signal beacons Position switch LS-Series 28 30 31
Advant Controller 31-S

Safe intelligence System data Safety-related input/output modules 34 35 36
Safety control devices

Rules for application EMERGENCY OFF control gear and safety door watchdog Two-hand control, Dribbling inspection and test equipment Extension device, Monitoring relay Technical data /Certifications C 57x Selection tables/Accessories C 57x Dimension drawings (C 57x, C 580) Electronic safety relay C 67xx Selection table C 67xx Terminology 38 41 45 46 47 48 49 51 52 53
Circuit examples
Switch safely Safety contactor combinations C 57x Relay safety combinations C 57x EMERGENCY OFF (EMERGENCY STOP) circuit Protective door monitoring Press control devices Monitoring underspeed Electronic safety relay 58 61 62 63 67 72 76 77
Appendix
Certificates 80
1 SAC 103 201 H 0201
Product overview
Safety handbook
Safety standards
Again and again, the practical implementation of safety requirements presents new challenges for plant designers and machine manufacturers. What frequently makes the design and planning stage more difficult is the fact that the safety requirements are continuously extended and tightened against the background of the CE label and compliance with the machine guidelines. ABB STOTZ-KONTAKT GmbH offers a comprehensive range of safety components for plant and machine manufacture. Depending on the type used, these components ensure safety directly at the machine, as well as in the switchgear cabinet. But ABB STOTZ KONTAKT also has a suitable product in stock for the safety of the complete system. Apart from fulfilling the applicable standards and requirements, ABB products are state of the art so that the protection of people, machines and the environment can be optimally realised in machines and plants. The safety components in ABB STOTZ-KONTAKTs product range and their applications are exemplary: Plant safety, Machine safety, Switchgear cabinet safety.
Control and Act
1 SAC 103 201 H 0201
Product overview
Safety handbook
Detect
Evaluate
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
Regulations and Standards
1 SAC 103 201 H 0201
General information

Goal
The goal of safety technology is to keep the potential hazards for man and the environment as low as possible by applying and utilizing technology. However, this should be achieved without imposing unnecessary restrictions on industrial production, the use of machines and the production of chemical products. By applying internationally harmonized regulations, man and the environment should be uniformly protected to the same degree in all countries. At the same time, differences in competitive environments, due to different safety requirements, should be eliminated. A new, global concept forms the (new approach, global approach) basis for the EC Directives: EC Directives only contain generally valid safety goals, and define fundamental safety requirements Legislation no longer specifies that specific standards have to be met Standards Committees, which have received the appropriate mandate from the EC Commission, can define technical details in the Standards. These Standards are harmonized under a specific Directive and are listed in the Official Journal of the EC. When the harmonized standards are fulfilled, then it is assumed that the associated safety requirements of the Directive are fulfilled. EC Directives specify that Member States recognize each others national regulations and laws. The EC Directives have the same degree of importance, i.e. if several Directives apply for a specific piece of equipment, then the requirements of all of the relevant Directives have to be met (e.g. for a machine with electrical equipment, the Machinery Directive, LowVoltage Directive and EMC Directive apply). Other regulations apply to equipment where the EC Directives are not applicable. They include regulations and criteria for voluntary tests and certification.
Basic principles of European legislation

Legislation states that we must focus our efforts at preserving and protecting the quality of the environment, and protecting human health through preventive actions (Council Directive 96/82/EC on the control of major-accident hazards involving dangerous substances). It also demands Health and safety at the workplace (Workplace, health and safety legislation, ). Legislation demands that this and similar goals are achieved for various areas (Areas which are legislated) in the EC Directives. In order to achieve these goals, legislation places demands on the operators and users of plants, and the manufacturers of equipment and machines. It also assigns the responsibility for possible injury. The EC Directives Specify demands placed on plants and systems and their operators/users to protect the health and safety of personnel and the quality of the environment Define product features and characteristics to protect the health and safety of users Contain regulations about health and safety at the workplace (minimum requirements).
Workplace health and safety legislation

Health and safety at the workplace is subject to national legislation, i.e. the national requirements must be observed, as other safety requirements can be derived from these. Note: The Directives and laws, mentioned in this Manual, represent a selection in order to provide information about the essential goals and principles. This does not claim to be complete.
1 SAC 103 201 H 0201
General information

Standardization goals
The demand to make plants, machines and other equipment as safe as possible, in-line with state-ofthe-art technology, comes from the responsibility of the manufacturers and users of equipment and products for their safety. State-of-the-art technology regarding all aspects which are of significance for safety, is described in the Standards. State-of-the-art technology is ensured by fulfilling the various relevant standards. This also ensures that the erector of a plant or system, or manufacturer of a machine or a piece of equipment, has fulfilled his responsibility for ensuring safety. In order to achieve functional safety of a machine or a plant, the safety-relevant parts of the pro-tective- and control devices must function correctly and, when a fault or failure occurs, the plant or system must remain in a safe condition or be brought into a safe state. To realize this, specific qualified technology is required, which fulfills the requirements specified in the relevant standards. The requirements to achieve functional safety are based on the basic goals: avoid systematic faults control systematic faults
Functional safety
control random faults or failures. From the perspective of the object to be protected, safety can not be segregated. As the causes of hazards and the technical measures applied to avoid them can differ widely, a differentiation is now made between various types of safety, e.g. by specifying the cause of the potential hazard. For instance, electrical safety is used if protection has to be provided against hazards due to electricity, or functional safety, if the safety is dependent on the correct function. This differentiation is now reflected in the new standardization in so much that there are special standards which are involved with functional safety. The area of safety of machinery, EN 954 (or ISO 13489) deals especially with safety-relevant parts of controls and therefore concentrates on the functional safety. IEC handles, in the pilot standard IEC 61508, the functional safety of electrical, electronic and programmable electronic systems, independent of any special application area. In IEC 61508, functional safety is defined as part of the overall safety relating to the EUC* and the EUC control system which depends on the correct functioning of the E/E/PE** safety-related systems, other safety-related systems and external risk reduction facilities. The measure for the achieved functional safety is the probability of dangerous failures, the fault tolerance and the quality which should be guaranteed by avoiding systematic faults. In the Standards, this is expressed using various terms. In IEC 61508: Safety Integrity Level (SIL), in EN 954 (ISO 13489): Categories and in DIN V 19250 and DIN V VDE 0801: Requirement class (AK).
* EUC: Equipment under control ** E/E/PE: Electrical, electronical, programmable electronical
1 SAC 103 201 H 0201
Machine safety

Machinery Directive (98/37/EC)*
With the introduction of a common European market, effective 01.01.1993, a decision was made to harmonize the national standards and regulations of all of the EC Member States. This meant that Machinery Directive, as an internal Directive, had to be implemented in the domestic legislation of the individual Member States. (For instance, in Germany, the contents of the Machinery Directive were implemented as the 9th Decree of the Equipment Safety Law.) For the Machinery Directive, this was realized with the goal to have unified protective goals and to reduce trading barriers. The application area of the Machinery Directive corresponds to its definition. Machinery also means an assembly of machines which, in order to achieve the same end, are arranged and controlled so that they function as an integral whole. The application area of the Machinery Directive thus ranges from a basic machine up to a complete plant. The Machinery Directive has 14 Articles and 7 Annexes. The basic health and safety requirements in Annex I of the Directive are mandatory for the safety
* substitute 89/392/EC, 91/368/EC, 93/68/EC
of the machine. The protective goals must be implemented in a responsible fashion in order to fulfill the requirements for conformance with the Directive. The manufacturer of a machine must prove that the basic requirements are fulfilled. This proof is made easier by applying harmonized standards. A certification technique is required for machines listed in Annex IV of the Machinery Directive, which represent a greater hazard potential.
Machinery Directive Application area, selling/marketing, free transfer of goods, protective clause Certification technique CE-marking, protection against arbitrary fulfillment Coming into force, transitional regulations, cancellation of regulations Appendix I Essential health and safety requirements relating to the design and construction of machinery and safety components Contents of 1. EC Declaration of Conformity for machinery and safety components 2. Declaration by the manufacturer or his authorized representatives established in the community III IV CE conformity marking Types of machinery and safety components which the procedure referred to in article 8 (2) (b) and (c) must be applied EC Declaration of Conformity Art. Art. Art. Art. 1 8 10 13 Art. Art. Art. Art. 7 9 12 14
Artikel 3 5 10 4 5 8 4
II
10 8
VI
EC type examination
VII
Minimum criteria to be taken into account by the Member States for the notification bodies
Overview of the Machinery Directive (from 89/392/EC)
10
1 SAC 103 201 H 0201
Machine safety

Types of machinery and safety components for which the procedure referred to in Article 8, Paragraph 2, letters b) and c) must be applied A. 1. Machinery Circular saws (single or multi-blade) for working with wood and analogous materials or for working with meat and analogous materials.
1.1. Sawing machines with fixed tool during operation, having a fixed bed with manual feed of the workpiece or with a demountable power feed. 1.2. Sawing machines with fixed tool during operation, having a manually operated reciprocating sawbench or carriage. 1.3. Sawing machines with fixed tool during operation, having a built-in mechanical feed device for the work-pieces, with manual loading and/or unloading. 1.4. Sawing machines with movable tool during operation, with a mechanical feed device and manual loading and/or unloading. 2. 3. 4. Hand-fed surface planing machines for woodworking. Thicknessers for one-side dressing with manual loading and/or unloading for woodworking. Band-saws with a fixed or mobile bed and band-saws with a mobile carriage, with manual loading and/or unloading, for working with wood and analogous materials or for working with meat and analogous materials. Combined machines of the types referred to in 1 to 4 and 7 for working with wood and analogous materials. Hand-fed tenoning machines with several tool holders for woodworking. Hand-fed vertical spindle molding machines for working with wood and analogous materials. Portable chainsaws for woodworking. Presses, including press-brakes, for the cold working of metals, with manual loading and/or unloading, whose movable working parts may have a travel exceeding 6 mm and a speed exceeding 30 mm/s. Injection or compression plastics-molding machines with manual loading or unloading. Injection or compression rubber-molding machines with manual loading or unloading. Machinery for underground working or the following types: machinery on rails: locomotives and brake-vans hydraulic-powered roof supports internal combustion engines to be fitted to machinery for underground working. Manually-loaded trucks for the collection of household refuse incorporating a compression mechanism. Guards and detachable transmission shafts with universal joints as described in Section 3.4.7. Vehicles servicing lifts. Devices for the lifting of persons involving a risk of falling from a vertical height of more than 3 meters. Machines for the manufacture of pyrotechnics. Safety components Electro-sensitive devices designed specifically to detect persons in order to ensure their safety (non-material barriers, sensor mats, electromagnetic detectors, etc.) Logic units which ensure the safety functions of bimanual controls. Automatic movable screens to protect the presses referred to in 9, 10 and 11 Roll-over protection structures (ROPS) Falling-object protective structures (FOPS)
5. 6. 7. 8. 9.
10. 11. 12.
13. 14. 15. 16. 17. B. 1. 2. 3. 4. 5.
Annex IV of the Machinery Directive

1 SAC 103 201 H 0201
11
Machine safety

Standards
To sell, market or operate/use products, these products must fulfill the basic safety requirements of the EC Directives. Standards can be extremely helpful when it involves fulfilling these safety requirements. In this case, a differentiation must be made between harmonized European standards and other technical rules and regulations which are known in the Directives as National Standards. Generally, all European Standards must be included, unchanged in the national standards of the Member States, independent of whether they are hamronized under the Machinery Directive or not. National standards handling the same subject must then be withdrawn. Thus, within a period of time in Europe, a unified set of regulations will be created. The European Standards of CEN for the safety of machines are hierarchically structured as follows A Standards; also known as Basic Standards. B Standards; also known as Group Standards. C Standards; also known as Product Standards. The diagram above shows the structure.
Type A Standards/Basic Standards

As Standards contain basic terminology and definitions for all machines. This includes EN 292 Safety of machinery Basic concepts, general principles for design. A Standards primarily address the party setting B- and C Standards. The techniques for minimizing risks, specified there, can however, also be helpful for manufacturers, if there are no relevant C Standards.
Harmonized European Standards

These are drawn-up by the two standards organizations CEN (Comit Europen de Normalisation) and CENELEC (Comit Europen de Normalisation lectrotechnique) as mandate from the EC Commission in order to fulfill the requirements of the EU Directives for a specific product. And they must be published in the official documentation of the European Communities. These Standards (EN Standards) are then transferred into the national standards unchanged. They are used to fulfill the basic health- and safety requirements and the protective goals specified in the Annex I of the Machinery Directive. When using such standards, there is an automatic presumption of conformity; i.e. the manufacturer can be trusted to have fulfilled all of the safety aspects of the Directive as long as they are handled in the particular Standard. However, not every European Standard is harmonized in this sense. The listing in the European documentation is decisive. The up-to-date version of these lists can always be called-up in the Internet (Address: http://www2.echo.lu/nasd/index.html).
Type B Standards/Group Standards

These include all Standards with safety-related statements, which can involve several types of machines. The B Standards also primarily address the party setting C Standards. However, they can also be helpful for manufacturers when designing and building machine if there are no relevant C Standards. For B Standards, an additional subdivision was made, and more precisely in: Type B1 Standards for higher-level safety aspects, e.g. ergonomic design principles, safety distances from potential sources of danger, minimum clearances to prevent crushing of body parts. Type B2 Standards for safety equipment are specified for various machine types, e.g. EMERGENCY STOP equipment, two-hand controls, interlocking/latching, contactless protective devices, safety-related parts of controls.
12
1 SAC 103 201 H 0201
Machine safety

Type C Standards/Product Standards
These involve the Machine-Specific Standards, e.g. for machine tools, woodworking machines, elevators, packaging machines, printing machines etc. The European Standards are conceived, in order to avoid repeating general statements, which are already included in type A, or type B standards; as far as possible, reference to these are made in type C Standards. In addition to machine-related requirements, Product Standards can also include requirements which, under certain circumstances, deviate from the Basicand Group Standards. For the machine OEM, type C Standard/Product standards have the highest priority. It can be assumed that it therefore contains the basic requirements of Annex I of the Machinery Directive (automatic presumption of conformity). If there is no Product Standard for a particular machine, then type B Standards can be applied as support when building a machine.
National Standards
If harmonized European Standards are not available, or they cannot be applied for certain reasons, then the manufacturer can utilize the National Standards. All of the other technical rules and regulations and European Standards, not listed in the European official documentation (non-harmonized), fall under this term of the Machinery Directive. Those not listed in official documentation can include, for example, still valid DIN Standards and VDE Regulations and are declared, also from the German government as helpful to fulfill the Machinery Directive. However, when such standards are applied, the above mentioned automatic presumption of conformity does not apply. This means, that a risk analysis must be carried-out and proven and if necessary, risk reduction measures applied which makes the whole procedure more costly. These national standards are for example, used by notified bodies in order to identify whether a specific product fulfills the goals of the Machinery Directive.
Group safety standards
General higher-level safety aspects standards
Typ B
Minimum clearances to prevent parts of the body being crushed: EN 349 Safety-relevant parts of control systems: EN 954-1 Safety clearances against accessing dangerous locations with the upper limbs: EN 294 Electrical equipment of machines: EN 60204-1 Safety of machines inter-latching devices with and without tumbler: prEN 1088
Reference to special protective devices Generally handled safety-related devices Special safety features for individual machine groups
Two-hand circuit: prEN 81-1 Emergency stop equipment, functional aspects design guidelines EN 418 Light barriers: prEN 61496 Elevators: prEN 81-1 Woodworking machines: prEN 691 Presses + shears: prEN 692, prEN963 Injection molding machines: EN 201 Food preparation machines: prEN 1672-1 Printing and paper machines: pr EN 1010 Machining centers: prEN 12417 Cable railways: prEN 1709 Automated production systems: prEN 1921 etc.
Specialist Standards
European Standards for safety of machinery

1 SAC 103 201 H 0201
Note for users: If harmonized C Standards exist for the particular product, then the associated Band if relevant, also the A Standards can be considered as secondary
Typ A
Basic safety standards
Basic design principles and terminology for machines
Safety of machines: DIN EN 292-1 Safety of machinery; basic terminology, general principles for design; technical principles and specifications: EN 292-2
Typ C
Typ B-2
Typ B-1
13
Machine safety

Risk analysis/evaluation
As a result of their general design and functionality, machines and plants represent potential risks. Thus, the Machinery Directive requires a risk assessment for every machine and, if relevant, risk reduction, so that the remaining risk is less than the tolerable risk. The following Standards should be applied for the technique to assess these risks: EN 292 Safety of machinery Basic concepts, general principles for design EN 1050 Safety of machinery Principles for risk assessment EN 292 mainly handles the risks to be evaluated and design principles to reduce risks. EN 1050 basically handles the iterative process with risk assessment and risk reduction to achieve safety.
Risk assessment
Risk assessment is a sequence of steps, which allows hazards, which are caused by machines, to be systematically investigated. Where necessary, the risk assessment phase is followed by risk reduction. The iterative process (refer to Graphic) is obtained by repeating this procedure. This allows potential hazards to be removed as far as possible, and allows the appropriate protective measures to be made. The risk assessment includes: Risk analysis Determining the limits of the machine (EN 292, EN 1050 Paragraph 5) Identification of hazards (EN 292, EN 1050, Paragraph 6) Techniques to estimate risks (EN 1050, Paragraph 7) Risk evaluation (EN 1050, Paragraph 8) After risk have been estimated, a risk evaluation is made as part of an iterative process to achieve safety. In this case, a decision has to be made whether it is necessary to reduce a risk. If the risk is to be further reduced, suitable protective measures must be selected and applied. The risk evaluation must then be repeated. If the required degree of safety has still not been reached, measures are required to reduce the risk. Risk reduction and the selection of suitable protective measures are not part of the risk evaluation. Suitable protective measures must be used to reduce risks. If the protective measures involve interlocking/latchingcontrol functions, then these must be configured in accordance with EN 954. Standard EN 1050 calls this operation an iterative process to achieve safety. Risk elements are defined as a support tool to evaluate risks. Graphic shows the inter-relationship of these risks elements.
S TA R T
Determine the machine limits R I S K A N A LY S I S
Identify the hazard
Risk estimation
Risk evaluation
YES Is the machine safe END
NO
Reduce risk
Risk reduction and the selection of appropriate safety measures are not part of the risk assessment. For a further explanation, refer to Section 5 of EN 292-1 (1991) and EN 292-2.
Iterative process to achieve safety in accordance with EN 1050
14
RISK ASSESSMENT
1 SAC 103 201 H 0201
Machine safety

Risk related to the considered hazard is a function Severity of the possible harm for the considered hazard
=
of
Risk elements
and
Probability of OCCURRENCE of that harm Frequency and duration of exposure Probability of occurrence of hazardous event Possibility to avoid or limit the harm
Residual risk (EN 1050)

Safety is a relative term in our technical environment. Unfortunately, it is not possible to implement the socalled zero risk guarantee where nothing can happen under any circumstance. The residual risk is defined as: Risk, which remains after the protective measures have been implemented. In this case, protective measures represent all of the measures to reduce risks.
Reducing risks
In addition to applying structural measures, risk reduction for a machine can also be realized using safetyrelevant control functions. For these control functions, special requirements must be observed, which are described in EN 954-1, graduated according to the level of risk. The requirements placed on safety-relevant parts of control systems are sub-divided into categories, graduated according to the level of risk. Techniques to select the suitable category as reference point for configuring the various safety-related parts of a control, are recommended in Annex B of EN 954-1.
S Severity of the injury S1 Slight (normally reversible) injury S2 Severe (normally irreversible) injury including death F Category B S1 Starting point for estimating the risk of the safety-related part of the control P1 F1 P2 S2 P1 F2 P2 1 2 3 4 Frequency and/or exposure time to the hazardous condition F1 Seldom up to quite often and/or the exposure time is short F2 Frequent up to continuous and/or the exposure time is long P Possibility of avoiding the hazard P1 Possible under specific conditions P2 Scarcely possible Selecting the category B, 1 to 4 Categories for safety-related parts of control systems Preferred categories for reference points Possible categories requiring further steps Measures which can be over-dimensioned for the relevant risk
Possible selection of the categories in accordance with EN 954-1

1 SAC 103 201 H 0201
15
Machine safety

The adjacent table indicates a brief summary of the requirements for the various categories. The complete text for the requirements is contained in EN 954-1, Section 6. Basic requirements to configure control systems are defined in the various categories. These are intended to make the systems tolerant to hardware faults. Additional aspects must be observed for more complex control systems, especially programmable electronic systems, so that random hardware failures can be controlled, systematic errors/faults in the hardware and software are avoided, and systematic errors/faults in the hardware and software can be controlled, so that sufficient functional safety is achieved for safety-critical tasks. The necessary requirements are described in the German Draft Standard DIN V VDE 0801 and the International Standard IEC 61508. The scope of the required measures is also graduated corresponding to the risk reduction required.
Safety Integrated
The measures which are required to make a complex control adequately functionally safe for safety tasks are extremely comprehensive and involve the complete development- and manufacturing process. Thus, controls such as these are specifically developed as failsafe devices. Advant Controller CS 31-S with AC 31 Safety Fieldbus are examples of such control systems.
Category
1)
Summary of requirements
System behaviour
2)
Principles to achieve safety
Safety-related parts of control systems and/or their protective equipment, as well as their components, shall be designed, constructed, selected, assembled and combined in accordance with relevant standards so that they can withstand the expected influence.
The occurrence of a fault can lead to the loss of the safety function.
Requirements of B shall apply. Well-tried components and well-tried safety principles shall be used.
The occurrence of a fault can lead to the loss of the safety function but the probability of occurrence is lower than for category B.
Mainly characterized by selection of components.
Requirements of B and the use of well-tried safety principles shall apply. Safety function shall be checked at suitable intervals by the machine control system.
The occurrence of a fault can lead to the loss of the safety function between the checks. The loss of safety function is detected by the check. When the single fault occurs the safety function is always performed. Some but not all faults will be detected. Accumulation of undetected faults can lead to the loss of the safety function. Mainly characterized by structure.
Requirements of B and the use of well-tried safety principles shall apply. Safety-related parts shall be designed, so that: a single fault in any of these parts does not lead to the loss of the safety function; and whenever reasonably practicable the single fault is detected. Requirements of B and the use of well-tried safety principles shall apply. Safety-related parts shall be designed, so that: a single fault in any of these parts does not lead to a loss of the safety function; and the single fault is detected at or before the next demand upon the safety function. If this is not possible, then an accumulation of faults shall not lead to a loss of the safety function.
When the faults occur the safety function is always performed. The faults will be detected in time to prevent the loss of the safety function.
1) The categories are not intended to be used in any given order or in any given hierarchy in respect of safety requirements. 2) The risk assessment will indicate whether the total or partial loss of the safety function(s) arising from faults is acceptable.
Description of the requirements for the Categories in accordance with EN 954-1
16
1 SAC 103 201 H 0201
Machine safety

Safety-related functions
The safety-related functions include, in addition to the classic functions stop actions in an emergency situation in the meantime, also more complex functions such as speed limiting position limiting speed deviation etc. The classic functions are defined in EN 60204-1 and are generally implemented using basic electromechanical components. Electronic programmable systems can also be used to implement more complex functions, if they fulfill the relevant standards (IEC 61508, EN 954 or DIN V VDE 0801). According to EN 60204-1 and EN 418, these functions are exclusively initiated by a conscious manual intervention. In the following text, only EMERGENCY OFF and EMERGENCY STOP will be discussed. The latter fully corresponds to the same terminology in the EC Machinery Directive. EMERGENCY OFF This is an intervention (action) in an emergency situation, which disconnects the electrical power to a complete system or installation or part of it if there is a risk of electric shock or another risk caused by electricity (from EN 60204-1 Annex D). Further, the following is defined in 9.2.5.4.3 of EN 60204-1: Functional aspects to disconnect the power in an emergency situation are defined in IEC 60364-4-46 (identical to HD 384-4-46). Power must be disconnected in an emergency situation, where protection against direct contact (e.g. with contact cables, slip ring assemblies, switch-gear in electrical rooms) is only achieved by maintaining a clearance or barriers; other hazard or damage could occur as a result of electric power. In an emergency situation, the power supply is disconnected from the machine which results in a Category 0 Stop. If a Category 0 Stop is not permissible for a machine, then it may be necessary to provide other protection, e.g. against direct contact, so that power does not have to be disconnected in an emergency situation. This means, that EMERGENCY OFF should be used where the risk analysis indicates a hazard due to electric voltage/power and therefore requires that the electric voltage is immediately disconnected from the complete machine.
Stop
Stop categories according to EN 60204-1 There are three stop categories, which are defined in EN 60204-1, independent of an emergency situation: Stop Category 0 Uncontrolled stop; stopping by immediate removal of power to the machine actuators (e.g. motor). Stop Category 1 Controlled stop; the power is only removed when the machine has come to a standstill. Stop Category 2 Controlled stop, where power is still fed to the machine when it is at a standstill. Emergency operations The new EN 60204-1/11.98 (IEC 60204-1), harmonized with HD 384 (IEC 60364), has defined the following possible actions for emergency situations (EN 60204-1 Annex D): Action in an emergency situation includes individually, or a combination of: EMERGENCY STOP EMERGENCY START EMERGENCY OFF EMERGENCY SWITCHING ON.
1 SAC 103 201 H 0201
17
Machine safety

In the application area of the EC, EMERGENCY OFF devices fall under the Low-voltage Directive 73/23/EEC, if they are not used in conjunction with machines. If they are used in conjunction with machines, then they come under the Machinery Directive 98/37/EC, as is true for all of the other electrical equipment. EMERGENCY STOP This is an action, in an emergency situation, which is defined to stop a process or movement which has become hazardous (from EN 60204-1 Annex D). Further, in 9.2.5.4.2 of EN 60204-1 the following is defined: Stop In addition to the requirements for stop (refer to 9.2.5.3), the following requirements apply for an emergency stop: It must have priority over all other functions and actions in all operating modes; The power to the machine actuators, which could cause hazardous conditions, must be disconnected as quickly as possible without creating other hazards (e.g. using mechanical stopping/ braking devices, which do not require an external supply by using counter-current braking) for Stop Category 1; Resetting may not initiate a restart. Stopping in an emergency situation must either be effective as a Stop, Category 0 or Category 1 (refer to 9.2.2). The Stop Category in an emergency situation must be defined as a result of the risk evaluation for the machine. To technically implement the EMERGENCY STOP, corresponding to the application recommendation in the foreword of EN 60204-1, the requirements of either EN 60204-1 or EN 954 and IEC 61508 can be applied. EN 60204-1 primarily requires that this is implemented using electromechanical components, as basic (programmable) electronic systems are not safe enough. By correctly applying EN 954 and, if required, IEC 61508, electronic- and programmable electronic components become functionally safe enough, that they can also be used to implement EMERGENCY STOP for all Categories. Devices for EMERGENCY OFF and EMERGENCY STOP In order to fulfill the protective goals, both of EN 60204-1 as well as EN 418, the following requirements are valid for both functions (also refer to 10.7 in EN 60204-1): When contacts switch, even with just a brief actuation, the control device must positively latch. It is not permissible that the machine can be restarted from a remote main operator control station without the hazard or danger first having been removed. The emergency stop device must be consciously released again locally. Other safety-related functions For all other safety-related functions, EN 60204-1 recommends that electromechanical components are used. With the argument that it is presently difficult to be able to secure the reliability of fault-free operation of a single-channel programmable electronic unit with sufficient confidence. This expressly refers to the time at which the associated text of the standard was drawn-up. The application recommendation in the foreword of the new EN 60204-1 for this Chapter takes into account the progress which has been made in developing safety-relevant technology. It recommends that the different requirements of other relevant standards, e.g. IEC 61508, should be taken into consideration. When taking into account the requirements of these standards, it is possible to use electronic and programmable electronics, for example, a fail-safe Advant Controller 31-S in a safety-related fashion, even for complex functions.
18
1 SAC 103 201 H 0201
Machine safety

Man Machine
In order to simplify the interaction between man and machines, reference is made to Standards EN 60073 an DIN EN 60204. Switches, pushbuttons and signaling lamps are, in the first instance, the machine components which are used as the interface between man and machine. These operator control elements are clearly and uniformly identified using color coding which has a very specific significance. This guarantees that the safety of operating personnel is increased and it is easier to handle and maintain the operating resources/plants and systems. The colors for pushbuttons, the significance of the colors, explanations and application examples are shown in Graphic. According to DIN EN 60204-1 (VDE 0113 Part 1) the following information has to be observed: The preferred colors for START/ON operator control devices should be White, Grey or Black, preferably White, Green can be used, Red may not be used. Red must be used for EMERGENCY OFF operator control devices. The colors for STOP/OFF operator control devices should be Black, Gray or White, preferably Black. Red is also permitted. It is not permissible to use Green. White, Grey and Black are the preferred colors for pushbuttons, which can be used alternating as START/ON- and STOP/OFF pushbuttons. It is not permissible to use Red, Yellow or Green. White, Grey and Black are the preferred colors for pushbutton control elements which initiate an operation while they are pressed, and end that operation when they are released (e.g. jogging). Green is reserved for functions, which display a safe or normal operating condition. Yellow is reserved for functions, which display an alarm or a non-standard (abnormal) condition. Blue is reserved for functions which require a specific action. Reset pushbuttons must be Blue, White, Grey or Black; if they also act as STOP/OFF pushbuttons, White, Green or Black are preferred, but preferaly Black. It is not permissible to use Green. The colors for the indicating lamps, their significance with reference to the status of the machine as well as their handling and application examples, are listed in Graphic (Page 18). For illuminated pushbuttons, the information in Graphics (Page 17 and 18) applies. If problems are encountered when assigning suitable colors, White must be used. For EMERGENCY OFF devices, the color Red must not be dependent on the illumination status of the device.
Colour Red
Meaning Emergency
Explanation Actuate in the event of a hazardous condition or emergency Actuate in the event of an abnormal condition
Examples of application EMERGENCY OFF; Initiation of emergency function
Yellow
Abnormal
Intervention to suppress abnormal condition; Intervention to restart an interrupted automatic cycle
Green
Normal
Actuate to initiate normal conditions
START/ON; however white should be preferably used
Coding cables
The color coding of switches, pushbuttons and indicator lamps has been discussed in the previous Section. EN 60204 offers a higher degree of flexibility when coding cables. It specifies that cables at every connection must be able to be identified in conformance with the technical documentation . It is sufficient if terminals are numbered, corresponding to the information in the circuit diagram, if the cable can be easily visually tracked. For complex controls, it is recommended that the internal wiring cables as well as the outgoing cables are coded so that after the cable has been disconnected from the terminal, it can be easily re-connected later to the same terminal. This is also recommended, for terminal locations
Blue
Mandatory
Actuate for a condition requiring mandatory action for general initiation of functions except for emergency stop (see note)
Reset function
White Grey Black
No specific meaning assigned
START/ON (preferred), STOP/OFF START/ON, STOP/OFF START/ON, STOP/OFF (preferred)
Note Where a supplemental means of coding (e.g. shape, position, texture) is used for the identification of pushbutton actuators, then the same colour White, Grey or Black may be used for various functions (e.g. White for START/ON and for STOP/OFF actuators).
Colors for pushbuttons and their significance in accordance with EN 60204-1 (VDE 0113 Part 1): 06.93
1 SAC 103 201 H 0201
19
Machine safety

which have to be disconnected when the equipment is transported. Using the wording in IEC 60204-1 1997, Paragraph 14.2.1 conductor core coding/identification, the Standards Committee wanted to make the following statement: areas which are handled by the same personnel. These definitions cannot be generalized due to the wide application range of the Standard, from small individual machines (high unit volume standard products) up to large, complex machinery plants (unique equipment and systems). Primarily, the avoidance of installation/assembly faults must be guaranteed using appropriate testing. Instead of many different colors, a single color can be used for the internal wiring. It should be color-coded as follows: Black for main AC and DC circuits Red for AC control circuits Blue for DC control circuits Orange for interlocking circuits, which are supplied from an external power source. The above color assignment is recommended if a decision is made to just use color coding. The only mandatory specification is the color coding of the protective conductor and the neutral conductor. For all other cabling and wiring, one of the methods, listed in 14.2.4 can be selected (color, numbers or letters; or a combination of colors and numbers or colors and letters). Protective conductor marking
Blue Mandatory Indication of a condition that requires action by the operator Other conditions; may be used whenever doubt exists about the application of Red, Yellow, Green, Blue Mandatory action Prompt to enter, specified values
Colour
Meaning
Explanation
Action by operator
Examples of application Pressure/temperature outside safe limits, voltage drop, voltage interruption, passing through a stop position Pressure/temperature outside normal operating ranges; Tripping a protective device Pressure/temperature within the normal operating ranges, permissive signal to continue
Red
Emergency
Hazardous condition
Immediate action to deal with hazardous condition (e. g. by operating emergency stop)
Yellow
Abnormal
Abnormal condition Impending critical condition
Monitoring and/or intervention (e.g. by re-establishing the intended function)
Green
Normal
Normal condition
Optional
White
Neutral
Monitoring
General information
The protective conductor must be uniquely identifiable as a result of its shape, location, coding or color. If it is only identified as a result of its color, then a two-color combination of green/yellow must be used along the whole length of the cable. The green/yellow color combination is exclusively reserved for protective conductors. Neutral conductor marking If a circuit has a color-coded neutral conductor, then light blue must be used. Light blue may not be used to code other cables if there is a danger of accidentally interchanging them. If there is no neutral conductor, a light-blue conductor may be used for other purposes, but not as protective conductor.
Colors for indicator lamps and their significance in accordance with EN 60204-1 (VDE 0113 Part 1): 06.93
1. Each individual cable must be able to be identified, however, only in correspondence with the documentation. It is not necessary that every cable must be able to be identified without the documentation 2. The type of coding and also the identification technique should be agreed between the manufacturer and operator. It is not the intention of the Standard to specify a specific coding type worldwide. For instance, for safety reasons, factory-internal specifications may have a higher priority in order to avoid confusion in specific
20
1 SAC 103 201 H 0201
Process industry

Legislation Requirements in Europe
For the process industry, essentially the following EC Directives must be applied: Council Directive 96/82/EC of 9th of Dec. 1996 on the control major-accident hazards involving dangerous substances (Seveso Directive II). Low-Voltage Directive Safety report Machinery Directive (98/37/EC) Pressure Equipment Directive (97/23/EC). The latter is only relevant in so much that the devices used must fulfill this Directive. The Directive on the other hand is not valid for assembling pressured devices at the users plant, for example, in industrial system under his responsibility. At the same time, the health and safety at work laws (Refer to Page 1/2, Workplace Health and Safety Legislation) and accident prevention regulations must always be observed. The owner/operating company is responsible in generating a safety report, in which the following is defined, that the concept to prevent severe accidents has been implemented, that the hazards have been identified and all of the required measures to prevent these types of accidents and limiting the results for man and the environment, have been put in place, and the implementation, erection and installation and operation of all plants and systems is adequately safe and reliable. Inspection The regulatory bodies must set-up a system of inspections to systematically check the operational-, organizational and management-specific systems of the operation which will allow these regulatory bodies to confirm that the user can prove, that he has undertaken measures to prevent severe accidents, and he has provided adequate measures to limit the results of any accident This EC Directive must be implemented on a national basis. Determining and evaluating the risks defining and applying techniques to systematically determine hazards Operation monitoring defining and applying techniques for safe operation, including the maintenance and service of the plants and systems. Quality assurance defining and applying techniques to continuously ensure that the goals are achieved.
Seveso Directive
This EC Directive specifies, corresponding to the principles explained in the introduction, the safety goal. preserving and protecting the quality of the environment, and protecting human health through preventive action; In order to achieve this goal, the following basic requirements have been drawn-up, which the Member States must ensure are fulfilled. Concept to prevent severe accidents The owner/operating company is responsible in drawing up a document setting out his major-accident prevention policy and to ensure that it is properly implemented. The major-accident prevention policy established by the owner/operating company shall be designed to guarantee a high level of protection for man and the environment by appropriate means, structures and management systems (Article 7 Paragraph 1). The document must take into account the following basic principles. The concept to prevent severe accidents must be in written form. A safety management system, in which, among others, the following issues are regulated:
1 SAC 103 201 H 0201
21
Process industry

Technical measures to fulfill the legislative goals
The first priority is to design the process so that it is intrinsically safe. Where this is not possible, then additional measures are required in order to reduce the remaining risk, as a result of the process, to a tolerable level. This can be realized using electronic controllers if these are suitable for the particular task. Electronic controllers are then suitable for securing the safety of the plant, if they have been especially designed for this purpose. The requirements are described in Standards. The national standard in the US is ISA S 84 Application of Safety Instrumented Systems for the Process Industries with Technical Report TR 84. The process industry in the US and Canada is not intending to replace ISA S 84 by IEC 61508, but only with IEC 61511 (the principles of ISA S 84 correspond to those of IEC 61508). Further, for the equipment and deviced used, there are additional standards which apply which are involved with specific safety requirements. Also refer to the Section on Machine Safety.
Relevant standards for safety measures using process control technology

For safety measures using process control technology, e.g. in Germany, presently the following national standards must be applied: DIN V 19250 Basic safety issues for control and instrumentation protective devices DIN V 19251 Instrumentation and control protective devices requirements and measures for safety-related functioning DIN V VDE 0801 Basic rules for computers in systems with safety-related tasks. The standards are also recognized in other European countries and appropriately applied, but however, this must be clarified on a case-for-case basis. The international standards for this application area are: IEC 61508 Functional safety of electrical/electronic/programmable electronic safety-related systems Draft IEC 61511 Functional safety: safety instrumented systems for the process industry sector. IEC 61508 is a basic standard, primarily for developing sector-specific standards. It can be directly applied, if there is no specific standard for the associated application area. Presently, in Germany, the above specified national standards are still valid. Today, instead of DIN V VDE 0801, IEC 61508 can be used. DIN V 19250 and 19251 are scheduled to be replaced by IEC 61511.
22
1 SAC 103 201 H 0201
Process industry

Reducing risks using process control technology
Measures are required to reduce risks, if a failure of the basic process control system can lead to a dangerous event or can cause the plant or system to go into a hazardous condition and if the resulting risk is unacceptably high. In this case, suitable protection measures must be taken either to sufficiently reduce the probability of a hazardous event occurring, or to reduce the extent of the damage. This can be realized using electronic controller-based safety instrumented systems, if these fulfill the safety requirements.
Prevention Safety instrumented prevention system Mitigation Safety instrumented mitigation system
Safety-related Non-safety relevant Basic Process Monitoring systems Basic Process Control systems
Announcement of process control systems in safety related/non-safety related configurations
Risk reduction
As it is not possible to completely exclude certain risks, both from a technical and cost-effective standpoint, it is necessary not only to determine the existing risk, but also to define and specify a risk which can be tolerated. The measure for the safety integrity of the riskreducing functions is then derived from the difference between these two factors. IEC 61508 defines Safety Integrity Level (SIL) as a target measure for the probability of failure for executing risk-reducing functions.
Draft IEC 61511 uses the Safety Integrity Level (SIL), defined in IEC 61508 as a target measure for the probability of failure of the execution of the risk-reducing functions.
Residual risk
Tolerable risk
EUC risk
Increasing risk
Necessary risk reduction Actual risk reduction
Risk reduction achieved by all safety-related systems and external risk reduction facilities
Partial risk covered by other technology safety-related systems
Partial risk covered by E/E/PE safetyrelated systems
Partial risk covered by external risk reduction facilities
Principle of risk reduction (acc. to IEC 61508)

1 SAC 103 201 H 0201
23
Process industry

Safety integrity level High demand or continuous mode of operation (Probability of a dangerous failure per hour) 10 9 10 8 10 7 10 6 to to to to < < < < 10 8 10 7 10 6 10 5 Low demand mode of operation (Average probability of failure to perform its design function on demand) 10 5 10 4 10 3 10 2 to to to to < < < < 10 4 10 3 10 2 10 1
Selecting the equipment and basics of the required features

Safety function Risk reduction using electronic controllers is realized by defining functions for each possible hazardous event or each possible dangerous condition of the plant or system, which prevents the dangerous event occurring. These so-called safety functions are to maintain the plant or system in a safe state or to re-establish this safe state if a dangerous event could occur due to a failure or a disturbance in the plant or system. The safety function can also be used to reduce the extent of damage due to a hazardous event. The definition of a safety function always includes the specification of the function itself (e.g. inhibiting the feed to a container, if the level has reached the upper limit), and the safety integrity, derived from the risk analysis. Implementing the safety functions Every safety function always includes the complete chain, from information acquisition, through information evaluation up to executing the required action. Equipment involved, for example, failsafe PLCs, sensors and actuators etc. must fulfill, as a total, the determined SIL from the risk evaluation. If a unit is used at the same time for various safety functions, it must fulfill the highest SIL of the individual functions.
4 3 2 1
Safety integrity levels according to IEC 61508: Target failure measure for a safety function, allocated to a safety-related system.
Requirement categories (DIN V 19250) 1 2 3 4 5 6 7 8
Category (EN 954-1)
Safety class (SIL) (IEC 61508) 0 1 1 2 3 3 4 4
B 12 23 3 4
Comparison of the requirement categories (This comparison is for information purposes only, as the classifications cannot be transferred one to one.
Sensor Acquire information
Evaluation unit Evaluate information
Actuator Execute action
Safety function
Evaluation unit, e.g. safety PLC
Extent of loss
Duration of stay
Risk avoidance
Probability relatively low high 1
very low
Injury possible seldom Risk parameters Fatality frequent not possible Several fatalities seldom frequent Catastrophe not possible possible
2 3 4 5 6 7 8
1 2 3 4 5 6 7
1 1 2 3 4 5 6
Risk graph and requirement classifications to DIN V 19250
24
1 SAC 103 201 H 0201
Process industry

Device characteristics and features If PLCs are used for information processing, these must fulfill as Safety-PLC the requirements of the relevant standards and fulfill the specified SIL. They must also be certified by an independent tester. This is also valid for other complex devices where not all of the potential fault/failure modes can be specified, because they use microprocessor technology. The essential characteristics and features of a fail-safe PLC, which are requested in the standards with various graduated levels, are: When developing, manufacturing and servicing, specific measures and techniques must be applied so that systematic faults can be avoided. The PLC must be able to control systematic failures which occur during operation. The PLC must detect random hardware failures during operation and be able to control them. To be able to control a failure means that when the system detects a fault or failure, the safety function, defined for this case (e.g. shutdown the plant), is reliably executed. Necessary fault tolerance. This is dependent on the possibilities available to detect faults and failures. Required service/maintenance. IEC 61508 defines the maximum permissible SIL of a system or subsystem dependent on its fault tolerance and the safe failure fraction over the total possible failures (refer to Graphic). Dangerous failures must be detected and a required response must be performed within a suitably short time. These time requirements are defined in IEC 61508-2. In order to detect faults or failures in peripheral devices, test- and monitoring functions can be integrated into the safety PLC. When using complex peripheral devices (e.g. transmitters with microprocessor), it must be ensured that these devices themselves fulfill the relevant standards (e.g. IEC 61508 or IEC 61511). The complete safety instrumented system must be configured, so that it fulfills the relevant standards for all of its safety-relevant functions. IEC 61508 and Draft IEC 61511 are relevant regarding functional safety.
Safe failure fraction
Hardware fault tolerance (see note 2) 0 (see note 1) 1 SIL 2 SIL 3 SIL 4 SIL 4 2 SIL 3 SIL 4 SIL 4 SIL 4
< 60 % 60 90 % 90 99 % 99 %
NOTE 1: NOTE 2:
SIL 1 SIL 2 SIL 3 SIL 4
See IEC 61508-2 for details on interpreting this table A hardware fault tolerance of N means that N + 1 faults could cause a loss of the safety function.
Maximum permissible SIL for a non-complex sub-systems dependent on its fault tolerance N and the achieved safe failure fraction (acc. to IEC 61508-2 FDIS)
Application
When using a fail-safe PLC, only the conditions, defined in the associated Safety Manual, and if relevant, additional conditions of the certificate, must be maintained. For the peripheral devices which are to be connected (e.g. sensors and actuators), in addition, the requirements in the standards (IEC 61508 and IEC 61511) must also be taken into account regarding the following aspects: Systematic faults must be avoided, e.g. configuring-, installations- and handling faults Random faults or failures must be detected and controlled.
1 SAC 103 201 H 0201
25
Furnaces

EC Directives
Furnaces and burners are subject to the relevant directives due to their application and the devices which are used. There are no specific EC Directives for furnaces. Furnaces are subject, where relevant, to application-specific directives. Industrial thermo-processing equipment are, for example, classified as machines under the Machinery Directive. Furnaces For furnaces, which do not belong to industrial thermo-processing equipment, and are not used to heat process liquids and gases in the chemical industry, there are the following general standards for electrical equipment the European Draft Standard prEN 50156 Electrical equipment for furnaces Part 1: Requirements for application design and installation and the German Standard Industrial thermo-processing equipment There is a European draft standard for these systems, which was drawn-up under a mandate of the Machinery Directive, and more precisely, prEN 746 Industrial thermo-processing equipment with Part 1: General safety requirements of industrial thermo-processing equipment Safety requirements for combustion and fuel handling systems. DIN VDE 0116 The following Standards are available for burners: prEN 676 gas burners; EN 230 oil-vapor burner in a mono-block design; EN 267 oil burners; EN 298 automation equipment for furnaces for gas burners and gas units with and without blower.
Standards
Part 2:
prEN 746 can be applied to industrial thermo-processing equipment, for example Metal producing and processing Glassworks, Ceramic plants, Cement-, lime-, and gypsum plants, Chemical plants, Incinerators etc. This refers to EN 60204-1 and EN 654-1 as well as, for safety-relevant electronic systems, also to IEC 61508.
EMERGENCY OFF for furnaces

For equipping furnaces with devices to switch-off in an emergency situation, prEN 50156 specifies that EN 60204-1 and EN 954-1 must be observed so that the appropriate EC Directives are fulfilled. The regulations are also involved with the associated equipment for storage, preparation and pumping fuels.
26
1 SAC 103 201 H 0201
Push buttons
1 SAC 103 201 H 0201
27
EMERGENCY OFF control devices
Push buttons
Relevant standards
IEC 60947-5-5 (Requirements for fulfilling the machine guidelines) EN 60204-1 (Safety of machines Electrical equipment of machines) EN 60947-5-1 (Low-voltage switchgear with positive opening contacts) EN 999 (Approach speed) EN 292-1 (Safety of machines General design guidelines) EN 954-1 (Safety of machines Safety-related parts of control systems)
Using with safety combination C 57 x evaluation unit Advant 31- S 07 EB 91 S
Category B, 1, 2: acc. to EN 954-1

Using a contact block
Using with a fail-safe Advant 31- S
Emergency OFF
Product safety through new standards

The EMERGENCY OFF operating devices from ABB are tested according to the new standard for electrical EMERGENCY OFF devices with mechanical latching, IEC 60947-5-5 (1997-11), and the corresponding guidelines EN 60204. The following tests have to be passed in order for the standard to be fulfilled: Use of two switching elements. A dual-channel control is absolutely necessary for this category when used for fail-safe evaluation and diagnostics equipment.
Emergency OFF
safety combination C 57 x (Cat. 2)
Continuous test: Robustness: Environmental test: High voltage test: Reset test: Shock test: Vibration test: Positive opening contacts:
6,050 cycles. This is not a test of the mechanical service life, which is 100,000 operations. A force of 113 N on three axes. Heat and cold, high air humidity and 5 % NaCl solution 2,500 V Tensile force < 50 N, Torque > 50 N 15 g 2 h at 50 m/s2
Using with a fail-safe Advant 31- S
Emergency OFF
according to IEC 947-5-1, K.2.2
evaluation unit Advant 31- S 07 EB 91 S
Using with safety combination C 57 x
Emergency OFF
safety combination C 57 x (Cat. 3, 4)
28
1 SAC 103 201 H 0201
Push buttons
Assembled stations
ABB has two enclosure systems for the installation of pushbuttons in situ: Insulated enclosure providing protection-rating IP65 Metal enclosure providing protection-rating IP67 While the insulated enclosure can withstand all normal internal and external loads, the metal enclosure made of lightweight metal provides increased loading capacity with respect to leaks and mechanical stresses. Apart from the individual enclosures, ABB also offers a range of the most common combinations of in-situ controls ready assembled ex stock. Furthermore, it is also possible for customer specific, tailor made and pre-assembled in-situ controls to be produced to order. The following in-situ controls are available pre-assembled ex stock: Insulated enclosure with 1 control (grey/black enclosure) 1x pushbutton with 1NO or 2NO 1x mushroom button 2NC EMERGENCY OFF controls 2NC (yellow/black enclosure) Insulated enclosure with 2 controls (grey/black enclosure) 2x pushbutton with 1NO or 2NO Insulated enclosure with 3 controls (grey/black enclosure) 3x pushbutton with 1NO or 2NO 2x pushbutton with 1x indicator light Metal enclosure with 1 control (grey enclosure) EMERGENCY OFF pushbutton 2NC
Accessories
ABBs comprehensive range of accessories enables virtually all the combinations of pushbuttons found in practice to be simply and inexpensively realised.
1 SAC 103 201 H 0201
29
Signal towers and signal beacons
Push buttons
Signal Tower K 70
Rapid assembly of the signal elements due to bayonet system Simple replacement of defective bulbs in every stage Flexible composition of the signal elements possible Up to 5 elements possible max. 10 elements with double angle Lightening elements can be fitted at every stage Use of up to 5 lightening elements High protection rating, IP54 for all optical and acoustic signal elements LED elements for long service life Colour selection to IEC 73, Version 4, 1991 Description and colours for pushbuttons/Signal beacons and information with respect to use of the colours (extract from the standard):
Signal Beacons K SB
Tamper-proof design withstands all mechanical and natural conditions both indoors and outdoors High protection rating IP65 Cap consists made of high-impact polycarbonate (up to 20 yrs) Rapid bulb change from the inside of the switchgear cabinet
Colour Red Amber
Pushbutton/Significance Risk: Act urgently Attention: Measures necessary
Indicator light/Significance Serious risk: Dangerous condition Attention/Imminent critical state Normal condition or safe
Green
Normal condition, Measures for normalisation or securing Predetermined significance
Blue
Status, which requires a defined action No special significance
White, grey, black
No special significance
30
1 SAC 103 201 H 0201
Position switches LS-Serie
Push buttons
Relevant standards
EN 1088 (Latching devices in conjunction with isolating protective devices) EN 60947-5-1 (Low-voltage switchgear with positive opening contacts) prEN 999 (Approach speed) EN 292-1 (Safety of machines General design guidelines) EN 954-1 (Safety of machines Safety-related parts of control systems) EN 60204-1 (Safety of machines Electrical equipment of machines)
Product spectrum
Position switches LS-Series can be used for: Monitoring protective equipment with hinges, such as hinged doors, flaps, covers etc. Monitoring protective equipment which can be moved sideways, for example, sliding doors, protective screens etc. Detecting hazardous movements of machine parts. Every category can be achieved by using ABB position switches LS-Series are optimally harmonized with the requirements for the highest degree of safety and offer the following advantages: Positive opening of the NC contacts Version with/without separate actuator Increased safety using additional latching (tumbler mechanism) High degree of protection IP 65/67 Standard enclosure, also in accordance with DIN EN 50047 and 50041 Different actuators Electrically insulated contacts with moving double contacts. Position switches LS-Series are supplied with separate actuators or without actuator. The actuator elements are shown for the particular switch types.
Positive opening operation of the contacts (EN 60947-5-1)

Positive opening operation is specified in accordance with DIN VDE 0660 Part 200 and is the same as IEC 947-5-1-3 and EN 60947-5-1. For the electrical equipment of machines, the positive opening of NC contacts is expressively specified in all safety circuits. It is designated according to IEC 947-5-1-3 by the following character (personnel protective funktion).
1 SAC 103 201 H 0201
31
Position switches
Push buttons
Product spectrum
Plastic casing
Double casing IP 65 protection degree Complying with: EN 50047 standard for 30 mm width 1 cable conduit Pg11 EN 50041 standard for 40 mm width 1 cabel conduit Pg13.5
Metal casing
IP 66 protection degree Complying width EN 50041 standard for 40 mm width 1 cable conduit Pg 13.5 Without normalisation for 60 mm width 3 cable conduits Pg 13.5
Actuators
Safety key, plunger, roller plunger, roller lever, adjustable lever, or spring rod
Contact blocks
Two electrically separated moving contacts, Zb shape Snap action or slow contact dependent action Positive opening operation of N.C. contact(s) The limit switches are delivered completely assembled, ready for installation. Many variants (Casing, actuators or contact blocks) are available on request.
Foot switches
Foot switches with cover
Double insulation IP 65 protection degree Actuation: free movement; locked in normal position; latched in low position
Mini foot switches

IP 40 protection degree Free movement
32
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
33
Save intelligence

A control for safety and restart functions
The Advant Controller 31-S can be used to design and standardise small, decentralised control units. With a control centre, the safety and restart functions are supported simultaneously. Safety signals are locally linked with the safety control centre via the AC31 safety field bus.
Areas of application
The Advant Controller 31-S is a safety-orientated control system which is suitable for a diverse range of uses in plant and machines. Typical applications are e.g.: Burner and boiler controls Fuel engineering, gas consumption equipment
Certification
The Advant Controller 31-S is certified to international standards: DIN V 19250: Basic safety issues for control and instrumentation protective devices Requirements category (AK) 1-4 EN 954-1: Safety of machines, Category 3 DIN VDE 0116: Electrical equipment for burner systems. Requirements for safety-oriented electronic components, Item 8.7 DIN EN 298: Automation equipment for furnaces for gas burners and gas units with and without blower, Items 8, 9 ,10 NFPA 8501: Standard for boiler functions with a burner NFPA 8502: Standard for the prevention of furnace explosions/implosions in boilers with several burners Storage and conveying equipment, mixing technology Machine manufacture, e.g. for printing and packaging machines Construction and container cranes Plant manufacture, environmental engineering Road traffic signal systems, tunnel construction Process locks and safety devices
AC31 Safety Fieldbus
AC31-S Controller
0V
+ 24 V E/A Module
System topology with modular construction
34
1 SAC 103 201 H 0201
System data

Safety-oriented automation device for programming software 907 PC 33/331/338
Type Order number Weight per item Programm memory Processing time (35% word, 65% bit) Integrated digital I/O Decentralised digital I/O Integrated Al (not-S) 07 KT 94-S GJR 525 2100 R 2161 0.25 kg 480 kbyte 0.2 ms 24/16/8 max. 992 8 (10 V, 5 V 0 10 V, 0 5 V 0 20 mA, 4 20 mA 50 C + 400 C 30 C + 70 C or as DI) 4 (10 V, 0 20 mA 4 20 mA or as DO) max. 96/96 2 x integrated integrated AC31 safety field bus Secures user program and data 128 free via software free via software 1 24 V DC 07 KT 93-S GJR 525 1300 R 2171 0.25 kg 56 kbyte 0.7 ms 24/16 max. 992
Integrated AO (not-S) Decentralised analogue I/O MODBUS connection ARCNET connection Integrated safety field bus Smart Media Card Sequencers per 16 steps Number of times Number of counters Real time clock Supply voltage Safety field bus
max. 96/96 via coupler integrated AC31 safety field bus 128 free via software free via software 1 24 V DC
AC31 safety field bus, RS 485-BUS, 2 wire cable (twisted, screened) max. 31 in-situ modules, max. cable length 500 m (2000 m with Repeater), also via optical fibre (via converter) Cycle time for 31 modules with 8 digital inputs or outputs: 12 ms Modules in plastic enclosure, fixing via top-hat rail 35 mm to DIN EN 50 022 or using screws on assembly panel Cycle monitoring, battery monitoring, identification of syntax errors, check sum monitoring 240 x 140 x 85 mm 240 x 140 x 85 mm
Mechanical construction Diagnostics Dimensions (W x H x D)
240 230
170 COM2
Depth of device: 85 mm COM 1 interface jack is placed lower so that the required installation depth doesnt increase even for plugged in interface cables. If top-hat rails are used the installation depth increases by the overall depth of the rails. (Dimensions for assembly drill holes are printed in bold type.)
65 111 COM1 65 5 130 140
230
1 SAC 103 201 H 0201
35
Safety-related input/output modules

Type 07 DI 90-S Safe inputs GJR 525 0900 R 0202 kg 0.25 8 24 V DC Short circuit after ZP: 0 15 % of UP (0 3.6 V at UP = 24 V) 0-Signal: 15 35 % of UP (+ 3.6 8.4 V at UP = 24 V) undefined level: 35 65 % of UP (+ 8.4 15.6 V at UP = 24 V) 1-Signal: 65 85 % of UP (+ 15.6 20.4 V at UP = 24 V) Short circuit after UP: 85 100 % of UP (+ 20.4 24,0 V at UP = 24 V) yes max. 8 120 x 140 x 85 mm 07 DO 90-S Safe outputs GJR 525 0800 R 0202 0.25 8 24 V DC 0-Signal: 0 3 V 1-Signal: > UP 2.5 V Monitoring 0-Signal: Output level > 8 V (5 V typical) at starting state 0 (0-Signal) lead to internal error (device switches off) 07 Al 90-S Safe analogue inputs GJR 525 1200 R 0202 0.25 4 24 V DC 4 20 mA Error message Range underflow: if input current < 3.6 mA Error message overrange: if input current > 20.4 mA Order number Weight Number of digital channels Number of analogue inputs Supply voltage Signal level/Measuring range
Potential separation against system bus Number of modules per line max. switching current of the transistor outputs Resolution Dimensions
yes max. 16 0.5 A, short-circuit proof 120 x 140 x 85 mm
yes max. 6 12 bit 120 x 140 x 85 mm
120 20 94 25
85
Depth of device: 85 mm If top hat rails are used, the installation depth increases by the overall depth of the rails. (Dimensions for assembly drill holes are printed in bold type.)
75
111 65
5 94
Programming and test software, additional package

Type Order No. Description German English 907 PC 33 GJP 520 3900 R 0302 GJP 520 4000 R 0302 Programming and test software General description of the programming interface excl. software (SW s. 907 PC 331) 907 PC 331 GJP 520 4500 R 0402 GJP 520 4600 R 0402 Programming and test software in AWL, FBS, KOP, system-specific part incl. software on disc, documentation 907 PC 338 GJP 520 6700 R 0102 GJP 520 6800 R 0102 Additional package of safety functions for 07 KT 93-S incl. safety manual 907 PC 339 GJP 520 7500 R 0102 GJP 520 7600 R 0102 Additional package of safety functions for 07 KT 94-S incl. safety manual
36
65
130
140
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
37
Rules for application

Safety Combinations types C 57x und C 581
The complete program of safety combinations has been especially designed for the requirements of state-ofthe as safety technology. Safety combinations can be simply used to configure safety circuits, as the devices fulfill EN 60204-1 (VDE 0113 Part 1) and are certified by the German Trade Association (BG), German Statutory Industrial Accident Insurance Association (BIA) and the Swiss Accident Insurance Institution (SUVA).
Relay-type safety combinations (C 571C 581)

In recent years, the trend in low-voltage technology has been towards miniaturization of the switching devices. With newly-developed, smaller devices, it was possible to increasingly accommodate more functionality in a cabinet. It was therefore a logical step that when it came to safety technology, that there would also be demand for smaller, more compact safety combinations. ABB fulfilled this enhanced safety demand by using space-saving safety relays with positively-driven contacts. These safety relays switch so that they are intrinsically fail-safe. In this case, 2 contacts, which are independent of one another, have to be switched in series; normally so-called NO contacts of monostable relays are used. If a contact was to weld, then the 2nd contact, connected in series, is used to disconnect the circuit. A positively-driven NC contact is used to signal the fault, in this case the welded NO contact. This NC contact is actuated in synchronism with the NO contact. For example, if the NO contact is closed, then the NC contact, which is provided for monitoring, must be open and vice versa. Using these paired, positively-driven contacts, it is ensured that the safety relay also drops-out, if all of the contacts of the circuit to be protected are welded. With this new-type of contact arrangement, the safety relay has positively-driven contacts, which are tested and recognized by SUVA and which fully conform to Standard ZH1/457. The relay safety combinations C57x and 581 can be used in ambient temperatures of up to 60C, up to 70C with some restrictions when mounted in-line. Many switching functions can be implemented using the series of C 57x and 581 safety combination. The following program overview shows the spectrum of devices available:
Applications
Safety combinations cover wide range of possible applications. These include monitoring EMERGENCYSTOP and protective door devices. It is also possible to monitor press control systems. Safety Combinations tend to be used for some-what less complex safety circuits as conventional switching technology used with electromechanical contacts. Safety circuits using PLC technology (Advant Controller 31-S) can be used for more complex plants and systems with a high functional scope (e.g. with a diagnostics function when an EMERGENCY OFF is initiated). A fail-safe Advant Controller 31-S is frequently used if a Advant Controller is used for the non-safety-relevant control of the plant or system.
Positively-driven contacts, a plus for safety

Relays are often used for safety circuits. The special feature of ABB safety combinations is the fact that contactors or safety relays use positively driven contacts. In this case, ABB offer two Versions of safety combinations, and more specifically, using contactors (CC 570) or relays (C 571C 581).
Contactor-type safety combinations (C 570)

Contactors have a high switching capacity. For safety combinations, rated operating currents of 6 A are possible for AC-1, and for DC-13, up to 6 A, and a thermal continuous current up to 10 A. This is also valid up to 55C when mounted in a cabinet without having to derate the devices. With this performance data, you can optimally configure every safety circuit, and it is even possible to switch smaller drives directly using a safety combination. With a safety combination, additional main contactors are not required to switch higher ratings. That naturally saves costs. Furthermore, high switching currents also mean more safety and safety combinations use auxiliary contactors with an extremely high contact reliability. Statistically, only 1 contact fault occurs every 100 million switching operations. These low fault statistics significantly increase the plant availability.
38
1 SAC 103 201 H 0201

Overview of safety combinations
Contactor safety combinations Relay safety combinations Press-control devices Expansion units
C 570
4 enabling contacts, 1 NC + 1 NO, single-channel, Category
C 571
2 enabling contacts, single/ two-channel, Category 3 (4)
Two-hand control device
Contact expension
C 575
2 enabling contacts, 2 NC, Category 4
C 579
4 enabling contacts, Category 4
C 572
3 enabling contacts, 2 NC, single/two-channel, autostart, monitored start, Category 4 Overtravel tester
C 578
3 enabling contacts, 1 NC, can only be used with C575, Category 4
C 574
2 enabling contacts, 1 NC, 2 delayed enabling contacts, single/two-channel, monitored start, Category 3
C 573
2 enabling contacts, 1 NC, single/two-channel, Category 3 (4)
C 576
2 enabling contacts, twochannel, autostart, Category 4
Voltages C 577
2 enabling contacts, twochannel, monitored start, Category 4
DC 24 V
AC 24 V
AC 115 V
AC 230 V
The safety combinations Series C 57x and C 581 consist of: Basic units Expansion units, and Press-control units.
EMERGENCY OFF devices must have priority over all of the other functions. The power feed to the machine drives, which can cause hazardous conditions, must be shut down as quickly as possible without creating other hazards. When the drives are reset, a restart may not be initiated. EMERGENCY OFF must act as stop, Category 0 or Category 1. The basic safety combination units can be used for EMERGENCY OFF applications up to a maximum of Category 4 according to EN 954-1. Depending on the external circuitry and how the cables are routed to the sensors, Category 3 or Category 4 can be achieved. Protective door monitoring according to EN 1088 makes a differentiation between latching, isolating protective devices, and latching isolating protective devices with tumbler.
Basic units
These are used to safely monitor EMERGENCY OFF devices and protective doors. The basic units have, in addition to instantaneous enabling contacts, also off-delayed enabling contacts. Depending on the device version, delay times of between 0.5 and 300 s are available. A sealable protective cover can be provided to protect against unauthorized changes to the selected delay time.
1 SAC 103 201 H 0201
39

Safety combinations series are also used here. Control systems up to Category 4 according to EN 954-1 can be configured.
Expansion units
Expansion units may not be used separately in safety circuits, and they must be combined with a basic C 57x and 581 safety combination unit. An enabling contact of the basic unit is required to connect an expansion unit. The category of a control system with expansion unit corresponds to the category of the basic unit.
Presses and punches

The two-hand control device is a device where both hands of the operator must be simultaneously used. This protects the operator from hazards. The overtravel tester is used for linear-driven presses and punches in accordance with VBG 7n5.2. It only checks once at the test stroke that the operator control elements have been correctly connected for external cable interruptions and breaks if the components which are cyclically monitored, have failed. The overtravel tester can only be used in conjunction with a two-hand control device. The press control devices and overtravel testers are suitable for installation in control system for eccentric, hydraulic and spindle presses. They can be used up to Category 4 in accordance with EN 954-1. Type III C according EN 574 can be especially used for presses.
40
1 SAC 103 201 H 0201
Type series C 57x

EMERGENCY OFF control gear and safety door watchdog C 570
1-channel protective circuit Feedback cycle for monitoring external contactors LED indication for mains and operations Output: 4 NO and 2 NC positively driven Overall width: 75 mm Made up of contactor relays, switching capacity AC-1/AC-12: GA
Control voltage Uc 24 V AC 110 V AC 230 V AC 24 V DC Order number 1 1 1 1 SAR SAR SAR SAR 501 501 501 501 042 042 042 042 R R R R 0002 0004 0005 0003 Weight per item 0.960 0.960 0.960 0.960 kg kg kg kg
Type C 570
10
L+ X1 X3 X5 13NO 23NO 33NO 43NO 57NO 65NO terminal assignment C 570
2 x (1 ... 2,5 mm2) 1 x 4 mm2
L X2 X4 X6 14NO 24NO 34NO 44NO 58NO 69NO
Ein On
2 x (0,75 ... 1,5 mm2)

Bereit Ready
release 13 23 33 43
INDICATION 57 65
0,8 x 5 ... 6 mm
0,8 ... 1,2 Nm/7 ... 11 lb.in
14 24 34 44
58 66

1- or 2-channel protective circuit Automatic start/Monitored start 24 V DC at EMERGENCY OFF pushbutton or position switch Crossfault detection at the EMERGENCY OFF pushbutton or position switch Feedback cycle for monitoring external contactors LED indication for mains, channel 1 and 2 Output: 3 NO and 2 NC positively driven Overall width: 45 mm
Control voltage Uc 24 V AC 110 V AC 230 V AC 24 V DC Order number 1 1 1 1 SAR SAR SAR SAR 501 501 501 501 032 032 032 032 R R R R 0002 0004 0005 0003 Weight per item 0.360 0.450 0.450 0.360 kg kg kg kg
Type C 572
1SAR 390 000 R2000
13 23 33
41 51
14 24 34
42 52
M 3,5
10
0,8 ... 1,2 Nm 7 ... 11 lb.in 1 x (0,5 ... 4,0) mm2 2 x (0,5 ... 2,5) mm2 1 x (0,5 ... 2,5) mm2 2 x (0,5 ... 1,5) mm2 2 x 20 to 14
10
+ Attachment
1 SAC 103 201 H 0201
AWG
41
Type series C 57x

1- or 2-channel protective circuit Automatic start/Monitored start Operational voltage UC at the EMERGENCY OFF pushbutton or position switch Feedback cycle for monitoring external contactors LED indication for mains, Channel 1 and 2 Output: 2 S positively driven Overall width: 22.5 mm
Control voltage Uc 24 V AC/DC Order number 1 SAR 501 020 R 0001 Weight per item 0.240 kg
Type C 571

1- or 2-channel protective circuit Operational voltage Ue at the EMERGENCY OFF pushbutton or position switch Feedback cycle for monitoring external contactors LED indication for mains, Channel 1 and 2 Output: 3 NO, 1 NC positively driven Overall width: 22.5 mm
Control voltage Uc 24 V AC(DC Order number 1 SAR 501 031 R 0001 Weight per item 0,240 kg
Type C 573
1SAR 390 000 R2000
13 23 33
41
14 24 34
42
M 3,5
10
10
+ Attachment
AWG
42
1 SAC 103 201 H 0201
Type series C 57x

EMERGENCY OFF control gear and safety door watchdog with time delay C 574
1- or 2-channel protective circuit Feedback cycle for monitoring external contactors LED indication for mains, Channel 1/2, delayed Channel 1/2 Output: 2 NO, 1 NC time delayed Overall width: 45 mm
... Monitored start ... Release time tv 0.5 to 30 s infinitely adjustable

Type C 574 Control voltage Uc 124 110 230 124 V V V V AC AC AC DC Order number 1 1 1 1 SAR SAR SAR SAR 503 503 503 503 041 041 041 041 R R R R 0002 0004 0005 0003 Weight per item 0.450 0.450 0.450 0.450 kg kg kg kg
Automatic start Release time tv 0.5 to 30 s infinitely adjustable

C 574 124 110 230 124 V V V V AC AC AC DC 1 1 1 1 SAR SAR SAR SAR 503 503 503 503 141 141 141 141 R R R R 0002 0004 0005 0003 0.430 0.600 0.600 0.430 kg kg kg kg
Monitored start Release time tv 0.05 to 30 s infinitely adjustable

Automatic start Release time tv 0.05 to 30 s infinitely adjustable

1SAR 390 000 R2000
13 23 31
47 57
14 24 32
48 58
3 1
4
M 3,5
10
10
1SAR 390 000 R1000 AWG
+ Attachment and cover plate

1 SAC 103 201 H 0201
43
Type series C 57x

Automatic start Crossfault detection at the EMERGENCY OFF pushbutton or position switch 24 V DC at the EMERGENCY OFF pushbutton 2-channel protective circuit Feedback cycle for monitoring external contactors LED indication for mains, Channel 1, Channel 2 and mains Output: 2 NO positively driven Overall width: 22.5 mm
Type C 576

Monitored start Crossfault detection at the EMERGENCY OFF pushbutton or position switch 24 V DC at the EMERGENCY OFF pushbutton 2-channel protective circuit Feedback cycle for monitoring external contactors LED indication for mains, Channel 1, Channel 2 and mains Output: 2 NO positively driven Overall width: 22.5 mm
Type C 577
1SAR 390 000 R2000
13 23
14 24
M 3,5
10
10
+ Attachment
AWG
44
1 SAC 103 201 H 0201
Type series C 57x

Two-hand control C 575
For switching on presses (e.g. in conjunction with follow-up testing device C 578 24 V DC at the two-hand switches Feedback cycle for monitoring external contactors 5 LED output indicators for mains, S1 ON, S1 OFF, S2 ON, S2 OFF Simultaneity monitoring: 0.5 s Output: 2 NO, 2 NC positively driven Overall width: 45 mm
Control voltage Uc 124 110 230 124 V V V V AC AC AC DC Order number 1 1 1 1 SAR SAR SAR SAR 504 504 504 504 022 022 022 022 R R R R 0002 0004 0005 0003 Weight per item 0.350 0.350 0.350 0.350 kg kg kg kg
Type C 575
13 23
1SAR 390 000 R2000
31 41
14 24
32 42
M 3,5
10
10
+ Attachment
AWG
Dribbling inspection and test equipment C 578

Crossfault detection at the EMERGENCY OFF pushbutton or position switch 24 V DC at the EMERGENCY OFF pushbutton Feedback cycle for monitoring external contactors LED indication for mains and release Output: 3 NO, 1 NC positively driven Controlled start Overall width: 45 mm
Control voltage Uc 124 110 230 124 V V V V AC AC AC DC Order number 1 1 1 1 SAR SAR SAR SAR 505 505 505 505 031 031 031 031 R R R R 0002 0004 0005 0003 Weight per item 0.450 0.450 0.450 0.450 kg kg kg kg
Type C 578
13 23 33 41
1SAR 390 000 R2000
14 24 34 42
M 3,5
10
10
+ Attachment
1 SAC 103 201 H 0201
AWG
45
Series C 57x und C 580

Extension device for extending the contact extension of the safety control device C 579
Release contact of the basic device is required to connect to the extension device LED displays for mains, Channel 1 and 2 4 NO positively driven Overall width: 22.5 mm
Type C 579
1SAR 390 000 R2000
13 23 33 43
14 24 34 44
M 3,5
10
10
+ Attachment
AWG
Relay for monitoring underspeeds C 580

Monitoring underspeed, stoppage, tripping or transport errors Speed pick up via three-core or NAMUR detecting element, contact or voltage Delay adjustable from 100 ms to 10 min in four time ranges On delay adjustable from 0.3 to 30 s LED indication of the voltage supply and the relay output
Supply voltage Uc 124 110 230 124 V V V V AC AC AC DC Order number 1 1 1 1 SAR SAR SAR SAR 480 480 480 480 010 010 010 010 R R R R 0002 0004 0005 0001 Weight per item 0.255 0.255 0.255 0.255 kg kg kg kg
Type C 580
min. 200 ms
U Hysteresis Displayed speed S2 Hysteresis Displayed speed Output relay Output relay
Blocking state delay
Without locking
With locking
46
1 SAC 103 201 H 0201
Technical data/Certifications

Technical data
Type 1-channel connection 2-channel connection Crossfault safety Test certificates Safety category to EN 954-1 Mechanical service life Rated insulation voltage Ui Fouling factor 3 Overvoltage category III to DIN VDE 0110 Rated impulse withstand voltage Uimp Fouling factor 3 Permissible ambient temperature for operations for storage Protection rating to EN 60 529 Protection against electric shock to VDE 0106 Rated power DC/AC confirmation at 1,0 x Us Working range AC-activation DC-activation Switching rate Shock resistance Rectangular impulse: Sinusoidal impulse: Short circuit protection (weld-free joggle at Ik = 1 kA) Fuse links for release/ signalling contacts: Operating classes: Wire ranges Fine-wired with wire end ferrules Single-cored Tightening torque Clamping piece M 3.5 Electrical service life for Ie Rated operational current to IEC 60 947-5-1 Thermal continuous current Ith I/AC-15 I/DC-13 C 570 x (x) 1) BIA, SUVA 2, (3) 1), (4) 1) 3 million switching cycles 250 V control circuit 400 V output contacts 3, (4)1) 4 3, (4) 1) C 571 x x (x) 1) C 572 x x x C 573 x x (x) 1) C 574 x x x 4, (3) 2) C 575 x x x 4 300 V C 756 x x x 4 C577 x x x 4 C 578 x 4 C 579 x x 4 BG, SUVA3, UL3, CSA3 10 million switching cycles
1.5 kV control circuit 4 kV output contacts 25 to + 55 C 25 to + 80 C IP 20 safe from finger touch 6W 0.8 to 1.1 x Us 0.8 to 1.1 x Us 500/h for AC-15 and DC-13 10/5 and 6/10 g/ms 13/5 and 8/10 g/ms
5)
4 kV
25 to + 60 C (suitable for side by side construction) 40 to + 80C IP 20 4) IP 20 IP 20 4) IP 20 IP 20 IP 20 4) IP 20 4) IP 20 IP 20 4)
safe from finger touch 1.5 W 3W 1.5 W 4W 3W 1.5 W 1.5 W 4W 1.5 W
0.85 to 1.1 x Us 0.85 to 1.1 x Us 1 000/h for load with Ie 8 g / 10 ms half sinus to IEC 60 068
NH, NEOZED, DIAZED gL7gG 2x (0.5 1.5) mm2 or 2x (0.5 2.5) mm2 2x (0.5 2.5) mm2 or 2x (0.5 4.0) mm2 0.8 to 1.2 Nm
NH Type 3 NA, DIAZED Type 5 SB, NEOZED Type 5 SE 6 A gL7gG
100,000 switching cycles
6A up to230 V / 4 A
5A 115 V / 5 A 230 V / 5 A 24 V / 2 A 115 V / 0,2 A 230 V / 0,1 A enable circuits: UT 70 C UT 60 C UT 50 C 2 FK 4.0 A 4.5 A 5.0 A 45 3 FK 3.5 A 4.5 A 4.5 A 22.5 4 FK 3.5 A 3.5 A 4.0 A 22.5 45 22.5
Thermal continuous current Ith at:
Permissible normal position Device width in mm

1) Possible with additional external measures. The figures in brackets only apply if the cables and sensors are securely laid and mechanically protected. See also operating instructions. 2) Only applies for undelayed contacts, Category 3 applies for time delayed contacts. 3) Applied for. 4) IP 20 terminals, IP 40 enclosure 5) Fusing supply: C 570: G-fuse flink/carrier, circuit breaker A, B, C-characteristics
any 75 22.5 45 22.5 45
Certifications
Committee Professional Employers Insurance Association BG, Electronics Committee TV Rhineland SA Sweden UL CSA BA Suva C 570 C 571 C 572 C 573 C 574 C 575 C 576 C 577 C 578 C 579
yes yes yes yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
Granted Applied for
1 SAC 103 201 H 0201
47
Selection tables/Accessories

Selection table according to the risk category (EN 954-1)
Category B 1 2 3 4 x x x 1) x x x x 1) x x x x x x x x 1) x x x x 2) x x x x x x x x x x C 570 C 571 C 572 C 573 C 574 C 575 C 576 C 577 C 578 C 579
1) Possible with additional external measures. 2) Only applies for undelayed categories. Category 3 applies for delayed contacts.
Selection table according to device properties

Properties EMERGENCY OFF Safety doors Mats Two-hand operation e.g. pressing Feedback cycle for monitoring external contactors Single-channel Two-channel Crossfault monitoring 24 V DC at the EMERGENCY OFF position switch Operational voltage at the EMERGENCY position switch Number of release contacts Number of time-delayed release contacts Number of signalling contacts Overall width in mm Check dribbling e.g. pressing Automatic start Controlled start
Contact extension 4) 2 semi-conductor A
C 570 yes yes
C 571 yes yes
C 572 yes yes
C 573 yes yes
C 574 yes yes
C 575 yes
C 576 yes yes
C 577 yes yes
C 578
C 579
yes yes yes 4 2 75 yes
yes yes yes yes 2 22.5 yes
yes yes yes yes yes 3 2 45 yes yes
yes yes yes yes 3 1 4) 22.5 yes
yes yes yes yes 2 1 2 45 yes
yes yes yes 2 2 45
yes 45 yes
4 22.2
Accessories
Cover plate sealable
Type Function Order number Packaging unit each 5 sets
C 560.10
For securing against unauthorised adjustments
1 SAR 390 000 R 1000
Attachment for screw fixing

Type Function Order number Packaging unit each 5 sets each with 2 items
C 560.20
Assembly of the safety relay C 571 C 579 without top DIN-rail assembly panel
1 SAR 390 000 R 2000
48
1 SAC 103 201 H 0201
Dimension drawings

C 570
75 55
148
EIN ON
4,8
96,6 110
77,2
35
Bereit Ready
M3,5
C 571, C 573, C 576, C 577, C 579

22,5 15 28,5 26,2
110 120
73,5
102
120
100
82 62
80
1 SAC 103 201 H 0201
49
Dimension drawings

C 572, C 574, C 575, C 578
7,2 (5x)
118,5
138,5
86,4
63,2
36,8 45
90,9 120
C 580
23 77
3,5 45 100
50
78,5
57
1 SAC 103 201 H 0201
81,1
104,2
148
102
Series C 67xx

Series C 67xx electronic safety relay
Monitoring device for connected sensors (e.g. position switch, EMERGENCY OFF pushbutton) and actuators (positively driven standard small contactors) electronic selection of the actuators, therefore no wear Sensors supplied with 24 V DC no contact failure for currents up to 17 V, 1 mA short circuit save High operating frequency Small overall width, overall depth / low weight
Basic device C 6700

without own safe outputs in conjunction with positively driven actuators: max. category 3 to EN 954-1 Overall width 22.5 mm Us = 24 V DC Ue = 24 V DC Ie = 0.5 A DC 13
Safety device C 6701

with electronic outputs direct switching off of consumers possible: up to Category 3 or 4 to EN 954-1 Overall width 22.5 mm Us = 24 V DC Ue = 24 V DC Ie = 1.5 A DC 13
Safety device C 6702

with electronic outputs direct switching off of consumers possible: up to Category 3 to EN 954-1 Stop categories 0 and 1 Adjustable time delay 0.05 3 s or 0.5 30 s Overall width 22.5 mm Us = 24 V DC Ue = 24 V DC Ie = 1.5 A DC 13
1 SAC 103 201 H 0201
51
Series C 67xx

Selection table according to device properties / order data
Type Order No. Automatic start Monitored start Single-channel Two-channel EMERGENCY OFF Safety door Release contact potential free stop-Cat. 0 Release contact potential free stop-Cat. 1 Release contact electronic stop-Cat. 0 Release contact electronic stop-Cat. 1 Enclosure width in mm Signalling contacts Achievable category to EN 954-1 B 1 2 3 4 C 6700 1 SAR 510 120 R 0003 yes yes yes yes yes 2 1) 22.5 yes yes yes yes 24 V DC
1) 2)
C 6701 1 SAR 511 320 R 0003 yes yes yes yes yes yes 2 22.5
2)
C 6702 1 SAR 543 320 R 0003 yes yes yes yes yes yes 1 1, tv = 0.05 3 s 22.5 yes yes yes yes yes 24 V DC
C 6702 1 SAR 513 320 R 0003 yes yes yes yes yes yes 1 1, tv = 0.05 30 s 22.5 yes yes yes yes yes 24 V DC
yes yes yes yes yes 24 V DC
Rated control feed voltage Us
Outputs are only safe in conjunction with external contactors Release contact can be used as signalling contact.
52
1 SAC 103 201 H 0201
Terminology

EMERGENCY OFF device
EN 60204 Part 1 specifies that when a hazardous situation occurs, a machine must be stopped as quickly as possible using EMERGENCY OFF. According to EN 60204-1, stop Categories 0 and 1 are permitted. There are 2 ways to fulfill these requirements:
Positively-driven contacts
Contacts are positively-driven, if all of the contacts of a switchgear device are connected with one another, so that the NC contact and NO contact cannot close simultaneously. Further, it must also be guaranteed, that over the complete lifetime of the switching device, that there is a least 0.5 mm contact clearance even when the device is in the faulted condition.
Ground-fault detection
Directly using an EMERGENCY OFF switch Using a arrangement of control circuits which allows all of the appropriate main circuits to be reliably and safely disconnected with one single command. The device identifies a connection between the sensor cable and ground potential and it goes into a safe condition. The device becomes operational again after the fault has been removed.
Diversity Protective door monitoring

Protective equipment is used to ensure the safety of operating personnel. If protective equipment is removed or opened, then all movements which cause these hazards must be permanently and effectively stopped. The machine can only be entered after it has come to a complete final stop. In order to minimize the probability that faults and failures can result in hazardous conditions, diversity is required. This is either achieved using different functional principles or by using different devices. In safety circuits, this is achieved by combining NC and NO contacts.
Enabling contacts Redundancy

Redundancy is present if there are more control- or drive lines than actually required to fulfill a specific function. Using redundancy, it is possible to reduce the probability that a single fault in an electrical circuit will result in a hazardous condition. For safety-related circuits, for reasons of redundancy, at least 2 switching devices than are required (input circuit/sensor control and load circuit/actuators). Enabling contacts are safety contacts, which are always realized as NO contacts. This means that if the safety combination is in the ON condition, the enabling contacts must be closed. Enabling contacts may also be used for signaling.
Signaling contacts
Signaling contacts can either be realized as NC contact or as NO contact. However, it is not permissible that they are used for enabling circuits.
Two-channel configuration
EN 60204 does not expressly specify two-channel configurations. The Standard states that the Category, according to EN 954-1, must be defined using a risk analysis. A two-channel EMERGENCY OFF circuit is used in environments with a high degree of dirt accumulation.
Ready ON
ON button Ready ON are used to enable safety combinations. After the main switch (circuit-breaker) of the machine has been closed or the safety combination has been initiated, the ON button Ready ON must be actuated, so that the safety combination is enabled.
Cross-circuit safety/ cross-circuit identification

With a two-channel control configuration, a device can identify a cross-circuit or a connection between the two externally operated control elements (e.g. EMERGENCY OFF or limit switch). If a cross-circuit occurs due to a damaged connecting cable, then the device goes into the safe initial condition.
The cross-circuit identification is realized using different potentials in the momentary-contact circuit.
1 SAC 103 201 H 0201
53
Terminology

Automatic start
In this case, the connecting terminals of the safety combination for the ON button Ready ON are jumpered. The safety combination automatically enables itself, as soon as the shutdown condition has been removed (e.g. after the protective door is re-closed). This circuit is not permissible for EMERGENCY OFF circuits and for door monitoring functions, even if a hazardous condition cannot occur.
Cable lengths
In a machine or a system, generally several sensors, such as EMERGENCY OFF switches and position switches are used to monitor protective doors. Depending on the complexity of the machine or system, long cables may be required to connect-up the sensor systems. In order that the safety combinations operate errorfree, it must be ensured that certain cable lengths are not exceeded.
The permissible cable length is dependent on 3 factors.

I = RL A S
RL RL
RL =
U Ri I K min
1. Short-circuit shutdown
When a short-circuit occurs between the sensor cables or a short-circuit in the device, the safety combination must safely shut down and the device may not be damaged.
Y11 F A1 I K min
Y12
Y21
Y22 I RL A S U I K min Ri R Sp permissible cable length Cable resistance cable cross-section conductivity of the cable rated supply voltage minimum short-circuit current input resistance of the unit coil resistance of the relay
2. Safety switch-on
The voltage available at the relay coils within the unit must be high enough, so that the response voltage is reliably reached. If this is not the case, then the safety combination cannot go into safe operation. The safe condition is not jeopardized, however it is not possible to operate the plant or system.
R Sp Ri A2
R Sp
Cross-circuit shutdown
I = RL A S
RL RL
3. Safety shutdown
The voltage at the relay coils inside the unit must be low enough so that the drop-out voltage is safely fallen below. This is especially important for AC operation, where although the sensors are shut down, sufficient current can flow as a result of cable capacitances so that the relay cannot drop-out. For this reason, for relay-type safety combinations, the sensor cables are always fed with DC.
RL =
Y11 F A1 I RL A S U UA Ri R Sp Y12 Y21 Y22
U R Sp R Sp R i UAb
R Sp Ri A2
R Sp
permissible cable length Cable resistance cable cross-section conductivity of the cable rated supply voltage response voltage input resistance of the unit coil resistance of the relay
Safety switch-on
CL =
CL Y11 F A1 I RL U UAb Ri R Sp CL Y12 Y21 CL Y22
I RL
RL =
U R Sp Ri UAb
R Sp Ri A2 Safety shutdown
R Sp
permissible cable length Cable resistance rated supply voltage drop-out voltage input resistance of the unit coil resistance of the relay cable capacitance
54
1 SAC 103 201 H 0201
Terminology

The following calculation uses as an example the C 577 relay Assumed values: Cable: 2 x 2,5 mm2, Voltage drop: 5 % Specific conductivity for Cu: 49,3 Sm/mm2 (bei 55 C), Cable capacitance: 170 nF/km 22,8 V 22 = 19,5 0,55 A Sm = 2 403 m mm2
1. Cross-circuit shutdown
RL =
I = 19,5 2,5 mm2 49,3
2. Safety switch-on
RL =
22,8 V 400 400 22 = 25 20,4 V Sm = 3 081 m mm2
I = 25 2,5 mm2 49,3 1 RL
3. Safety shutdown
CL =
Da bei 24 V DC die Frequenz f = 0 Hz ist, ergibt sich fr CL = Result To determine the single cable length, the lowest value of the 3 possibilities shown above, should be used. In this case it involves an outgoing and incoming cable. The maximum single cable length for this particular example is l=
Example to calculate the cable length
2 403 m = 1 200 m 2
U [V]
Cross-circuit
0,75 mm 2 1,5 mm 2 2,5 mm 2 0,75 mm 2
Switch-on
1,5 mm 2 2,5 mm 2
27
24 Only for C 571 and C 573, AC operated
170 nF 21
150 nF
130 nF
Shutdown
2 4 6 8 10 12 L [km]
Possible single cable lengths for sensors C 571/C 572/C 573/C 574/C 575/C 576/C 577/C 578
1 SAC 103 201 H 0201
55
Terminology

C 570 1. Limiting using a fuse to interrupt the short-circuit (VDE 0636) Maximum permissible single cable length for 5s shutdown time for the equipment fuse F1 for short-circuit protection DC 224 V AC 224 V AC 110 V AC 230 V 158 158 747 1 569 m m m m Distance
2. Limiting to guarantee safety switch-on of the units Maximum permissible single cable length due to the ohmic voltage drop (distance) DC 224 V AC 224 V AC 110 V AC 230 V 296 m 296 m 6 214 m 27 166 m
3. Limiting to guarantee safety shutdown of the units Maximum permissible single cable length due to the cable capacitance (distance) DC 224 V AC 224 V AC 110 V AC 230 V infinity 32 287 m 1 470 m 262 m
4. Combination of Points 1 to 3 Permissible single cable length (distance) DC 224 V AC 224 V AC 110 V AC 230 V 158 158 747 262 m m m m
Maximum permissible cable lengths for contactor safety combinations

The following data is assumend when calculating the cable lengths: Voltage drop 5% Copper cable, 2 x 2,5 mm2 with K = 49,3 ( mmm2) Capacitance 170 nF/km Line supply frequency 50 Hz (this is only relevant for AC-operated units) external to the block 2 A gL fuse outside the block (the required shortcircuit curent, which causes the fuse to rupture at the latest after 5 s, is 9 A) Series impedance 0.1 W (control transformer, feeder cable etc.). (at 55C)
56
1 SAC 103 201 H 0201
Circuit examples
1 SAC 103 201 H 0201
57
Switch safely
Circuit examples
The following circuit examples have been harmonized with the German Trade Association (BG) and have been approved. Contactor circuits Safety combinations using contactors using safety relays Suitable for: EMERGENCY OFF Protective door monitoring functions Press controls
EMERGENCY OFF circuits for extremely simple machines

EMERGENCY OFF switch The EMERGENCY OFF function may only be fed through an EMERGENCY OFF switch for extremely simple machines, depending on the result of a risk analysis. In this particular case, only Stop Category 0 is possible. Such an EMERGENCY OFF switch switches, contrary to usual EMERGENCY OFF pushbuttons, the main circuit (circuit diagram 1). An EMERGENCY OFF switch must be configured, so that There is only one EMERGENCY OFF switch;
Manual drive mechanism
To loads, which must be shutdown for an EMERGENCY OFF EMERGENCY OFF switch
Switch lock Release Mushroomhead pushbutton
the EMERGENCY OFF switch is located in the supply to those circuits which can result in hazardous motion in the system. The complete power suply to all of the circuits does not have to be interrupted; the EMERGENCY OFF switch must be able to interrupt the current of the largest motor when the motor stalls; the sum of the currents of all of the loads which must be disconnected using the EMERGENCY OFF switch must be able to be safely interrupted. An EMERGENCY OFF switch may be manually actuated; act on an undervoltage release via one or several EMERGENCY OFF control devices (circuit diagram 1); be provided with overload- and/or short-circuit releases (version as circuit-breaker); be simultaneously used as main switch, if it additionally fulfills the requirements for a main switch (however, a main switch must disconnect all circuits). An example for such an EMERGENCY OFF switch for extremely simple machines is illustrated in circuit diagram 2.
To loads, which dont have to be/may not be disconnected for EMERGENCY OFF
U<
Main switch
EMERGENCY OFF control device
Supply Circuit diagram 1: EMERGENCY OFF switch with manual actuation or remote actuation via undervoltage release
EMERGENCY OFF switcher
Control
To loads, which dont have to be/may not be disconnected for EMERGENCY OFF Main switch
Off
Off
On
K1
On
K2
K1
K2
Supply
e. g. plant protective conductor
To loads, which must be shutdown for an EMERGENCY OFF
Circuit diagram 2: Example of a machine control with EMERGENCY OFF switch (this is only permissible with some restrictions)
58
1 SAC 103 201 H 0201
Switch safely
Circuit examples
To loads, which dont have to be/may not be disconnected for EMERGENCY OFF
EMERGENCY OFF contactor Generally, a so-called EMERGENCY OFF contactor is not permitted. Such a contactor is only permissible in precisely defined exceptional cases: This contactor may only be used as an EMERGENCY-STOP contactor in the branch to be shutdown. Additional contactors in series are not permitted. This means that this concept is restricted for applications on extremely simple machines (refer to circuit diagram 3). An EMERGENCY OFF contactor must be configured, so that
Main switch EMERGENCY OFF control device located in the control circuit
Supply
To loads, which must be shutdown for an EMERGENCY OFF
each EMERGENCY OFF contactor must be immediately de-energized by the EMERGENCY OFF control device; there are no additional contactors in series.
Circuit diagram 3: Example of a machine control with 2 EMERGENCY OFF contactors, only permitted with some restrictions
Safety circuits using individual contactors

L1 F1 Enable signals
EMERGENCY OFF device, if required several in series Actuator Onor On after EMERGENCY OFF
K1
Configured using two auxiliary contactors Safety circuits of any complexity can be configured using auxiliary contactors. Up to several years ago, the circuit with two auxiliary contactors and overlapping auxiliary contacts (circuit diagram 4) was considered to be state-of-the-art. This circuit offers redundancy. However, due to the fact that the contacts are not positively driven, the two auxiliary contactors do not mutually monitor each other for correct functioning. This means, that if a contact welds, this fault is not detected and the circuit still continues to function. A subsequent fault in the second contactor could completely disable the combination. This would mean that the level of safety would no longer be guaranteed. Thus, today, this circuit is no longer used (circuit diagram 4). Using three auxiliary contactors Today, circuits with three auxiliary contactors represent state-of-the-art technology. Three auxiliary contactors, with positively-driven contacts are used, as shown in circuit diagram 5. The three auxiliary contactors guarantee redundancy and function monitoring. The positively-driven contacts guarantee that the auxiliary contactors mutually monitor themselves. Faults are therefore detected and the circuit can not longer be closed after shutdown, therefore eliminating subsequent faults. With this circuit, using todays state-of-the-art technology, it can be assumed that if the auxiliary contactors incorrectly function this will not result in a hazardous status in the system.
K2 K1 K2 K1 K2 no positively-drives contacts no self-monitoring
K1 N
K2 This circuit is no longer used.
Circuit diagram 4: This contactor combination consists of two auxiliary contactors with overlapping contacts
L+/L1
F1 EMERGENCY OFF device, if required several
Enable signals
K1 K1 K3 K2
Actuator On or control voltage On K2 K3 K1
K2 K3 K1 K3
K1 L/ N
K2
K3
Circuit diagram 5: Contactor combination using three auxiliary contactors with self-monitoring, single-channel
1 SAC 103 201 H 0201
59
Switch safely
Circuit examples
Connecting several EMERGENCY OFF control devices
In the previous circuit diagrams, only one EMERGENCY OFF device was shown. Generally, there are several EMERGENCY OFF control devices (e.g. at different locations) on a machine. The contacts of these EMERGENCY OFF control devices are then connected in series. Several auxiliary contactors are combined to form a safety circuit in the form of the C 57x contactor safety combinations. Naturally, the circuits can also be implemented using individual contactors.
Circuit examples to monitor protective devices

Circuits to monitor protective devices use position switches. Various possibilities of the different devices are shown in the examples for EMERGENCY OFF. These circuit examples will not be repeated here as the EMERGENCY OFF control device is only replaced by one or two position switches per protective device.
Classification in Categories according to EN 954-1

The classification of circuits into categories according to EN 954-1 has now been made clear using the previous examples. The classification below, is valid when the wiring is correctly realized according to the published circuit diagrams, also under difficult ambient conditions, for example dirty industrial environments (pollution level 3). If special care is taken connecting-up the wiring, it may be possible to achieve a higher safety category, e.g. using separate cables or routing the cable to EMERGENCY OFF contacts and position switches so that it is mechanically protected (e.g. in special cable ducts). Thus, Category 4 can be achieved without having a cross-circuit proof configuration, under the assumption, that the appropriate peripheral devices are used. The internal circuit diagrams are valid for DC-operated devices. The AC-operated combinations essentially correspond to those for DC operation. Only the polarity protection diode V1 is eliminated and a bridge rectifier is located in front of every contactor. This mean that AC-operated contactor safety combinations can also be used for DC voltages with some restrictions.
Single-channel
Two-channel
Circuit diagram 6: Several EMERGENCY OFF control devices
Doors
Open
Closed
Closed Open
Circuit diagram 7: position switches used to monitor moving protective equipment
Category acc. to EN 954-1 B, 1, 2 3 4
Circuit version Single channel Two channel Two channel and cross-circuit proof
Possible equipment Possible with all basic- and expansion devices C 571 C 575 also in conjunction with one or several expansion units C 572/C 574/C 575 also in conjunction with one or several expansion units.
60
1 SAC 103 201 H 0201
Safety contactor combinations C 57x
Circuit examples
L1/L+ N /L Enable Signal Signal transmitter Ready ON
Immediately ready after the power returns (it is not necessary to open and close the protective device): The Ready ON is not required (jumper X5X6), if the resulting automatic reclosure (restart) does not represent potential danger.
F1
Door Open Closed
(X2) (X3) (X4) X5 (X6) 13
L1/ L +
X1
C 570
K1 K2 K3 N / L X2 X4 X6 14
Circuit diagram 8: Contactor safety combination C 570 to monitor moving protective devices.
L1/L+ N /L Enable Signal Signal transmitter EMERGENCY OFF 13 23 33 43 57 65 Ready ON
F1
L1/ L +
X1
(X2)
(X3) (X4)
X5
(X6) K3 K1
C 570
K2
N / L
X2
X4
X6
14 24 34 44 58 66
Circuit diagram 9: Contactor safety combination C 570 for an EMERGENCY OFF circuit.
L+ V1 U R3 K1 K2 K3 R2 H2 K3 K1 K1 X1 X2 X3 X4
X5 X6
13 23 33 43
57 65 Enabling contacts Signaling contacts Signal transmitter Ready ON Ready LED ON LED
C 570
K3 K2 K1 K3 R1 K1
K2
K1 L
K2
K3
H1
14 24 34 44
58 66
Circuit diagram 10: Internal circuit diagram of a C 570 contactor safety combination (DC operation)
1 SAC 103 201 H 0201
61
Relay safety combinations C 57x
Circuit examples
Y 33 Y 34 A1 K1 K1 C1 K1 K2 K2 K2 V1 K2 A2 Y 11 Circuit diagram 11: Internal circuit diagram of the C 573 Y 12 14 24 K1 K2 K1 Y 22 Y21 13 23
C 577
A1/A2 Y33/34 Y11/12 Y21/12 13/14 23/24
power supply ready ON Feedback circuit sensor (e.g. EMERGENCY OFF pushbutton) sensor (e.g. EMERGENCY OFF pushbutton, tow-channel) enable circuit enable circuit POWER LED Channel 1 LED Channel 2 LED PTC fuse
Function description Power-on Connect the power, the Power LED is lit, EMERGENCY OFF closed, C1 is charged, press ON, C1 is charged, K1, V1 are energized, K2 starts, K1 + K2 latch, Channel 1 and Channel 2 LEDs are lit. ON monitoring ON is pressed fault! EMERGENCY OFF closed, V1 immediately start K2, C1 is not charged K1 does not start. Only the Channel 2 LED is lit Cross-circuit If EMERGENCY OFF 1 and EMERGENCY OFF 2 are shortcircuited, a short-circuit current flows through the PTC fuse.
Y 33 Y 34 A1 K1 K1
Y22 Y21
13 23
C 577
K2 K1 C1 K1 K2 K2 K2 V1 K2 K1
A2 Circuit diagram 12: Internal circuit diagram of the C 577
Y2 A1 K1
Y1
13 23
(33) (41) A1/A2 Y1/Y2 13/14 23/24 33/34 41/42 power supply via EMERGENCY OFF pushbutton ON feedback circuit enable circuit enable circuit enable circuit signaling circuit POWER LED Channel 1 LED Channel 2 LED PTC fuse
C 573
K1 K2 K2 K1 K2 K2 K1
A2 14 24 Circuit diagram 13: Function description C 577 (34) (42)
62
1 SAC 103 201 H 0201
Circuit examples
The following circuit diagrams have been harmonized with the German Trade Association (BG) and also approved.
EMERGENCY OFF (EMERGENCY-STOP) circuits

24 V AC/DC K1 K2 EMERGENCY OFF A1 K3 Y1 EIN Y2 13 23 (33) (41) K1 M
L/+
C 571/C 573
K2 M
A2
14 K1
24 K2
(34) (42) K3 H1 K3 M
Circuit diagram 14: C 571/C 573 for EMERGENCY OFF, Category 2, singlechannel, with feedback circuit
N/
N/
24 V AC/DC EMERGENCY OFF ON
L/+
A1
Y1 Y2
13
23 (33)
(41)
C 571/C 573
K1 K1 K2 K2 A2 14 K1 Circuit diagram 15: C 571/C 573 for EMERGENCY OFF, Category 3 (4), twochannel, with feedback circuit 24 (34) K2 (42) H1 M
N/
N/
24 V AC/DC K1 K2 EMERGENCY A1 Y11 Y12
L/+
ON Y33 Y34 13 23
C 577
K1 OFF K2 M Y11 Y12 A2 Circuit diagram 16: C 577 for EMERGENCY OFF, Category 4, two-channel, with feedback circuit, monitored start 14 K1 24 K2
N/
N/
1 SAC 103 201 H 0201
63
Circuit examples
L/+ L /+ ON A1 Y 10 Y 11 Y 12 Y 21 Y22 13 23 33 41 51
C 572
K1 K2 K3 EMERGENCY OFF Y 33 Y 34 Y 43 Y 44 PE A2 14 K1 PE N/ N/ 24 K2 34 K3 42 H1 52 H2 K1 M K2 M K3 M
Circuit diagram 17: C 572 EMERGENCY OFF, Category 2, single-channel, according to EN 954-1, monitored start
L/+
L /+ A1 Y 10 Y 11 Y 12 Y 21 Y22 13 23 33 41 51
ON
C 572
K1 K2 K2 EMERGENCY OFF Y 33 Y 34 Y 43 Y 44 PE A2 14 K1 PE N/ N/ 24 K2 34 42 H1 52 H2 M K1
Circuit diagram 18: C 572 EMERGENCY OFF, Category 4, two-channel, according EN 954-1, monitored start
L/+ L /+ A1 Y 10 Y 11 Y 12 Y 21 Y22 13 23 31 47 57
ON
C 574
K2 K1 K2 EMERGENCY OFF Y 33 Y 34 PE A2 14 24 32 H1 48 K1 58 K2 N/ PE N/ Circuit diagram 19: C 574 EMERGENCY OFF, Category 2, two-channel, according EN 954-1, monitored start K1
64
1 SAC 103 201 H 0201
Circuit examples
L /+ L /+ A1 Y 10 Y 11 Y 12 Y 21 Y 22 13 23 31 47 57 K1 K2 ON
C 574
K1 K2 EMERGENCY OFF Y 33 Y 34 PE A2 14 24 32 H1 PE N/ Circuit diagram 20: C 574 EMERGENCY OFF, Category 3, two-channel, according EN 954-1, monitored start 48 K1 58 K2 N/
L /+ L /+
EMERGENCY OFF
A1
Y 10
Y 11 Y 12 Y 21 Y 22
13
23
31
47
57 K1 K2
C 574
Y 33 Y 34 K1 ON K2 PE N/
PE
A2
14
24
32 H1
48 K1
58 K2 N/
Circuit diagram 21: C 574 with switch off in Stop-cat. 1, Category 3 acc. EN 954-1, two-channel, with feedback control loop, monitored start
24 V AC/DC K1 ON K5 A1 EMERGENCY OFF Y 11 Y 12 Y 33 Y 34 13 23 A1 13 23 33 43 51 L/+
C 577
Y 21 Y 22 A 2
14 K1 N/
24
C 579
14 K2
A2
24 K3
34 K4
44 K5
52
N /
Circuit diagram 22: C 577 expanded by C 579 for EMERGENCY OFF, Category 4. acc. to EN 954-1, two-channel, with feedback circuit
1 SAC 103 201 H 0201
65
Circuit examples
N/+ 24 V AC/DC ON
K1
A1
Y 10
Y 11 Y12 Y21 Y22
13
23
33
41
51
A1
13
23
33
43
51
C 572
K5
K6 EMERGENCY OFF Y 33 Y 34 PE A2 14 24 34 42 52 A2 14 24 34 44 52
PE N/
K1
K2
H1
H2
N/ N/ N/
C 579
K3
K4
K5
K6
Circuit diagram 23: C 572 expanded by C 579 for EMERGENCY OFF, Category 4 acc. to EN 954-1, two-channel, monitored start
N/+
24 V AC/DC ON
K1
A1
Y 10
Y 11 Y12 Y21 Y22
13
23
31
47
57
A1
13
23
33
43
51
C 574
K7 Y 33 Y 34 PE A2 14 24 32 48 58 A2 14 24 34 44 52
EMERGENCY OFF
PE N/
K1
K2
H1
K3
N/ N/ N/
C 579
K4
K5
K6
K7
Circuit diagram 24: C 574 expanded by C 579 for EMERGENCY OFF, Category 4 acc. to EN 954-1, two-channel, monitored start
66
1 SAC 103 201 H 0201
Circuit examples
Protective door monitoring
24 V AC/DC L/+ K1 K2 open closed K3 A1 open closed Y1 Y2 13 23 (33) (41)
C 571/C 573
K1 M K2 M K3 M
Circuit diagram 25: C 571/C 573 for protective door monitoring (2 protective doors are cascaded, each with 1 position switch), Category 2 acc. to EN 954-1, single-channel with feedback circuit, autostart
A2
14 K1
24 K2
(34) (42) K3 H1
N/ N/
open closed
24 V AC/DC
L/+
K1 K1 K2 M K3 open closed A1 Y1 Y2 13 23 (33) (41)
C 571/C 573
K2 M
Circuit diagram 26: C 571/C 573 for protective door monitoring with tumbler (2 protective doors are cascaded, each with 2 position switches with tumbler), Category 2 acc. to EN 954-1, single-channel with feedback circuit, autostart
A2
14 K1
24 K2
(34) (42) K3 H1 K3 M
N/ N/
1 SAC 103 201 H 0201
67
Circuit examples
24 V AC/DC L/+ K1 K2 A1 Y1 Y2 13 23 (33) (41)
C 571/C 573
open closed K1
K2 Circuit diagram 27: C 571/C 573 for protective door monitoring (2 protective doors are cascaded, each with 2 position switches), Category 3 (4) acc. to EN 954-1, two-channel with feedback circuit, autostart ( for Ca-tegory 4 the cable has to be routed so that it is especially protected) M A2 open closed N/ N/ 14 K1 24 K2 (34) (42) H1
24 V AC/DC
L/+
K1 K2 A1 Y11 Y12 Y33 Y34 13 23
C 576
open closed K1
K2 M Circuit diagram 28: C 576 for protective door monitoring (2 protective doors are cascaded, each with 1 position switch), Category 4 acc. to EN 954-1, two-channel with feedback circuit, autostart Y21 Y22 A2 14 K1 N/ N/ 24 K2
68
1 SAC 103 201 H 0201
Circuit examples
L/+ L /+ A 1 Y 10 Y 11 Y12 Y21 Y22 open closed K1 K1 K2 open closed K3 Y 33 Y 34 Y 43 Y44 PE PE N/ N/ Circuit diagram 29: C 572 for protective door monitoring (2 protective doors are cascaded, each with 1 position switch), autostart, Category 2 acc. to EN 954-1, single-channel, with feedback circuit A2 14 K1 24 K2 34 K3 42 H1 52 H2 M M M K2 K3 13 23 33 41 51
C 572
L/+
open closed
L /+ A 1 Y 10 Y 11 Y12 Y21 Y22 13 23 33 41 51 K1
K1
C 572
K2
K2 Y 33 Y 34 Y 43 Y44 PE PE N/ N/ Circuit diagram 30: C 572 for protective door monitoring with 2 position switches, autostart, Category 4 acc. to EN 954-1, two-channel, with feedback circuit A2 14 K1 24 K2 34 42 H1 52 H2 M
1 SAC 103 201 H 0201
69
Circuit examples
L/+ L /+ A 1 Y 10 ON open closed Y11 Y12 Y21 Y22 13 23 33 47 57
C 574
K1 K2
K1 open closed K2 Y 33 Y 34 PE A2 14 24 34 H1 48 K1 58 K2 M M
N/ PE N/ Circuit diagram 31: C 574 for protective door monitoring (2 protective doors are cascaded, each 1 position switch), stop Category 1, Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart
L/+
open closed
L /+ A 1 Y 10 Y 11 Y12 Y21 Y22 13 23 33 47 57 K1 K2
ON
C 574
K1 K2 Y 33 Y 34 PE A2 14 24 34 H1 48 K1 58 K2 M
N/ PE N/ Circuit diagram 32: C 574 for protective door monitoring with 2 position switches, stop Category 1, Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart
70
1 SAC 103 201 H 0201
Circuit examples
24 V AC/DC L/+
open closed K1
A 1 Y 10
Y 11 Y12 Y21 Y22
13
23
33
41
51
A1
13
23
33
43
51
C 572
K6 Y 33 Y 34 Y 43 Y44 PE A2 14 K1 PE N/ N/ 24 K2 34 42 H1 52 H2 N/ A2 14 K3 24 K4 34 K5 44 K6 52
Circuit diagram 33: C 572 expanded by C 579 for protective door monitoring with 2 position switches, Category 4 acc. to EN 954-1, two-channel, with feedback circuit, autostart
C 579
1 SAC 103 201 H 0201
71
Circuit examples
Press control devices
A1 Y 11 Y 12 Y 21 Y 22 Y 23 13 23 31 41 Operating voltage Outputs A1 A2 13, 14 23, 24 31, 32 41, 42 Y11, Y12 Y21, Y22, Y23 Y31, Y32, Y33 L/+ N/ Enable circuit 1 (NO contact) Enable circuit 2 (NO contact) NC contact NC contact Feedback circuit Pushbutton S1 Pushbutton S2
C 575
Inputs
14 24 32 42
Power supply unit PTC fuse Control logic Channel 1 Channel 2 Safety circuits
A2
Y 31 Y 32 Y 33
Circuit diagram 34: Internal circuit diagram of the C 575 two-hand control device
L /+ S1 K1 K2 A1 Y 11 Y 12 Y 21 Y 22 Y 23
L/+
13
23
31
41 S1, S2 buttons on the two-hand operating console H1 Signaling lamps K1, K2 must be contactors with positively-driven contacts K1
C 575
K2 M
A2
Y 31 Y 32 Y 33
14 K1
24 K2
32
42 H1
N /
S2
N/
Circuit diagram 35: C 575 two-hand control device, Category 4 acc. to EN 954-1
72
1 SAC 103 201 H 0201
Circuit examples
A1 Y 11 Y12 Y 13 Y 14 Y21 Y 22 13 23 33 41 Operating voltage Outputs A1 A2 13, 14 23, 24 33, 34 41, 42 Y11, Y12, Y13, Y14 Y21, Y22 Y31, Y32, Y33, Y34 L/+ N/ Enable circuit (tool down) NO contact (tool up) NO contact (overtravel OK) NC contact (hydraulic pump on) Feedback circuit (K4) Position switch (S4) for test cams Upper dead center, switch (S3)
C 578
Inputs
Power supply unit PTC fuse Control logic Safety circuits
A2
Y 31 Y 32 Y 33 Y 34
14 24 34 42
Circuit diagram 36: Internal circuit diagram of the C 578 overtravel tester
S0 L /+
L /+
S0
S1 K3 S4 K4 A 1 Y 11 Y 12 Y 21 Y 22 Y23 13 23 31 41 A1 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41 K4
C 575
C 578
K1
Main switch S1, S2 Button on the two-hand operating console S3 Positioning switch at the upper dead center S4 Position switch for test cams S5 Hydraulic pump ON S6 Tool UP (manual operating) K1 Contactor for the hydraulic pump K2 Tool UP K3, K4 Tool DOWN H1 Signal lamp
A2
Y 31 Y 32 Y 33 14 24 32 42
A2 Y31 Y32 Y33 Y34
14 24 34 42 S5
S3 S2 K4 N / N/ S6 K3 K2 H1 K1
Circuit diagram 37: C 575 two-hand control device in conjunction with a C 578 overtravel tester to monitor the overtravel in linear hydraulic-, pneumatic- and spindle presses acc. to VBG 7 n 5.2 11, Category 4 acc. to EN 954-1
1 SAC 103 201 H 0201
73
Circuit examples
Sequence after the press has been powered-up: 1. The hydraulic pump is powered-up with S5, the ram is moved up to upper dead center, if required, using S6. 2. Press S1, S2 at the two-hand operating console until the position switch for the test cams (S4) opens. 3. Release S1, S2 4. Depress S1, S2 again: Signal lamp H1 lights-up (bright), if the overtravel is OK. 5. Release S1, S2: The ram returns to the upper dead center. 6. If the overtravel is OK, all of the outputs remain active until the control voltage is disconnected. If the cam actuates position switch S4, then the signal lamp H1 is not lit-up. The machine part, which is potentially hazardous, can then only be moved to the upper dead center using S6. This press can then no longer be used. Contact the technician to check the press. A more detailed description of the function of the C 575 two-hand control divece is provided in the Instruction Manual, Order No. 1 SAC 105 798 S 4001.
LEDs Power Release Overtravel OK Overtravel erronous or test still not executed Operation
Fault situation
A US S 1, S 2 C 575 23/24 (K 4) S3 S4 S5 S6 C 578 13/14 (K 3) 23/24 (K 2) 33/34 (H 1) 41/42 K1 1 2 3 4 5 6 7
Overtravel OK 1 2 3 4 5 6 Power (US ) on. S5 is pressed, K1 pulls-in (latches). S6 is pressed, K2 pulls-in (the ram moves upwards in the manual mode). The upper dead center is reached, S3 is actuated. S6 is released, K2 drops-out. S1 and S2 are pressed on the two-hand operating console, the two-hand control device C 575 outputs an enable signal, K3 and K4 pull-in. The ram moves downward, S3 is no longer actuated. Test cams are reached, S4 is actuated, K3 drops-out. The ram remains stationary, S1, S2 are released, K4 drops-out. S1, S2 are pressed, K4 pulls-in again, H1 lights up. S1, S2 are released, K4 drops-out. K2 pulls-in, the ram moves upwards.. S4 is no longer actuated. Upper dead center is reached, S3 is actuated. S1 and S2 are pressed, K2 drops-out, K3 and K4 pull-in. The ram moves downwards, S3 is no longer actuated. S1, S2 are released, K3 and K4 open. K2 pulls-in. points 14 to 16 are repeated at each stroke of the press.
7 8 9 10 11 12 13 14 15 16
10 11 12 13 14 15 16
74
1 SAC 103 201 H 0201
Circuit examples
A US S 1, S 2 C 575 23/24 (K 4) S3 S4 S5 S6 C 578 13/14 (K 3) 23/24 (K 2) 33/34 (H 1) 41/42 K1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B D
Overtravel too long 1 2 3 4 5 6 Power (US ) on. S5 is pressed, K1 pulls-in (latches). S6 is pressed, K2 pulls-in (the ram moves upwards in the manual mode). The upper dead center is reached, S3 is actuated. S6 is released, K2 drops-out. S1 and S2 on the two-hand operating console are pressed, the C 575 two-hand control device outputs enable signals, K3 and K4 pull-in. The ram moves downwards, S3 is no longer actuated. Test cams are reaches, S4 is depressed, K3 drops-out. The ram does not remain stationary, S4 is no longer actuated (is passed-over), K3 pulls-in. S1 and S2 are released, K3 and K4 drop-out. S1 and S2 are actuated, K4 zieht pulls-in again. Overtravel tester is inhibited.
7 8 9 10 11
S3
S S
S4
Function schematic of the press control. The permissible overtravel s corresponds to the length of the cam which actuates position switch S4. According to ZH 1/456, the press manufacturer must define s.
1 SAC 103 201 H 0201
75
Relay safety combinations C 580
Circuit examples
N/+ 24 V DC + S1 A1 11 S2 Y1 +24V e 0V A1 A2 11 12 14 +24 V E O V EOV 8 V 2 Y2 Voltage supply Output relay (R) Three wire detecting element PNP Voltage input Contact input/Namur detecting element + PNP
C 580
R
A2
12
14
Y2
+8V2 potentialfreier Kontakt
N/ Namur
Circuit diagram 38: Relay for monitoring underspeeds C 580
76
1 SAC 103 201 H 0201
Electronic safety relay C 67xx
Circuit examples
NOT-AUS Ein
C 6701
Circuit diagram 39: Principle internal wiring diagram of the electronic safety relay C 6701
N/+ 24 V DC L1 L2 L3
A1 Y22 Y11
12
11
C 6700
EIN NOT AUS
A2
Y12 Y21
Y33 Y34
M N/ Circuit diagram 40: Principle wiring diagram of a safe load feeder with C 6700 and positively driven small contactors.
1 SAC 103 201 H 0201
77
78
1 SAC 103 201 H 0201
Appendix
1 SAC 103 201 H 0201
79
80
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
81
82
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
83
84
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
85
86
1 SAC 103 201 H 0201
1 SAC 103 201 H 0201
87
ABB STOTZ-KONTAKT GmbH
ABB STOTZ-KONTAKT GmbH

Eppelheimer Strae 82 D-69123 Heidelberg Telefon (06221) 701-0 Telefax (06221) 701-1325 [email protected]
Vertriebsbros: Lessingstrae 79 D-13158 Berlin Telefon (030) 9177-2148 Telefax (030) 9177-2101 Hildesheimer Str. 25 D-30169 Hannover Telefon (0511) 6782-240 Telefax (0511) 6782-320
Eppelheimer Strae 82 D-69123 Heidelberg Telefon (06221) 701-1368 Telefax (06221) 701-1377 Lina-Ammon-Strae 22 D-90471 Nrnberg Telefon (0911) 8124-0 Telefax (0911) 8124-286 Oberhausener Strae 33 D-40472 Ratingen Telefon (02102) 12-1144 Telefax (02102) 12-1725
http://www.abb.de/totzkontakt
Document No. 1 SAC 103 201 H 0201 Printed in the Federal Republic of Germany (08/01 5 GKD) VERMEER KommunikationsDesign, Berlin, Gestaltung A. Pch

ABB Safety Handbook

Uploaded by

Copyright:

Available Formats

ABB Safety Handbook

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ABB Safety Handbook

Uploaded by

Copyright:

Available Formats

Safety

1 SAC 103 201 H 0201

Advant Controller 31-S

Safety control devices

1 SAC 103 201 H 0201

Control and Act

1 SAC 103 201 H 0201

1 SAC 103 201 H 0201

1 SAC 103 201 H 0201

Regulations and Standards

1 SAC 103 201 H 0201

Regulations and Standards

Basic principles of European legislation

Workplace health and safety legislation

1 SAC 103 201 H 0201

Regulations and Standards

* EUC: Equipment under control ** E/E/PE: Electrical, electronical, programmable electronical

1 SAC 103 201 H 0201

Regulations and Standards

Overview of the Machinery Directive (from 89/392/EC)

1 SAC 103 201 H 0201

Regulations and Standards

10. 11. 12.

13. 14. 15. 16. 17. B. 1. 2. 3. 4. 5.

Annex IV of the Machinery Directive

Regulations and Standards

Type A Standards/Basic Standards

Harmonized European Standards

Type B Standards/Group Standards

1 SAC 103 201 H 0201

Regulations and Standards

Group safety standards

General higher-level safety aspects standards

European Standards for safety of machinery

Basic safety standards

Basic design principles and terminology for machines

Regulations and Standards

Determine the machine limits R I S K A N A LY S I S

Identify the hazard

YES Is the machine safe END

1 SAC 103 201 H 0201

Regulations and Standards

Residual risk (EN 1050)

Possible selection of the categories in accordance with EN 954-1

Regulations and Standards

Principles to achieve safety

Mainly characterized by selection of components.

Description of the requirements for the Categories in accordance with EN 954-1

1 SAC 103 201 H 0201

Regulations and Standards

1 SAC 103 201 H 0201

Regulations and Standards

1 SAC 103 201 H 0201

Regulations and Standards

Examples of application EMERGENCY OFF; Initiation of emergency function

Intervention to suppress abnormal condition; Intervention to restart an interrupted automatic cycle

Actuate to initiate normal conditions

START/ON; however white should be preferably used

White Grey Black