2702901

PSR-MC42 SILCL IEC 62061 Safety relay for emergency stop, safety door and light grid monitoring Data sheet 108719_en_00 1 © PHOENIX CONTACT 2018-12-10 Description Intended Use Control The safety relay is used to monitor safety-related signal generators and to control actuators. The safety relay monitors two sensor circuits. The sensor circuits can be designed as single-channel or two-channel circuits. When at least one sensor circuit is interrupted, the safety relay initiates the safe state. The safety relay interrupts circuits in a safety-related way. – – Possible signal generators – – – Emergency stop button Door locking mechanisms Light grids Achievable safety integrity – – – – – 2 sensor circuits 2 undelayed enabling current paths 1 digital signal output I/O link interface Suitable up to category 4, PL e (EN ISO 13849-1), SILCL 3 (EN 62061) Additional features Contact type – – – – Single or two channel Automatic or manual, monitored start Diagnostic data via IO-Link in combination with PSR-CT safety switches Cross circuiting detection Option of screw or spring-cage terminal blocks for plug-in 17.5 mm housing width Approvals  The enabling current paths drop out without delay according to stop category 0 (EN 60204-1). WARNING: Risk of electric shock Observe the safety regulations and installation notes in the corresponding section. Make sure you always use the latest documentation. It can be downloaded from the product at phoenixcontact.net/products. This document is valid for the products listed in the “Ordering data”. This document meets the same requirements as the original operating instructions with respect to the contents. PSR-MC42 2 Table of contents 1 Description .............................................................................................................................. 1 2 Table of contents ..................................................................................................................... 2 3 Ordering data .......................................................................................................................... 3 4 Technical data ......................................................................................................................... 4 5 Notes regarding documentation .............................................................................................. 9 6 Safety regulations and installation notes................................................................................ 10 7 Function description .............................................................................................................. 12 8 Function and time diagrams .................................................................................................. 15 9 Basic circuit diagram ............................................................................................................. 16 10 Derating................................................................................................................................. 17 11 Load curve............................................................................................................................. 17 12 Operating and indication elements ........................................................................................ 18 13 Mounting and removing ......................................................................................................... 19 14 Wiring .................................................................................................................................... 19 15 Startup................................................................................................................................... 21 16 Calculating the power dissipation .......................................................................................... 22 17 Function test/proof test .......................................................................................................... 22 18 Device diagnostics ................................................................................................................ 23 19 IO-Link communication and diagnostic data .......................................................................... 28 20 Application examples ............................................................................................................ 33 21 Attachment ............................................................................................................................ 35 108719_en_00 PHOENIX CONTACT 2 / 36 PSR-MC42 3 Ordering data Description Type Safety relay with IO-Link for emergency stop, safety doors, and light grids, up to SILCL 3, Cat. 4, PL e, 2 sensor circuits, automatic or manual, monitored start, 2 enabling current paths, 1 signal output, US = 24 V DC, plug-in screw terminal block PSR-MC42-2NO-1DO-24DC- 2702901 SC 1 Safety relay with IO-Link for emergency stop, safety doors, and light grids, up to SILCL 3, Cat. 4, PL e, 2 sensor circuits, automatic or manual, monitored start, 2 enabling current paths, 1 signal output, US = 24 V DC, plug-in spring-cage terminal block PSR-MC42-2NO-1DO-24DC- 2702902 SP 1 Accessories Type Order No. Pcs./Pkt. Proximity safety circuit up to Cat. 4, PL e (EN ISO 13849), PSR-CT-C-SEN-1-8 SIL 3 (IEC 61508), unicode sensor with RFID coding, model 4 (EN ISO 14119), automatic or manual start, integrated diagnostics, 24 V DC supply, IP69K, M12 connector 2702972 1 Proximity safety circuit up to Cat. 4, PL e (EN ISO 13849), PSR-CT-M-SEN-1-8 SIL 3 (IEC 61508), multicode sensor with RFID coding, model 4 (EN ISO 14119), automatic or manual start, integrated diagnostics, 24 V DC supply, IP69K, M12 connector 2702975 1 Proximity safety circuit up to Cat. 4, PL e (EN ISO 13849), PSR-CT-F-SEN-1-8 SIL 3 (IEC 61508), fixcode sensor with RFID coding, model 4 (EN ISO 14119), automatic or manual start, integrated diagnostics, 24 V DC supply, IP69K, M12 connector 2702976 1 Proximity safety circuit up to Cat. 4, PL e (EN ISO 13849), PSR-CT-C-ACT SIL 3 (IEC 61508), coded actuator, compatible with all sensor coding types, supplied inductively via the sensor, IP69K 2702973 1 108719_en_00 Order No. Pcs./Pkt. PHOENIX CONTACT 3 / 36 PSR-MC42 4 Technical data Hardware/firmware version HW/FW ≥ 00/100 The technical data and safety characteristics are valid as of the specified HW/FW version. Supply Designation A1/A2 Rated control circuit supply voltage US 24 V DC -20 % / +25 % (provide external protection) Rated control supply current IS typ. 60 mA Power consumption at US typ. 1.44 W Inrush current typ. 2.5 A (Δt = 500 µs at Us) Filter time 1 ms (at A1 in the event of voltage dips at Us) Protective circuit Serial protection against polarity reversal Suppressor diode IO-Link ports: Class A Number of ports 1 Connection method Screw connection/ Spring-cage connection Connection technology 3-wire Specification Version 1.1 Transmission speed 230 kbps (COM3) Cycle Time 5 ms Process data update 5 ms Amount of process data max. 31 Byte (Input data) max. 16 Byte (Output data) IO-Link port supply: L+/LNominal voltage for I/O supply 24 V DC -20 % / +25 % (is provided via the IO-Link interface of the IO-Link master.) Current consumption typ. 16 mA Protective circuit Serial protection against polarity reversal Suppressor diode IO-Link switching and communication cable: C/Q Number of inputs 1 Protective circuit Suppressor diode Digital inputs: Sensor circuit S0 Number of inputs 2 (safety-related sensor inputs: S12, S22) Description of the input NPN (S12), NPN/PNP (S22) Input voltage range "0" signal 0 V DC ... 5 V DC (S12) For S22, see note in “Signal generator connection versions” section. Input current range "0" signal 0 mA ... 2 mA (S12, S22) Input voltage range "1" signal 11 V DC ... 30 V DC 108719_en_00 PHOENIX CONTACT 4 / 36 PSR-MC42 Digital inputs: Sensor circuit S0 Inrush current < 5 mA (typ. with US at S12, Δt = 150 ms) < 5 mA (typically with US at S22/24 V, Δt = 500 s) > -5 mA (typically with US at S22/0 V, Δt = 500 s) Current consumption < 5 mA (Typically with US at S12) < 5 mA (typically with US at S22/24 V) > -5 mA (typically with US at S22/0 V) Filter time 1.5 ms (Test pulse width of low test pulses) Test pulse rate = 5 x Test pulse width Deactivate switch-on pulses/light tests for safety applications. Max. permissible overall conductor resistance 150 Ω Concurrence input 1/2 ∞ Protective circuit Suppressor diode Digital inputs: Sensor circuit S1 Number of inputs 2 (safety-related sensor inputs: S32, S34) Description of the input NPN Input voltage range "0" signal 0 V DC ... 5 V DC Input current range "0" signal 0 mA ... 2 mA Input voltage range "1" signal 11 V DC ... 30 V DC Inrush current < 20 mA (typically with US) Current consumption < 5 mA (typically with US) Filter time max. 1.5 ms (Test pulse width of low test pulses) Test pulse rate = 5 x Test pulse width Deactivate switch-on pulses/light tests for safety applications. Max. permissible overall conductor resistance 150 Ω Concurrence input 1/2 ∞ Protective circuit Suppressor diode Digital inputs: Diagnostic input Number of inputs 1 (non-safety-related diagnostic input: DGN) Current consumption typ. 30 mA Protective circuit Suppressor diode Digital inputs: Start circuit Number of inputs 1 (Start input: S34) Description of the input NPN (manual start), PNP (autostart) Input voltage range "1" signal 19.2 V DC ... 30 V DC (manual start, autostart: 0 V) Inrush current < 10 mA (typically with US, Δt = 100 ms) Current consumption < 5 mA (typically with US at S34/24 V) > -5 mA (typically with US at S34/0 V) Max. permissible overall conductor resistance 150 Ω Protective circuit Suppressor diode 108719_en_00 PHOENIX CONTACT 5 / 36 PSR-MC42 Relay outputs: Enabling current path Number of outputs 2 (safety-related N/O contacts: 13/14, 23/24) Output description 2 NO contacts each in series, without delay, floating Contact material AgSnO2 Switching voltage min. 12 V AC/DC max. 250 V AC/DC (Observe the load curve) Limiting continuous current 6A Inrush current min. 3 mA max. 6 A Sq. Total current ITH2 = I12 + I22 + ... + IN2 72 A2 (observe derating) Switching capacity min. 60 mW Switching frequency 0.5 Hz Mechanical service life 10x 106 cycles Switching capacity according to IEC 60947-5-1 4 A (24 V (DC13)) 5 A (250 V (AC15)) Output fuse 6 A gL/gG 4 A gL/gG (for low-demand applications) Alarm outputs Designation M1 Number of outputs 1 (non-safety-related) Output description PNP Voltage approx. 22 V DC (Us - 2 V) Current max. 100 mA Maximum inrush current 500 mA (Δt = 1 ms at Us) Protective circuit Suppressor diode Times Typical starting time with Us < 250 ms (when controlled via A1) Typical response time at Us < 220 ms (automatic start) < 175 ms (manual, monitored start) Typical release time with Us < 20 ms (on demand via the sensor circuit) < 20 ms (on demand via A1) Restart time < 1 s (Boot time) Recovery time < 500 ms General data Relay type Electromechanical relay with forcibly guided contacts in accordance with IEC/EN 61810-3 (EN 50205) Nominal operating mode 100% operating factor Degree of protection IP20 Min. degree of protection of inst. location IP54 Mounting type DIN rail mounting Mounting position vertical or horizontal Assembly instructions See derating curve 108719_en_00 PHOENIX CONTACT 6 / 36 PSR-MC42 General data Type of housing PBT yellow Operating voltage display 1 x green, yellow, red LED Status display 5 green LEDs Air clearances and creepage distances between the power circuits according to DIN EN 60947-1 Rated surge voltage/insulation See “Insulation coordination” Basic insulation 4 kV between all current paths and housing Safe isolation, reinforced insulation 4 kV between input circuit and enabling current path (13/14) and enabling current path (23/24) Degree of pollution 2 Overvoltage category II Maximum power dissipation for nominal condition 6.45 W (US = 30 V, UL = 30 V, I² = 72 A²) Note on power dissipation See “Calculating the power dissipation” Dimensions Screw connection Spring-cage connection WxHxD 17.5 x 112.2 x 114.5 mm 17.5 x 116.6 x 114.5 mm Connection data Screw connection Spring-cage connection Conductor cross section, solid 0.2 mm² ... 2.5 mm² 0.2 mm² ... 1.5 mm² Conductor cross section, flexible 0.2 mm² ... 2.5 mm² 0.2 mm² ... 1.5 mm² Conductor cross section AWG/kcmil 24 ... 12 24 ... 16 Stripping length 7 mm 8 mm Screw thread M3 Torque 0.5 Nm ... 0.6 Nm Ambient conditions Ambient temperature (operation) -25 °C ... 60 °C (observe derating) Ambient temperature (storage/transport) -40 °C ... 85 °C Max. permissible relative humidity (operation) 75 % (on average, 85% infrequently, non-condensing) Max. permissible humidity (storage/transport) 75 % (on average, 85% infrequently, non-condensing) Information on operating height See the “Using PSR devices at altitudes greater than 2000 m above sea level” section Shock 15g Vibration (operation) 10 Hz ...150 Hz, 2g Conformance/Approvals Conformance CE-compliant The full EC Declaration of Conformity can be downloaded for the product at phoenixcontact.net/products. Approvals  Safety data Stop category according to IEC 60204 108719_en_00 0 PHOENIX CONTACT 7 / 36 PSR-MC42 Safety parameters for IEC 61508 - High demand Equipment type Type A HFT 1 SIL 3 PFHD 1.00 x 10-9 (4 A DC13; 5 A AC15; 8760 switching cycles/year) Demand rate < 12 Months Proof test interval 240 Months Duration of use 240 Months Safety parameters for IEC 61508 - Low demand Equipment type Type A HFT 1 SIL 3 PFDavg 3.76 x 10-5 Proof test interval 36 Months Duration of use 240 Months Safety characteristic data according to EN ISO 13849 Category 4 Performance level e (4 A DC13; 5 A AC15; 8760 switching cycles/year) Duration of use 240 Months For applications in PL e, the required demand rate for the safety function is once per month. Safety parameters for EN 62061 SILCL 3 For applications in SILCL 3 the required demand rate for the safety function is once per month. 108719_en_00 PHOENIX CONTACT 8 / 36 PSR-MC42 5 Notes regarding documentation 5.1 Explanation of symbols used and signal words This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety measures that follow this symbol to avoid possible injury or death.         There are three different categories of personal injury that are indicated with a signal word. DANGER This indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING This indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. This symbol together with the signal word NOTE and the accompanying text alert the reader to a situation which may cause damage or malfunction to the device, hardware/software, or surrounding property. This symbol and the accompanying text provide the reader with additional information or refer to detailed sources of information. 5.2 Validity This data sheet is valid for the described product(s) from the hardware/firmware version specified in the technical data. 5.3 Target group This data sheet is therefore aimed at: – Qualified personnel who plan and design safety equipment for machines and systems and are familiar with regulations governing occupational safety and accident prevention. – Qualified personnel who install and operate safety equipment in machines and systems. 108719_en_00 Qualified personnel: Qualified personnel are people who, because of their education, experience, and instruction and their knowledge of relevant standards, regulations, accident prevention, and service conditions, have been authorized by those responsible for the safety of the system to carry out any required operations and who are able to recognize and avoid any possible dangers. Requirements: Knowledge of the following topics is required: – Handling safety components – Valid EMC regulations – Valid regulations governing occupational safety and accident prevention PHOENIX CONTACT 9 / 36 PSR-MC42 6 Safety regulations and installation notes WARNING: Death, serious personal injury or damage to equipment Depending on the application, incorrect handling of the device may pose serious risks for the user or cause damage to equipment. • Observe all the safety notes and warning instructions provided in this chapter and elsewhere in this document. General • Observe the safety regulations of electrical engineering and industrial safety and liability associations. Disregarding these safety regulations may result in death, serious personal injury or damage to equipment. Direct/indirect contact • Protection against direct and indirect contact according to VDE 0100 Part 410 must be ensured for all components connected to the system. In the event of an error, parasitic voltages must not occur (single-fault tolerance). Power supply units for 24 V supply • • • • Only use power supply units with safe isolation and SELV/PELV according to EN 50178/VDE 0160. Protect the 24 V area with a suitable external fuse. Make sure that the power supply unit is able to supply four times the nominal current of the external fuse, to ensure that it trips in the event of an error. Make sure that the output voltage of the voltage supply does not exceed 32 V even in the event of error. Startup, mounting, and modifications Startup, mounting, modifications, and upgrades may only be carried out by an electrically skilled person. • Before working on the device, disconnect the power. • Carry out wiring according to the application. Refer to the “Application examples” section for this. In operation During operation, parts of electrical switching devices carry hazardous voltages. • Protective covers must not be removed when operating electrical switching devices. For emergency stop applications, automatic startup of the machine can pose serious risks for the user. • The machine must be prevented from restarting automatically by a higher-level controller. With the manual, monitored reset device, a machine start may not be triggered in accordance with EN ISO 13849-1. Inductive loads can lead to welded relay contacts. • Connect a suitable and effective protective circuit to inductive loads. • Implement the protective circuit parallel to the load and not parallel to the switch contact. Magnetic fields can influence the device. The magnetic field strength of the environment must not exceed 30 A/m. • Do not use the device in the vicinity of strong magnetic fields (e.g., caused by transformers or magnetic iron). Noise emission may occur when operating relay modules. Wireless reception may be disrupted in residential areas. The device is a Class A product. • Observe the requirements for noise emission for electrical and electronic equipment (EN 61000-6-4). • Implement appropriate precautions against noise emission. Reliable operation is only ensured if the device is installed in housing protected from dust and humidity. • Install the device in housing protected from dust and humidity (min. IP54). 108719_en_00 PHOENIX CONTACT 10 / 36 PSR-MC42 Faulty devices The devices may be damaged following an error. Correct operation can no longer be ensured. • In the event of an error, replace the device. Only the manufacturer or their authorized representative may perform the following activities. Otherwise the warranty is invalidated. – Repairs to the device – Opening the housing 6.1 Safety of machines or systems Draw up and implement a safety concept The machine or system manufacturer and the operator are responsible for the safety of the machine or system and the application in which the machine or system is used. In order to use the device described in this document, you must have drawn up an appropriate safety concept for your machine or system. This includes a risk assessment in accordance with the directives and standards specified in the EC Declaration of Conformity, as well as other standards. Taking out of service and disposal • • Dispose of the device in accordance with environmental regulations. Make sure that the device can never be reused. The EC Declaration of Conformity can be downloaded for the product at phoenixcontact.net/products. Risk assessment, validation and function test • • • • Before using the device, perform a risk assessment on the machine or system. Validate your entire safety system. Carry out a new validation every time you make a safety-related modification. Perform a function test on a regular basis. Achievable safety integrity Functional safety is guaranteed for the device as a single component. However, this does not guarantee functional safety for the entire machine or system. In order to achieve the desired safety level for the entire machine or system, define the safety requirements for the machine or system as well as how to implement them from both a technological and organizational perspective. 108719_en_00 PHOENIX CONTACT 11 / 36 PSR-MC42 7 Function description 7.1.2 Startup behavior 7.1 Safety instrumented function Start conditions 7.1.1 Monitoring of the sensor circuits – – Both sensor circuits are closed Enable signal is present The safety relay monitors two sensor circuits. The sensor circuits can be designed as single-channel or two-channel circuits.  See “Enable principle” section. The safety relay can only be operated using both sensor circuits. If only one sensor circuit is used, the second sensor circuit must be bridged. If the start conditions are met, the device starts automatically. The sensor circuits evaluate various signal generators. – Sensor circuit S0 with cross-circuit detection, suitable for single-channel or two-channel safety sensors – Sensor circuit S1 suitable for OSSD signals, crosscircuit detection by signal generator Manual, monitored start  See “Block diagram” section.  See “Start and feedback circuit connection versions” section. Single-channel sensor circuit Automatic start When the start conditions are met, the device starts once the start circuit has been closed and opened again by pressing and releasing the reset button. A connected reset button is monitored. The sensor circuit is not designed with redundancy. 7.1.3 The safety relay does not detect short and cross-circuits in the sensor circuit. Safe shutdown If at least one sensor circuit is interrupted, the enabling current paths open without delay. Two-channel sensor circuit When the enabling current paths are open, the device is in the safe state. The connection of the two-channel sensor circuit is equivalent. With the corresponding wiring, the safety relay detects short and cross-circuits in the sensor circuit.  See “Signal generator connection versions” section. 108719_en_00 PHOENIX CONTACT 12 / 36 PSR-MC42 7.2 IO-Link communication and functions 7.3 Communication and functions with PSR-CT safety switches 7.3.1 Diagnostic Data The safety relay is an IO-Link device. Communication via IO-Link offers cyclic and acyclic data exchange. The cyclic and acyclic data can be found in the “IO-Link communication and diagnostic data” section. The following information is transmitted: – Device information for the safety relay (electronic rating plate, device states) – Status information regarding connected PSR-CT safety switches In addition, IO-Link communication can be used for the following functions: – Enable principle: non-safety-related control of the enabling current paths of the safety relay – Chain reset: the PSR-CT safety switch chain is reset 7.2.1 Enable principle The enabling current paths of the safety relay can be controlled via a non-safety-related enable signal by means of IO-Link communication. It is not necessary to press the reset button again. When the safety relay detects an IO-Link connection, the enable signal must be set accordingly for operation via IOLink communication. This optional function is not safety-related and is subordinate to the safety instrumented function of the safety relay. This means that the non-safety-related enable signal cannot start the enabling current paths of the safety relay while the safety-related requirements for the sensor circuits and start circuit of the safety relay are not met. The DGN connection on the safety relay allows you to connect the diagnostic cable for a PSR-CT safety switch chain. The DGN link represents non-safety-related communication between the safety relay and the safety switches. When the safety switch chain is started up, the switches perform “head-counting” to address the individual switches. Addressing enables clear diagnostics for each safety switch. Following a restart, the safety relay synchronizes with the safety switch chain. All safety switches are then available for communication and diagnostics. 7.3.2 Hot plugging – Swapping a PSR-CT safety switch It is possible to swap a safety switch within a PSR-CT safety switch chain during operation. This process is known as “hot plugging”. In order to ensure that addressing is performed correctly after a swap, only one safety switch can be swapped at a time (1:1 swap). If another safety switch needs to be swapped, the required switch-on delay of the previously swapped switch must be taken into consideration. Observe the technical data for the PSR-CT safety switches in the corresponding product documentation. The enable signal is controlled via cyclic data exchange. 7.2.2 Chain reset A chain reset can be used to restart all PSR-CT safety switches in a chain centrally via IO-Link communication. This function facilitates a return to the ready state after troubleshooting. The chain reset command is controlled via cyclic data exchange. 108719_en_00 PHOENIX CONTACT 13 / 36 PSR-MC42 7.4 Functions of signal output M1 Principle of serial diagnostics 7.4.1 When using IO-Link communication The signal for serial diagnostics is inverted, i.e., a logical “0” is represented by 24 V and a logical “1” by 0 V. When an IO-Link connection is detected, signal output M1 behaves as follows: The signal level of the signal output is not equivalent to the state of the enabling current paths of the safety relay. Data transmission commences with a start bit. The start bit consists of a rising edge from the idle state, followed by a High signal for a symbol duration (bit length) of 60 ms. The diagnostic data is then transmitted after this. When the enabling current paths are closed, the signal output is inactive (Low level). An even parity bit is connected to the diagnostic data for error detection. When at least one enabling current path is open, the signal output is active (High level). Data transmission ends with a stop bit. The stop bit is followed by a rest period of 2800 ms. 7.4.2 Without IO-Link communication: serial diagnostics tTransmission tinactive tSymbol High ..... Start bit Data 1 Stop bit Parity 108719_en_00 ..... Data 20 The actual diagnostic data can be found in the “Serial diagnostics via signal output M1” section. Data 1 The information transmitted via serial diagnostics can be evaluated in the higher-level controller. Figure 1 Data 2 Serial diagnostics transmits the following non-safety-related information: – State of sensor circuits and enabling current paths as well as the reset demand of the safety relay – State of connected PSR-CT safety switches (16 switches) Low Start bit When no IO-Link connection is detected, the safety relay offers serial diagnostics via signal output M1. Data transmission serial diagnostics Key: tTransmission tinactive tSymbol Transmission time = 1380 ms Idle state = 2800 ms Symbol duration = 60 ms Evaluation in the controller For reliable diagnostics, parameterize a constant cycle time of