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Circuit Examples

7.1 Safety-Related Low-Voltage Switchgear and Sensors

7.2 Controllers: Fail-safe controls

7.3 Motion Control Systems: Safe Motion Control

The following circuit examples havebeen checked with the German TradeAssociation (BG) and have beenapproved.

EMERGENCY STOP circuits forextremely simple machines

EMERGENCY STOP switch

The EMERGENCY STOP function may only be routed through an EMER-GENCY STOP switch for extremelysimple machines, depending on theresult of the risk analysis. In this partic-ular case, only Stop Category 0 is pos-sible. Such an EMERGENCY STOPswitch, contrary to usual EMERGENCYSTOP pushbutton, interrupts the maincircuit (Fig. 7/1).

7/2 Safety Integrated Application Manual Siemens AG

An EMERGENCY STOP switch mustbe configured so that

• There is only one EMERGENCYSTOP switch;

• The EMERGENCY STOP switch islocated in the supply to those circuitswhich can result in hazardous motionin the system. The complete powersupply to all of the circuits does nothave to be interrupted;

• The EMERGENCY STOP switch mustbe able to interrupt the current ofthe largest motor when the motorstalls;

• The sum of the currents of all of theloads, which must be disconnectedusing the EMERGENCY STOPswitch, must be able to be safelyinterrupted.

An EMERGENCY STOP switch may

• be manually actuated;

• act on an undervoltage release viaone or several EMERGENCY STOPcontrol devices (circuit diagram 7/1);

• be provided with overload and/orshort-circuit releases (version ascircuit-breaker);

• be simultaneously used as mainswitch if it additionally fulfills therequirements for a main switch(however, a main switch mustdisconnect all circuits).

An example for such an EMERGENCYSTOP switch for extremely simplemachines is illustrated in Fig. 7/2

7.1 Safety-Related Low-Voltage Switchgear and Sensors

To loads which do not have to beor may not be disconnected forEMERGENCY STOP

Line supply disconnection(main switch)

Supply

EMERGENCY STOP switch

Manual drivemechanism

U<

Switch lockReleaseMushroomheadpushbutton

EMERGENCYSTOPcontrol device(alternative actuation)

Fig. 7/1EMERGENCY STOP switch with manual actuation or remote actuation via under-voltagerelease

• Contactor circuits

• SIGUARD safety combinations

suitable for:

• EMERGENCY STOP

• Protective door monitoring func-tions

• Press controls

7.1.1 Switch safely

EMERGENCY STOP contactor

Generally, a so-called EMERGENCYSTOP contactor is not permitted. Sucha contactor is only permissible in pre-cisely defined exceptional cases: Thiscontactor may only be used as anEMERGENCY STOP contactor in thebranch to be shutdown. Additionalcontactors in series are not permitted.This means that this concept is restric-ted for applications on extremely sim-ple machines (refer to circuit diagram7/2).

An EMERGENCY STOP contactormust be configured so that

• each EMERGENCY STOP contactormust be immediately de-energizedby the EMERGENCY STOP controldevice;

• there are no additional contactors in series.

Safety circuits using individualcontactors

Configured using two auxiliarycontactors

Safety circuits of any complexity canbe configured using auxiliary contac-tors. Several years ago, the circuit withtwo auxiliary contactors and overlap-ping auxiliary contacts (Fig. 7/3) wasconsidered to be state-of-the-art.

This circuit offers redundancy. However,due to the fact that the contacts arenot positively driven, the two auxiliarycontactors do not mutually monitoreach other for correct functioning. Thismeans that if a contact welds, thisfault is not detected and the circuitstill continues to function.

A subsequent fault in the secondcontactor could completely disable thecombination. This would mean that thelevel of safety would no longer be gua-ranteed. Thus, today, this circuit is nolonger used (Fig. 7/3).

Safety Integrated Application Manual Siemens AG 7/3

777

EMERGENCYSTOP controldevice in thecontrol circuit

To loads which do nothave to be or may notbe disconnected forEMERGENCY STOP

Mainswitch

Supply To loads which must be shutdownfor EMERGENCY STOP

Fig. 7/2Example of a machine control with 2 power contactors,only permitted with some restrictions

L1

Actuator “On“or “On“ afterEMERGENCYSTOP

N

K1

K2

K2K1

EMERGENCY STOP device,if required several in series K1

K2

Enable signals

K1

K2

- No positively driven contacts- No self-monitoring

F1

Today, this circuit is no longer used

Fig. 7/3This contactor combination consists of two auxiliary contactors withoverlapping contacts (Category 2 according to EN 954-1)

Configured using three auxiliarycontactors

Today, circuits with three auxiliarycontactors represent state-of-the-arttechnology. Three auxiliary contactorswith positively driven contacts areused, as shown in circuit diagram 7/4.The three auxiliary contacts guaranteeredundancy and function monitoring.The positively driven contacts guaran-tee that the auxiliary contactorsmutually monitor themselves. Faultsare therefore detected and the circuitcan no longer be closed after shutdo-wn, therefore eliminating subsequentfaults.

With this circuit, using today's state-of-the-art technology, it can be assumedthat if the auxiliary contactors incor-rectly function, this will not cause thesystem to go into a hazardous condi-tion.

Connecting several EMERGENCYSTOP control devices

In the previous circuit diagrams, onlyone EMERGENCY STOP device wasshown. Generally, there are severalEMERGENCY STOP control devices(e.g. at different locations) on a machi-ne.The contacts of these EMERGENCYSTOP control devices are then connec-ted in series.


Circuit examples to monitor protec-tive devices

Circuits to monitor protective devicesuse position switches. Various possibi-lities of the different devices are sho-wn in the examples for EMERGENCYSTOP. These circuit examples will notbe repeated here as the EMERGENCYSTOP control device is only replacedby one or two position switches per

protective device. The number of posi-tion switches which are required foreach protective door can be takenfrom Section 3 of the Manual.

L+/L1

K3

K1

Actuator “On“or control voltage"On"

L–/NK2 K3

EMERGENCY STOP device,if required several in series

K1 K2

K1

K1

K3

K2

K3

K1

K2

Enable signals

K3

F1

Fig. 7/4Contactor combination using three auxiliary contactors with self-monitoring,single-channel, Category 3(4) acc. to EN 954-1

Doors

Open

Closed

Closed

Open

Fig. 7/6SIGUARD position switches used to monitor movingprotective equipment

In the 3TK28 contactor safety combi-nations, which are complete devices,several auxiliary contactors are con-nected to form a safety circuit. These

circuits can also be implementedusing individual contactors.

1-channel

EMERGENCYSTOPcontrol devices

2-channel

EMERGENCYSTOPcontrol devices

Fig. 7/5Several EMERGENCY STOP control devices


7777.1.2 SIGUARD 3TK28 Safety Combinations

12

3

1

2

3

4

4

ϑ

K1

K2

K1 K2

K1

K1C1

V1

K2

K1

K2

A1

A2

Y34 Y22 Y21 13 23

Y11 Y12 14 24

Y33

K2

Power supply

“Ready ON”feedback circuit

Sensor(e.g. EMERGENCY STOP pushbutton)

Sensor(e.g. EMERGENCY STOP pushbutton2-channel)

Enable circuit

Enable circuit

“POWER” LED

“Channel 1” LED

“Channel 2” LED

PTC fuse

A1/A2

Y33/34

Y11/12

Y21/22

13/14

23/24

12

3

4

Power on;Connect the power;The “Power” LED is lit, EMERGENCY STOP closed,C1 is charged, press ON,C1 starts to charge K1, V1 is energized,K2 starts, K1 + K2 latch,“Channel 1” and “Channel 2” LED‘s are lit.

ON monitoringON is pressed fault!EMERGENCY STOP is closed,V1 immediately starts K2, C1 is not charged K1 does not start.Only LED “Channel 2” is lit.

Cross-circuitIf EMERGENCY STOP 1 and EMERGENCY STOP 2 areshort-circuited, a current flows through the PTC fuse.The PTC goes into a high-ohmic state.None of the LED‘s are lit.

Function description

ϑA1

A2

Y11 Y12 14 24

H2H1K1

K2

K1

K1

K1C1

V1

K2

H3K1

K2

Y33 Y34 Y22 Y21 13 23

K2

K2

Fig. 7/7Internal circuit diagram of the 3TK28 23

Fig. 7/8Function description of the 3TK28 23

1

2 3 1

2

3

4

4

A1/A2

Y1/Y2

13/14

23/24

33/34

41/42

Power supply viaEMERGENCY STOP pushbutton

“ON”Feedback circuit

Enable circuit

Enable circuit

Enable circuit

Signaling circuit

LED “POWER“

LED “Channel 1“

LED “Channel 2“

PTC fuse

K2

13Y2 Y1 23 (33) (41)

K1

K1

14

K2

K1

(42)(34)24

K2

K2K1

A1

A2

ϑ

Fig. 7/9Internal circuit diagram of the 3TK28 21/24


M

M

M

13 23

14 24K2

A2K1

N/–N/–

EMERGENCYSTOP

A1

24 V AC/DCL/+

(34) (42)

(33) (41)

K3K3 H1

K2

K1

K1

K2

K3

ON

Y1 Y2

3TK

28 2

1/24

Fig. 7/103TK28 21/24 for EMERGENCY STOP,Category 2, single channel,with feedback circuit

EMERGENCY SWITCHING-OFF(EMERGENCY STOP) circuits

Circuit diagrams

The following circuit diagrams havebeen checked with the German TradeAssociation (BG) and approved.Connection designation:The connection designations are incompliance with DIN EN 50042.

M

13 23

14 24

K2

K1

K2

A2

K1

N/–N/–

EMERGENCYSTOP

A1

24 V AC/DC L/+

(34) (42)

(33) (41)

ON

Y1

K1

K2

3TK

28 2

1/24

Y2

H1Fig. 7/113TK28 21/24 EMERGENCY STOP,Category 3 (4),two-channel with feedback circuit

M

K2

K1

Y11 Y34 13 23

14 24

K2

A2Y21 Y22

K1

N/–N/–

EMER-GENCYSTOP

A1 Y12

ON

L/+

Y33

K1

K2

3TK

28 2

3

24 V AC/DC

Fig. 7/123TK28 23 for EMERGENCY STOP,Category 4, two-channel,with feedback circuit, monitored start


777

Fig. 7/13 3TK28 25 EMERGENCY STOP, Category 2, single-channel, according to EN 954-1, monitored start

Fig. 7/14 3TK28 25 EMERGENCY STOP, Category 4, two-channel, according to EN 954-1, monitored start

M

K3

M

K1

M

K2

13 23

14 24

K2

Y33

K1

N/–

A1

L/+

34 42

33 41Y22

Y44

L/+

N/–

52

51

PE

K3

PE

K1

K2

ON

Y21

Y34

Y12

Y43

Y10 Y11

K3

3TK

28 2

5

A2

EMER-GENCYSTOP

H2H1

M

13 23

14 24

K2

Y33

K1

N/–

A1

L/+

34 42

33 41Y22

Y44

L/+

N/–

52

51

PE

PE

K1

K2

ON

Y21

Y34

Y12

Y43

Y10 Y11

3TK

28 2

5

A2

K1

K2

EMER-GENCYSTOP

H2H1

Y33

A1 Y22

L/+

N/–

PE

PE

K1

ON

Y21

Y34

Y12Y10 Y11

3TK

28 2

7

A2

13 23

14 24

N/–

L/+

32 48

31 47

58

57

K2K1

K2 K1

EMER-GENCYSTOP

H1

M MK2

Fig. 7/15 3TK28 27 EMERGENCY STOP, Category 2, single-channel, according to EN 954-1, monitored start


Y33

A1 Y22

L/+

N/–

PE

PE

K1

K2

ON

Y21

Y34

Y12Y10 Y11

3TK

28 2

7

A2

13 23

14 24

N/–

L/+

32 48

31 47

58

57

K2K1

EMER-GENCYSTOP

H1

K2

K1

M

Fig. 7/163TK28 27 EMERGENCY STOP withshutdown, Stop Category 1, for Category 3according to EN 954-1, two-channel, with feedback circuit, monitored start

K5

K1

Y34 13 23

14 24

K1

N/–N/–

ON

L/+

Y33 A1

K2 K3 K4 K5

13 23 33 43 51

A2 14 24 34 44 52

3TK

2830

Y11

A2Y21 Y22

EMER-GENCYSTOP

A1 Y12

24 V AC/DC

3TK

28 2

3

Fig. 7/173TK28 23 expanded with 3TK28 30 forEMERGENCY STOP, Category 4 acc. to EN 954-1, two-channel, with feedback circuit


777

Fig. 7/183TK28 25 expanded by 3TK28 30 for EMERGENCY STOP, Category 4 acc. to EN 954-1, two-channel cc. to EN 954-1, monitored start

Fig. 7/193TK28 27 expanded by 3TK28 30 for EMERGENCY STOP, Category 4 (Category 3 for delayed contacts), two-channel, monitored start

24 V AC/DC

Y33

A1 Y22

N/–

PE

PE

K1

K5

ON

Y21

Y34

Y12Y10 Y11

3TK

28 2

5

A2

13 23

14 24

K2K1

N/–

L/+

34 42

33 41

52

51 A1 13

14

K3

N/–

A2

N/–

23

K4

33

K5

43

K6

51

24 34 44 52

3TK

2830

K6

H2H1

EMER-GENCYSTOP

Y33

A1 Y22

24 V AC/DC

N/–

PE

PE

K1

ON

Y21

Y34

Y12Y10 Y11

3TK

28 2

7

A2

13 23

14 24

K2K1

N/–

L/+

32 48

31 47

58

57 A1 13

14

N/–

A2

N/–

23

K4

33

K5

43

K6

51

24 34 44 52

3TK

2830

K7

K3 K7

EMER-GENCYSTOP

H1


Fig. 7/20EMERGENCY STOP, Category 4 acc. to EN954-1, 3TK2823(25) in conjunction with operational control of a standard PLC (SIMATIC S7-300/ET200M), load current for each enable circuit, max. 5 A. When using 3TK285.-.. max. 10 A for each enable circuit

M 3TK

28 4

1

K2

1L+

Y12Y11 13 23A1

A2 14 24

Y32

K4 K6 • • • K16

M

2019

17

13

15

11

2MK15

K9

2L+

M7

4

3

S7 300

0

M

109

7

3

5

1

1M

K1

K7

Backplane businterface

Channel numberStatus display, green

M

L+24V DC

• •

• •

••

• •

• •

• •

• •

••

• •

• •

For 3TK2825, additionalsignaling output for PLCor via auxiliary contact

K15

K16

Y32

K1

K16

• •

3TK

28 4

1

Y12Y11 13 23A1

Y22Y21 A2 14

Y32

M

L+24V DC

EMERGENCY STOP

Y32

K1

K16

• •

• •

• •

• •

•

K1

K2

ON

Fig. 7/21EMERGENCY OFF, Category 2 acc. to EN954-1, 3TK2821 in conjunction with operational control of a standard PLC(SIMATIC S7-300/ET200M), load current, max. 5 A per output group (8 digital outputs)

M

3TK

28 2

1/24

1L+

Y2Y1 13 23A1

A2 14 24

M

2019

17

13

15

11

2MK8

K5

2L+

M7

4

3

S7 300

0

M

1M

K1

K4

Backplanebus interface

Channel numberStatus display, green

M

L+24V DC

EMERGENCYSTOP

• •

• •

••

• •

• •

• •

• •

••

• •

• •

109

7

3

5

1K1

K2

K8

• •

ON4133

34 42

• •

• •

• •

•

K1

K2

K8

Signaling contactfor PLC


777

Fig. 7/223TK28 21/24 for protective door monitoring(2 protective doors are cascaded each with 1 SIGUARD position switch),Category 2 acc. to EN 954-1, single- channel, with feedback circuit, autostart

MM M

13 23

14 24

K2

A2

K1

N/–

N/–

A1

24 V AC/DCL/+

(34) (42)

(33) (41)

K3

K2K1 K3

open closed

3TK

28 2

1/24

K1

K2

K3

Y1 Y2

H1

open closed

Protective door monitoring

Fig. 7/233TK28 21/24 for protective door monitoringwith tumbler (2 protective doors are cascad-ed, each with 2 SIGUARD position switcheswith tumbler) Category 2 acc. to EN 954-1,single-channel, with feedback circuit,autostart

13 23

14 24K2

A2K1

N/–N/–

A1

24 V AC/DCL/+

(34) (42)

(33) (41)

K3K3 H1

K2

K1K1

K2

K3

Y1 Y2

openclosed

openclosed

3TK

28 2

1/24

M

M

M


Fig. 7/253TK28 22 for protective door monitoring(protective doors, each with 2 SIGUARDposition switches).Category 4 acc. to EN 954-1,two-channel, with feedback circuit, autostart

M

13 23

14 24K2

A2K1

N/–

N/–

A1

24 V AC/DC

L/+

(34) (42)

(33) (41)

K1

K2

open closed

3TK

28 2

1/24

K1

K2

Y1 Y2

H1∞

∞

∞

∞

open closed

M

13 23

14 24K2

A2K1

N/–N/–

A1

24 V AC/DCL/+

Y33 Y34

open closedK1

K2

Y21

Y11

Y22

Y12

3TK

28 2

2

K1

K2

Fig. 7/243TK28 21/24 for protective door monitoring(2 protective doors are cascaded, each with2 SIGUARD position switches), Category 3(4) acc. to EN 954-1, two-channel, with feed-back circuit, autostart, ( ∞ for Category 4 -the cable has to be routed so that it is wellprotected). Sensors must be fail-safe.


777

Fig. 7/273TK28 25 for protective door monitoring with 2 SIGUARD position switches, autostart,Category 4 acc. to EN 954-1, two-channel, with feedback circuit

Fig. 7/263TK28 25 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD positionswitch), autostart, Category 2 acc. to EN 954-1, single-channel, with feedback circuit

MMM

13 23

14 24

K2

A2

K1

N/–

A1

L/+

34 42

33 41Y22L/+

N/–

52

51Y21

Y34

Y12

Y44

Y10 Y11

Y43

PE

PE

K3

K2K1 K3

K1

K2

closedopen

open closed

K3

3TK

28 2

5

Y33

H2H1

M

13 23

14 24

K2K1

N/–

L/+

34 42

33 41

52

51

open closed

3TK

28 2

5

K2

K1

A2

A1 Y22L/+

N/–

Y21

Y34

Y12

Y44

Y10 Y11

Y43

PE

PE

K1

K2

Y33

H1 H2


Fig. 7/283TK28 28 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD positionswitch), Stop Category 1, Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart

Fig. 7/293TK28 28 for protective door monitoring with 2 SIGUARD position switches, stop Category 1,Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart

M M

A2

A1L/+

PE

Y21

Y33

Y12Y10 Y11

N/–

PE

13 23

14 24

N/–

L/+

32 48

31 47

58

57

K2K1

K1 K2

K1

closedopen

open closed

K2

3TK

28 2

8Y22

Y34

H1

M

13 23

14 24

N/–

L/+

32 48

31 47

58

K2K1

K23TK

28 2

8 K1

A2

A1

L/+

PE

Y21

Y33

Y12Y10 Y11

N/–

PE

K1 open closed

K2

Y22

Y34

H1

57


777

N/–

A1

K3 K4 K5 K6

13 23 33 43 51

A2 14 24 34 44 52A2

A1

24 V AC/DC

N/

Y21

Y34

Y12Y11Y10

PE

PE

13 23

14 24

K2K1

N/–

L/+

34 42

33 41Y22

Y44 52

51

N/–

K1

K6open closed

3TK

28 2

5

3TK

28 3

0

Y33 Y43

H2H1

Fig. 7/303TK28 25 expanded by 3TK28 30 for protective door monitoring with 2 SIGUARD position switches,Category 4 acc. to EN 954-1, two-channel, with feedback circuit, autostart

Fig. 7/31Protective door monitoring with magnetically-operated switch,Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart

Magnetically-operated switch

MagnetsReedcontacts

L/+

1 1

2 2

N/- N/-

K1

K2

Y33 Y34Y12Y11A1

A2Y22Y21

13 23

14 24

K1 K2

L1 L2 L324V AC/DC

K1

K2

Protective door monitoring withcontactless SIGUARD magnetically-operated switches

Protective doors are monitored usingan evaluation unit up to Cat. 3 acc. toEN 954-1 (Fig. 7/32).

The evaluation unit can be operated,both with automatic restart as well aswith monitored start.The start buttonis not necessarily required.

Monitoring several protective doorswith evaluation unit up to Cat. 3acc. to EN 954-1

A maximum of eight SIGUARD mag-netically-operated switches can beconnected to the 3SE6808-6DB evalu-ation unit. If one of the eight magneti-cally-operated switches is actuated(the protective door is opened), thenthe unit shuts down.There is a PLC signaling output (switch-ing to p) for each input.The fail-safeshutdown is realized using two relaysafety outputs.

If an input is not used, then the appro-priate terminals of the NO contactmust be bridged.

For limited safety requirements, theevaluation unit can also be used with-out a start button. For this particularapplication, contacts X1 and Y1 mustbe permanently bridged.


Fig. 7/32SIGUARD magnetically-operated switch with 3SE6801-1CC evaluation unitfor Category 3 acc. to EN 954-1

M3~

/L/+

0V

+24 V DC

S21

K1

K2

S22 14 24S14S13

A1 A2 Y1 X1 13 23

sw/b

k 13

bl/b

l 14

100 mA

br/b

r 21

ws/

wh

22

K3

K4

//N/-Enable

START

I max.

µP1

µP2

3SE

680

1-1C

C


777

Fig. 7/33A maximum of 8 protective doors can be monitored using SIGUARD magnetically-operated switches and evaluation unit 3SE6808-6DB for Category 3 acc. to EN 954-1

Magnetically operatedswitch 5

+PLC

+24 V

4AT




Signaling outputsto the PLC

Y5 Y6 Y7 Y8 Y+ L+ 23

S21 S22S13 S14 Y1 Y2 Y3 Y4 X4 L– 24

13

14Signaling outputsto the PLC





0 V

START

(C)1998

S21 S22S13 S14

S21 S22S13 S14

S21 S22S13 S14

S21 S22S13 S14

S21 S22S13 S14

S21 S22S13 S14

S21 S22S13 S14

3SE

6808

-6D

B

For press control devices with contac-tors also refer to Pages 7/14 and 7/15.


Press control devices

Fig. 7/34Internal circuit diagram of the 3TK28 34 two-hand control device

Fig. 7/353TK28 34 two-hand control device, Category 4 acc. to EN 954-1

13 23

14 24 32 42

4131

A2 Y33

A1 Y23

3TK

28 3

4

6

4

5

Y32

Y22

Y31

Y21Y12Y11

1 23

ϑ

OperatingvoltageOutputs

A1A213, 1423, 2431, 3241, 42Y11, Y12Y21, Y22, Y23Y31, Y32, Y33

Inputs

L/+N/–Enable circuit 1 (NO contact)Enable circuit 2 (NO contact)NC contactNC contactFeedback circuitPushbutton S1Pushbutton S2

Power supply unit

PTC fuse

Control logic

Channel 1

Channel 2

Safety circuit

1

2

3

4

5

6

13 23

14 24 32 42

4131

A2 Y33

A1 Y23

3TK

28 3

4

Y32

Y22

Y31

Y21Y12Y11S1, S2 button on the two-hand operating consoleH1 signaling lampsK1, K2 must be contactors with positively drivencontacts

K1 H1

S1K1

K2

L/+ L/+

S2

K2

N/–N/–

K1

K2

M


777

Fig. 7/36Internal circuit diagram of the 3TK28 35 overtravel tester

Fig. 7/373TK28 34 two-hand control device in conjunction with a 3TK28 35 overtravel tester to mon-itor the overtravel on linear hydraulic, pneumatic and spindle presses acc. to VBG 7 n 5.2 §11, Category 4 acc. to EN 954-1

1 2 3 4

1

2

3

4

13 23

14 24 34 42

4133

A2 Y33

A1 Y21

3TK

28 3

5

Y32

Y14

Y31

Y13Y12Y11

Y34

Y22

Power supply unit

PTC fuse

Control logic

Safety circuit

OperatingvoltageOutputs

A1A213, 1423, 2433, 3441, 42Y11, Y12, Y13, Y14Y21, Y22Y31, Y32, Y33, Y34

Inputs

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 camUpper dead center, switch (S3)

ϑ

Main switchButton on the two-handoperating consolePosition switch at theupper dead centerPosition switchfor test camsHydraulic pump “ON”Tool “UP”(manual operation)Contactor for thehydraulic pumpTool “UP”Tool “DOWN”Signal lamp

S0S1, S2

S3

S4

S5S6

K1

K2K3, K4H1

K4

N/–

13 23

14 24 34 42

4133

A2 Y33

A1 Y21

3TK

28 3

5

Y32

Y14

Y31

Y13Y12Y11

K2

K4

Y22

S4

Y34

K3

K1

K1H1

S5

S6

S3

13 23

14 24 32 42

4131

A2 Y33

A1 Y23

3TK

28 3

4

Y32

Y22

Y31

Y21Y12Y11

S1

K3

K4

L/+

L/+

S2

N/–

S0

Fig. 7/38

Sequence after the press hasbeen powered-up:

1. The hydraulic pump is powered-up with S5, the ram is moved up to the upper dead center, ifrequired, using S6.

2. Depress S1, S2 at the two-handoperating console until the posi-tion switch for the test cams(S4) opens.

3. Release S1, S2 .

4. Depress S1, S2 again: Signallamp H1 lights up (bright) if the overtravel is OK

5. Release S1, S2: The ram returnsto the upper dead center.

6. If the overtravel is OK, all of theoutputs remain active until thecontrol voltage is disconnected.


Fig. 7/39

Fault situation

If the cam actuates position switchS4, then the signal lamp H1 is not litup. The machine part, which is poten-tially hazardous, can then only bemoved to the upper dead center usingS6.

This press can then no longer beused. Contact the technician to checkthe press.

A more detailed description of thefunction of the 3TK28 34 two-handcontrol devices is provided in theInstruction Manual, Order No.3ZX1012-0TK28-7CA1,for the overtravel tester3ZX1012-0TK28-6CA1.

LED‘s Operation

POWER RELEASE

Overtravel OK

Overtravel erroneous or test still not executed

123456

789

1011

1213141516

Power (Vs) onS5 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-handcontrol device 3TK2834 outputs an enable signal, K3 and K4 pull in.The ram moves downwards, S3 is no longer actuated.Test cams are reached, S4 is actuated, K3 drops out.The ram remains stationary, S1, S2 are released, K4 drops out.S1, S2 are pressed, K4 pulls in again, H1 lights up.S1, S2 are released, K4 drops out. K2 pulls in, the ram moves upwards.S4 is no longer actuated.Upper dead center is reached, S3 is actuated.S1 and S2 are pressed; K2 drops out, K3 and K4 pull in.The ram moves downwards, S3 is no longer actuated.S1, S2 are released, K3 and K4 open. K2 pulls in.Points 14 to 16 are repeated at each stroke of the press.

Overtravel OKUs

3TK28 3423/24 (K4)

S3S4S5S6

3TK28 3513/14 (K3)23/24 (K2)33/34 (H1)41/42

K1

S1, S2

1 2 3 4 5 6 7 8 9 11 12 13 14 15 1610

A B C


777

Fig. 7/40

Fig. 7/41Function 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”.

123

456

789

1011

Power (Vs) onS5 is pressed, K1 pulls in (latches).S6 is pressed, K2 pulls in (the ram moves upwards in the manualmode).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 3TK2834two-hand control device outputs enable signals, K3 and K4 pull in.The ram moves downwards, S3 is no longer actuated.Test cams are reached, 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, S2 are actuated, K4 pulls in again. Overtravel tester is inhibited.

Overtravel too longUS

3TK28 3423/24 (K4)

S3S4S5S6

3TK28 3513/14 (K3)23/24 (K2)33/34 (H1)41/42

K1

S1, S2

1 2 3 4 5 6 7 8 9 11 12 13 14 15 1610

A B D

A

S3

S4

SS

B C D !

Fig. 7/42SIGUARD 3TK28 41, internal circuit diagram, standard electronic device

Fig. 7/43SIGUARD 3TK28 40, basic electronic device, EMERGENCY STOP, 2-channel,Category 3 acc. to EN 954-1

MicrocontrollerMOS FETDriverEnable circuits(electronic, safe)(dyn. monitored)Sensor connection(dyn. monitored)Feedback circuitON button(monitored)

1234

5

6

Y11 Y12 Y35 Y21 Y22 Y32 Y34 1 A1

A2 14 24

1

5 6

4

3

2µC1 µC2

Y12Y11 Y33 Y34A1

A2Y22 14 24Y21 Y20

K1 K2

EMERGENCYSTOP

M

* *

3TK

28 4

0

K1 K2

ONL+

MM

K1

K2


Circuit examples SIGUARDelectronic safety combinations

777

Fig. 7/44SIGUARD 3TK2840, EMERGENCY STOP, Category 2 acc. to EN 954-1, single-channel,with feedback circuit

Fig. 7/45SIGUARD 3TK2840, protective door monitoring, Category 3 acc. to EN 954-1,two-channel with feedback circuit

Y12Y11 Y33 Y34A1

K1

24V DC

M

Y22Y21 A2 14Y20 24

K1

3TK

28 4

0

L1 L2 L3

EMERGENCYSTOP

K1

ON

L1 L2 L3

Y12Y11 Y33 Y34A1

K1

24V DC

M

Y22Y21 A2 14Y20 24

K1

3TK

28 4

0

K2

K2

open closed

K1

K2


Fig. 7/47SIGUARD 3TK2841, EMERGENCY STOP,Category 2 acc. to EN 954-1, one-channel, with feedback circuit, monitored start

Y12Y11 Y33 Y34A1

K1

M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

1

K2

K2

L+ L1L2L3

L1L2L3

EMERGENCY STOP

K1

K2

ON

Fig. 7/46SIGUARD 3TK2841, protective door monitoring,Category 4 acc. to EN 954-1, two-channel with feedback circuit, autostart

L1 L2 L3

Y12Y11 Y33 Y34A1

K1

24V DC

M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

1

K2

K2

1

open closed

K1

K2


777


Fig. 7/48SIGUARD 3TK2841, EMERGENCY STOP, Category 4 acc. to EN 954-1,two-channel, with feedback circuit, monitored start with “ON” button

Fig. 7/49SIGUARD 3TK2841, light grid monitoring, Category 4 acc. to EN 954-1,2-channel, with feedback circuit, autostart

Y12Y11 1 Y34A1

K1

M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

1

K2

K2

L1 L2 L3

24V DC

K1

K2

ON

EMERGENCY STOP

L1 L2 L3

Y12Y11 1 Y34A1

K1

M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

1

K2

K2

L+

Y32

QSSD 1 2

K1

K2

7/26 Siemens AG Safety Integrated Application Manual

Fig. 7/50SIGUARD 3TK2841, EMERGENCY STOP, 2-channel, monitored start,with additional on button and protective door monitoring, 2-channel,autostart, Category 4 acc. to EN 954-1

Fig. 7/51SIGUARD 3TK2841, contact mat, Category 3 acc. to EN 954-1, 2-channel, autostart

L1 L2 L3

K1

K2

Y12Y11 1 Y34A1

M

K1

3TK

28 4

1

K2

L+

Y32

Y22Y21 14 24Y35 A2

Y12Y11 1 Y34A1 Y32

3TK

28 4

1

Y22Y21 14 24Y35 A2

K1 K2

ON

EMERGENCYSTOP

Protective door

L1 L2 L3

K1

K2

Y12Y11 1 Y34A1

K1

M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

1

K2

K2

L+

Y32Contact mat

Siemens AG Safety Integrated Application Manual 7/27

777

Fig. 7/52SIGUARD 3TK2841, EMERGENCY STOP, Category 4 acc. to EN 954-1,in conjunction with operational control of a standard PLC (SIMATIC S7 300/ET200M) load current for each enable circuit, max. 2 A

Fig. 7/53SIGUARD 3TK2841, EMERGENCY STOP and light grid, Category 4 acc. to EN 954-1,cascaded with operational control of a standard PLC (SIMATIC S7 300/ET200M)

M 3TK

28 4

1

K2

1L+

Y12Y11 1 Y34A1

Y22Y21 A2 14Y35 24

Y32

K4 K6 • • • K16

M

2019

17

13

15

11

2MK15

K9

2L+

M7

4

3

S7 300

0

M

109

7

3

5

1

1M

K1

K7


Channel numberStatus display - green

M

L+24V DC

EMERGENCY STOP

K1

K16

• •

• •

••

• •

• •

• •

• •

••

• •

• •

• •

Signal to the PLCvia auxiliary contactat K1..K16

K15

K16

ON

K1

K2

M 3TK

28 4

1

K2

1L+

Y12Y11 1 Y34A1

Y22Y21 A2 14Y35 24

Y32

K4 K6 K8

M

2019

17

13

15

11

2MK15

K9

2L+

M7

4

3

S7 300

0

M

109

7

3

5

1

1M

K1

K7



M

L+24V DC

EMERGENCY STOP

K1

K16

• •

• •

••

• •

• •

• •

• •

••

• •

• •

• •

3TK

28 4

1

Y12Y11 1 Y34A1

Y22Y21 A2 14Y35 24

Y32

K10

K16

• •

K10 K12 K14 K16

EMERGENCY STOP

PLC/DO

Contactless device

M M M M M M M M

ON


Fig. 7/54SIGUARD 3TK2842, protective door monitoring, Category 4 acc. to EN 954-1,2-channel, with feedback circuit with AC drive inverter and delayed shutdown,Stop Category 1

Fig. 7/55SIGUARD 3TK2842, EMERGENCY STOP, Category 2 acc. to EN 954-1,1-channel, monitored start with ON button with checkback circuit,with AC drive inverter and delayed shutdown, Stop Category 1

Y12Y11 Y33 Y34A1

K1

L+

Y22Y21 A2 14Y35 28

K1

3TK

28 4

2

K1

K2

K2

K2

1

open closed

M

L1 L2 L3

FU

Y12Y11 Y32 Y34A1

K1

L+

Y22Y21 A2 14Y35 28

K1

3TK

28 4

2

K1

K2

K2

K2

1

M

L1 L2 L3

FU

EMERGENCY STOPON


777

Fig. 7/56SIGUARD 3TK2842, EMERGENCY STOP, Category 4 acc. to EN 954-1, 2-channel,monitored start with ON button, with AC drive and delayed shutdown,Stop Category 1

Fig. 7/57SIGUARD 3TK2842, EMERGENCY STOP and protective door monitoring,Category 4 acc. to EN 954-1, 2-channel, with tumbler, monitored start

Y12Y11 Y32 Y34A1

K1

L+

Y22Y21 A2 14Y35 28

K1

3TK

28 4

2

K1

K2

K2

K2

1

M

L1 L2 L3

FU

EMERGENCY STOP

ON

Y12Y11 Y32 Y34A1

K1

L+

Y22Y21 A2 14Y35 28

K1

3TK

28 4

2

K1

K2

K2

K2

1

M

L1 L2 L3

EMERGENCYSTOP

open

closed

ON


Fig. 7/58SIGUARD 3TK2841, cascaded with 3TK2842 for EMERGENCY STOP,2-channel, monitored start with ON button and protective door monitoring,2-channel, autostart, Category 4 acc. to EN 954-1

Fig. 7/59SIGUARD 3TK2842, light grid monitoring, 2-channel,autostart, Category 4 acc. to EN 954-1

Y12Y11 1 Y34A1

M

K1

3TK

28 4

1

K1K2

K2

L1 L2 L3L+

Y32

Y22Y21 14 24Y35 A2

Y12Y11 1 Y34A1 Y32

3TK

28 4

2

Y22Y21 14 24Y35 A2

K1 K2

Protective door

ON

EMERGENCYSTOP

FU

Y12Y11 1 Y34A1

K1M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

2

K1

K2

K2

K2

L1 L2 L3L+

Y32

QSSD 1 2FU


777

Fig. 7/60SIGUARD 3TK2842, contact mat, Category 3 acc. to EN 954-1, 2-channel, autostart

Fig. 7/61SIGUARD 3TK2850, 51, 52, internal circuit diagram, electronic basic unit with auxiliarycontactors, Category 3 acc. to EN 954-1

Y12Y11 1 Y34A1

K1M

Y22Y21 A2 14Y35 24

K1

3TK

28 4

2

K1

K2

K2

K2

L1 L2 L3

L+

Y32Contact mat

FU

Y12Y11 Y34A1 Y20

1 2

A2 Y21 Y22 Y33 A1 A2

3TK2850

3 4

K1

K2

33 4313

34 4414

2313 4333 7153 83

3TK

2852

2414 4434 7254 84

3113 43

3TK

2851

3214 44


Fig. 7/62The electronic basic 3TK2850 device with auxiliary contactors,protective door monitoring, 2-channel, autostart, Category 3 acc. to EN 954-1

Fig. 7/63The electronic basic 3TK2850 device with auxiliary contactors, protective door monitoring,1-channel, autostart, Category 2 acc. to EN 954-1

3TK

28 5

0

open closed

N/-

A2

A1 Y33 Y34

Y11Y21

Y22Y12

L/+

14 24 34

13 23 33

K1

K2

3TK

28 5

0

open closed

N/-

A2

A1 Y33 Y34

Y11Y12

Y20Y21

L/+

14 24 34

13 23 33

K1

K2


777

Fig. 7/64The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,1-channel, with additional ON button, Category 2 acc. to EN 954-1

Fig. 7/65The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,2-channel, Category 3 acc. to EN 954-1

3TK

28 5

0

N/-

A2

A1 Y33 Y34

Y11Y21

Y22Y21

L/+

14 24 34

EMERGENCY STOP

ON

13 23 33

K1

K2

3TK

28 5

0

N/-

A2

A1 Y34 Y33

Y11Y21

Y22Y12

L/+

14 24 34

EMERGENCY STOP

ON

13 23 33

K1

K2


Fig. 7/66The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,2-channel, Category 4 acc. to EN 954-1 SIL 3

Fig. 7/673TK285.-.., EMERGENCY STOP, Category 4 acc. to EN 954-1, P-M switching inconjunction with operational control of a standard PLC (SIMATIC S7 300/ET200M),load current per enable circuit, 10 A

3TK

28 5

3

N/-

A2

A1 Y32

Y11Y21

Y22Y12

L/+

14 34 44

ON

EMERGENCY STOP

2

431 13 33 43

K1

K2

Y33 Y34

M

1L+

2019

17

13

15

11

2MK16

K9

2L+

M7

4

3

S7 300

0

M

109

7

3

5

1

1M

K1

K8



• •

• •

••

• •

• •

• •

• •

••

• •

• •

Signal tothe PLC(3TK2852)

K21 K22 K23 •K36

14 24 34 44 54 72 84

13 23 33 43 53 71 83

24V DC 24V DC 24V DCM M

Y34 A1 A2Y33Y22Y21Y20Y12Y11A2A1

24V

K1•••

Kn

L/+

N/M

24V

DC

3TK2850, 51, 52

EMER-GENCYSTOP ON

K1

K2

K16

K36


777

Fig. 7/683TK2853, internal circuit diagram, electronic basic device with auxiliary contactors,Category 4 acc. to EN 954-1

Fig. 7/69The electronic basic 3TK2853 device with auxiliary contactors, protective doormonitoring, 2-channel, autostart, Category 4 acc. to EN 954-1, SIL 3

Y12Y11 Y34A1 Y35A2 Y21 Y22 Y33 A1 A2

3TK2853

33 4313

34 4414

Y32

2431

3

4

21

5 6 7

K2

K1

3TK

28 5

3

open closed

N/-

A1

Y11Y12

Y22Y21

L/+

14 34 44

1 3 4

A2 2

13 33 43

K1

K2

Y34Y33Y32


Fig. 7/70The electronic basic 3TK2853 device with auxiliary contactors,protective door monitoring, 1-channel, autostart, Category 2 acc. to EN 954-1, SIL 3

Fig. 7/71The electronic basic 3TK2853 device with auxiliary contactors, EMERGENCY STOP,1-channel, with additional EN button, Cat. 2 acc. to EN 954-1, SIL 3

3TK

28 5

3

N/-

A1

Y11Y12

Y22Y21

L/+

14 34 44

1 3 4

A2 2

Y35

open closed

13 33 43

K1

K2

Y32 Y34Y33

3TK

28 5

3

N/-

A1

Y11Y12

Y22Y21

L/+

14 34 44

Y32 Y34Y33 1 3 4

A2 2

Y35

ON

EMERGENCY STOP

13 33 43

K1

K2


777Fig. 7/72The electronic basic 3TK2853 device withauxiliary contactors, light curtain/grid,2-channel, autostart, Category 4 acc. to EN 954-1

Fig. 7/73The electronic basic 3TK2853 device withauxiliary contactors, cascading EMERGENCYSTOP and protective door monitoring,2-channel, Cat. 4 acc. to EN 954-1, SIL 3

3TK

28 5

3

A1

Y11Y21

Y22Y12

L/+

14 34 44

1 3 4

A2 2

3TK

28 5

3

A1

Y11Y21

Y22Y12

L/+

14 34 44

Y32 3 4

A2 2

13 33 43

K1

K2

Y34 1Y33 A1 A2

EMERGENCY STOP

Y32 Y34Y33

Y33

13 33 43

K1

K2

Protective door

ON

3TK

28 5

3

N/-

A1

Y11Y21

Y22Y12

L/+

14 34 44

Y32 Y34Y33 1 3 4

A2 2

Y35

OSSD 1 2

13 33 43

K1

K2


Typical application for

load feeder outgoing cables

• Six actuation units are monitored by

two EMERGENCY STOP switches

• The actuation equipment can either

be individual de-activated or in groups

using the protective doors

• During operation, the equipment is

switched-over using a PLC or a pushbutton.

EM

ERGENCY

S T O P

Protective doors

21 EM

ERGENCY

S T O P

654321

1 2 3 4

Conventional solution

• Conventional wiring =>

approx. 160 different solutions

• Complex installation =>

high costs => increased space

requirement

• Frequent faults

• No overload or short-circuit

protection

653321

1

Feedbackcircuit

Feedbackcircuit

Feedbackcircuit

Feedbackcircuit

EM

ERGENCY

S T O P

2

EM

ERGENCY

S T O P

Load feeders with Integrated Safety Technology

777


Solution with 3RA7

• Combination of 3RA7 and

3TK28 (cascading)

• Approx. 80 connections

• Simpler installation => lower

costs => compact design

• Few faults due to the

"single wire connection"

• Motor protection using a

protection circuit-breaker

2

24 V DCM

1

1 2 3 4 5 6

EM

ERGENCY

S T O P

EM

ERGENCY

S T O P

3RA7 3RA7

3SB3 3SB3

Typical applications for

safe combinations

• 3TK2840 electronic basic device

• Protective door monitoring

• Category 3 acc. to EN 954-1

• 2 channels with feedback circuit

3TK2840

24 V DC (+)

A1 Y11 Y12 Y33 Y34

K1

Y20

M

K1

Y21 Y22 A2 14 24

K1

K2

K2

K2

open closed

L3L2L1

3SE2

3SE2



• EMERGENCY STOP


• 1 channel with feedback circuit

3TK2840

24 V DC (+)

A1 Y11 Y12 Y33 Y34

K1

ON

Y20

M

Y21 Y22 A2 14 24

K1

EM

ERGENCY

S T O P

L1 L2 L3

K1

3SB3

3SB3


• EMERGENCY STOP


• 2 channels with feedback circuit

24 V DC (+)

Y33 Y34

L1 L2 L3

K1

K2

Y21

Y22

A1

Y11

Y12

ON

EM

ERGENCY

S T O P

3TK2840

3SB3

3SB3

Y20

M

Y21 Y22 A2 14 24

K1


777

Circuit examples for SIGUARD lightcurtains

Connection example, light curtainCategory 4 connected to a standardevaluation unit 3RG7847-4BB

Light curtain or light grid 3RG7842connected through 2 channels to the evaluation unit 3RG7847-4BB:


• Manual start with monitoredstart button

• Contactor monitoring

Connection example, light curtainCategory 4 connected to an evalua-tion unit with muting function

A light curtain or light grid 3RG7842connected to the evaluation unit withmuting function 3RG7847-4BF:


• Integrated muting function(e.g. with light barriers asmuting sensors)

• Manual start with dynamicallymonitored start button

• Dynamic contactor monitoring

7.1.3 Contactless Protective Devices

Fig. 7/74Connection example, light curtain Category 4 connected to a standard evaluation unit3RG7847-4BB

Fig. 7/75Connection example, light curtain Category 4 connected to an evaluation unit with mutingfunction

0 V

1)

+ 24 V

4 15 24 22 23 20 21 31 32 13 14 11

k2

k1

2

9 19 33 30 28 29 7 6 10 1

M1 M2 M3 M4T1 T2 S1 S2

+ 2

4 V

0 V

2.5 AT

Test AOPDs Muting sensors

RE

SE

T

MutingindicatorsState outputs Warn.Diagn. State

R-Output

6 AT

max

.

ED

M

Sta

rt

1 2

RS

232

S1-

S2

Mut

ing

Failu

re

Res

tart

inhi

bit

Con

tact

orm

onito

ring

Muting indicators24 V, 5 W max.

Possible common conductorfor fault/alarm active low

K2

1)K1

+24V

PE

Receiver

0 V1234567

+24V

PE

Sender

0 V1234

567

SIGUARDlight curtain/grid3RG7842

OS

SD

1 N

.O.

OS

SD

2 N

.O.

M1 M2 M3 M4

M-S

enso

r 1

Mut

ing

func

tion

Safety output

L+Ph

L-N

L+Ph

L-N

k1 k2 k1

k2

M-S

enso

r 2

M-S

enso

r 3

M-S

enso

r 4

SIGUARD 3RG7847-4BF

6 AT

max

.

s

2-channelenablecircuit

Use both contacts inthe enable circuit!K1 and K2 with positivelydriven contacts


1) Provide suitable arc quenching

0 V

1)

SIGUARD 3RG7847-4BB

+ 24 V

S11 13 23

14 24

1 AT

K2

1)K1

+24V

Receiver

0 V1

23456

7

+24V

Sender

0 V1

234

5

6

7


N.O

.

N.O

.

Safetyoutput

k1 k2 k1

k2

s

A1(L+) S33 S34 S35 S31 S22

A2 (L-)

PE PE

Sta

rtR

esta

rt in

hibi

t

Con

tact

or m

onito

ring

6.3

AF

6.3

AF

CH1

CH2

32S21 S12

=

+

31

K2

K1



Use both contacts inthe enable circuit!K1 and K2 with positivelydriven contacts



Fig. 7/76Connection example, light curtain Category 2 connected to a standard evaluation unit3RG7847-4BD

0 V

1)

SIGUARD 3RG7847-4BD

+ 24 V

4 15 24 22 23 13 14 11

k2

k1

2

9 7 6 10 1

T1 T2 S1 S2

+ 2

4 V

0 V

2.5 AT

Test AOPDs

RE

SE

T

Diagn. State

R-Output

6 AT

max

.

ED

M

Sta

rt

RS

232

Res

tart

inhi

bit

Con

tact

orm

onito

ring

K2

1)K1

+24V

Receiver

0 V

1234

567

+24V

Sender

0 V

1234

567


OS

SD

1 N

.O.

OS

SD

2 N

.O.

Safety output

L+Ph

L-N

L+Ph

L-N

k1 k2 k1

k2

6 AT

max

.

8 8

0 V

h I

Test input s


Use both contacts inthe enable circuit!K1 and K2 with poitivelydriven contacts



Fig. 7/77Connection example, light curtain Category 4 connected to an evaluation unit with cyclecontrol


Use both contacts inthe enable circuit!K1 and K2 with poitivelydriven contacts


The following appliesfor cycle mode:

Signal output 6 and LEDdisplay ”restart inhibitinterlocked” pulse, afterbeing released, with thenumber of requiredinterventions in theprotective field.

Only interventions longerthan 300 ms are acceptedfor control.

Machine contacts closeto the upper end positionopen OSSDs and cancelthe entered cycles.


+24 V

k k k

k

0 V

4 15 24 22 23

T1 T2 S1 S2

Res

et

ED

13 14 11 2

+24

V

Test AOPDs

L-N

L+Ph

2.5

AT

L-N

L+Ph

20 21

Con

tact

orm

onito

ring

Ena

ble

inhi

bit

Sta

rt 6 A

T m

ax.

k

k

Cyc

le c

ance

l

Pro

tect

ion

Sin

gle-

cycl

e

Machinecontact

Signal outputs

Two-

cycl

eS

elec

t

Cle

ar

7 6 10 1

OS

SD

1 N

.O.R-Output

Diagn. State

RS

232

0 V

K2

K1

9

OS

SD

2 N

.O.SIGUARD 3RG7847-4BH

19

S1-

S2

6 A

T m

ax.

State

1)

1)

+24V

PE

Receiver

0 V

1

2345

6

7

+24V

PE

Sender

0 V

1234

56

7


Connection example, light curtainCategory 2 connected to a standardevaluation unit 3RG7847-4BD

A light curtain 3RG7841 connected to the evaluation unit 3RG7847-4BD:


• Cyclic testing of the light curtain



Connection example, light curtainCategory 4 connected to an evalua-tion unit with cycle control

A light curtain or grid 3RG7842/44connected through 2 channels to the evaluation unit 3RG7847-4BH:


• Automatic single or two-cyclecontrol



Circuit examples for SIGUARD light barriers


777

3RG7821-7BG00 3RG7821-7CD00

WH WHBN

3RG7821-7BG00 3RG7821-7CD00

X10X9 X12X11X6X5 X8X7A2A1 X1 X3X2 X4

X13 X14

0 V(internal)OUTIN

0 V(int.)OUT

TEST

X15 X16 X17 X18 X19 X20X22 Y1 X23

PNP-OUT

13 14 X21

K1

Contactor

3RG

7826

-1C

B1

+24 V(int.)IN

+24 V(int.)

+24 V(internal)

Externalfeedbackcircuits

+24V 0VStart

+24 V(int.)

IN OUT 0V(int.)

WH BNWH BNBN

Sender 2 Receiver 2Sender 1 Receiver 1

Fig. 7/78


1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3

M3~

1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3

3RG7822-7CD003RG7822-7BG00

+24 V DC

A1 X4 X5 X6 X7 X8 13 23 39 41

Y1 Y2 + – 14 24 34 42

L1

Relay

24V T1 Q1 T2 Q2 RESTART Cont.M

RESTART

0 V

0V T3 Q3 T4 Q4 PM Indic.

K4

K5

N

Sender Receiver Sender Receiver

Sender Receiver Sender Receiver

Cont.M

3RG

7827

-1D

E2

UB OUT

UB OUT

0 V

X14A2 X9 X10 X11 X12 X13

X1 X2 X3 + –

SS

3RG... 3RG...

3RG... 3RG... 3RG... 3RG...

Fig. 7/79

LS4 laser scanner application

777


• Start button for a manualrestart directly at the scanner(connection 2)

• Alarm output at connection 5(e.g. alarm lamp)

• The protective field is changed-over at connections 4, 6, 7 and 8

• The safe outputs are safelyprocessed (connections 11 and 12)when using an evaluation unit orfail-safe PLC

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

LS4 SIGUARD laser scanner

Evaluation unitor safety PLC

X1

1.25A mT

+ 24V0VPE

Connection example, LS4 SIGUARD laser scannerChanging-over the protective field, start button


Connection example, LS4 SIGUARD laser scannerConnected to a standard 3RG7847-4BB evaluation unit

• Start button for a manualrestart directly at the scanner(connection 2)

• Fixed protective field pair 1(24 V always present at connection 4)

LS4 SIGUARD laser scanner

1 A

T

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Safe output

0V

S11 S33 S34 S35 S31 S22

+24V

A2(L-) S12

CH1

CH2

SIGUARD 3RG7847-4BB

K1

K2 N.O

.

N.O

.

2414 32

13 23 31A1(L+)

1.25 AmT

K5*

*A suitable arc quenchingdevice must be provided

K4*

6.3

AF

6.3

AF

Neu

star

tspe

rre

Contactormonitoring

k4

k5

+ 24V0VPE

S21

777

Circuit examples with evaluationunit

SIGUARD switching strips, togetherwith the 3RG78 57-1BD evaluationunit, can be used as a safety systemup to Category 4 acc. to EN 954-1.Theevaluation electronics in the 22.5 mmenclosure is used to evaluate thetransmitter/receiver signal and to moni-tor the complete system for faults anderrors.

The power supply voltage of the evalu-ation unit is 24 V DC.Two relay outputs are available assafety-related outputs. A semiconduc-tor output can be used to issue asignal to a PLC. After the switchingstrip has been actuated, the devicemust be enabled using a manual startbutton, so that the system can restart.


14 24

13 23

Safetyoutputs

K1 K2

Start button

X2 X3

Signaloutput

X1

12 Vcontroller

Safety-relatedsignal processing

A2(–)Safetyoutputs

K1 K2

K1

K2

K1

K2

A1(+)wh gn bn

3RG

7857

-1B

D

24 V DCpowersupply

Receiver Sender3RG7855-1R

Fig. 7/80

7.1.4 SIGUARD Switching Strips

7.1.5 Circuit examples, ET 200S SIGUARD


Fig. 7/82EMERGENCY STOP circuit with monitored start, Category 2 acc. to EN 954-1

Fig. 7/81EMERGENCY STOP circuit with monitored start, Category 4 acc. to EN 954-1

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

Power module

SupplycontactorKO

Circuit-breaker

PM-DF1

IM151

PM-X

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PM-DF1

Direct starterDS

Reversing starterRS

Auxiliary contact block(for the feedback circuit)F Kit

Connection modulePM-X

Terminating cover

PLC

L1 L2 L3

Term

inat

ing

mod

ule

DS

F kit-1

M~

RS

F-Kit-2

M~

DS

F kit-1

M~

Circuit-breaker

PM-DF1

IM151

PM-X

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PM-DF1

DS

RS

F Kit

PM-X

Terminating cover

PLC

L1 L2 L3

Term

inat

ing

mod

ule

12

67

Power module

Direct starter

Reversing starter

Auxiliary contact block(for the feedback circuit)

Connection module

777


Fig. 7/84EMERGENCY STOP circuit arranged in a cascade

Fig. 7/83EMERGENCY STOP circuit in two groups

L1 L2 L3

PM-X

PM-DF1

EMERGENCY STOP 1 EMERGENCY STOP 2

A1+A2-

TM-PF30 S47-B1 TM-PF30 S47-B1

DS

F kit

M~

DS

F kit

M~

PM-DF1

IM151

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOP button

PLC RS

F-KitSupplycontactorKO2

Circuit-breaker

PM-X

Terminating cover

Term

inat

ing

mod

ule

M~

M~

L1 L2 L3

SupplycontactorKO2

Circuit-breaker

F-Kit

DS

F kit

DS

F kit

L1 L2 L3

PM-X

PM-DF1

EMERGENCY STOP 2

A1+A2-


DS

F kit

M~

DS

F kit

M~

PM-DF1

IM151

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton


PLC RS

F-KitSupplycontactorKO1

Circuit-breaker

PM-X

Terminating cover

Ter

min

atin

g m

odul

e

M~

M~

L1 L2 L3

SupplycontactorKO2

Circuit-breaker

F-Kit

DS

F kit

DS

F kit

EMERGENCY STOP 1


Fig. 7/85EMERGENCY STOP circuit arranged in a cascade with delayed shutdown (Stop Category 1)

L1 L2 L3

PM-X

PM-DF3

EMERGENCY STOP 1

Stop Cat. 1Cat. 3

TM-PF30 S47-B1 TM-PF30 S47-C0

Stop Cat. 0Cat. 4

DS

F kit

M~

DS

F kit

M~

PM-DF1

IM151

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton


PLC RS

F kitSupplycontactorKO1

Circuit-breaker

PM-X

Terminating cover

Term

inat

ing

mod

ule

M~

M~

L1 L2 L3

DS DS

A2+A1-

SupplycontactorKO2

Circuit-breaker

F kit

777


Fig. 7/86EMERGENCY STOP combined with protective door


PM-DF1

IM151

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PLC DS

F kit

M~

RS

F kit

M~

DS

F kit

M~

PM-X

DS

F kit

M~

open closed

Protective door

DS

SupplycontactorKO2

Circuit-breaker

PM-X

Terminating cover

L1 L2 L3

Term

inat

ing

mod

ule

PM-DF2


Fig. 7/88Integrated in an external EMERGENCY STOP circuit, Category 4 acc. to EN 954-1

Fig. 7/87One EMERGENCY STOP circuit for several ET 200S rails

DS

F kit

M~

DS

F kit

M~

PM-DF1

IM151

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PLC

L1 L2 L3

SupplycontactorKO1

Circuit-breaker

PM-X

Terminating cover

Term

inat

ing

mod

ule

DS

F kit

M~

DS

F kit

M~

DF DF

PM-DF4

IM151

L+M

A1+A2–

L1 L2 L3

SupplycontactorKO2

Circuit-breaker

PM-X

Terminating cover

Term

inat

ing

mod

ule

TM-PF30 S47-B1 TM-PF30 S47-C1

EMERGENCY STOP 1

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

PM-XPM-D

AUX2AUX3

EMERGENCYSTOPbutton

ONbutton

3TK2823

SupplycontactorKO

Circuit-breaker

Terminating cover

L1 L2 L3

Ter

min

atin

g m

odul

e

IM151

PROFIBUS-DP

Mas

ter

PLC

L+M

A1+A2–

PM-XA1+

777


Fig. 7/90SIMATIC ET 200S SIGUARD and AS-i Safety at Work

Fig. 7/89Integrated in an external EMERGENCY STOP circuit, Category 2 acc. to EN 954-1

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

PM-XPM-D

AUX2AUX3

EMERGENCYSTOPbutton

ONbutton

3TK2823

Circuit-breaker

Terminating cover

L1 L2 L3

Ter

min

atin

g m

odul

e

IM151

PROFIBUS-DP

Mas

ter

PLC

L+M

A1+A2–

PM-XA1+

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

PM-XPM-D

AUX2AUX3

ONbutton

Shutdown circuit

Feedback circuit

AS-iSafetyMonitor

EMERGENCYSTOP switch 1





SupplycontactorKO

Circuit-breaker

Terminating cover

L1 L2 L3

Term

inat

ing

mod

ule

IM151

PROFIBUS-DP

Mas

ter

PLC

L+M

A1+A2–

PM-X

A1+

Category 4(EN 954-1) – separate shutdown groups are also possible


Fig. 7/92EMERGENCY STOP circuit with integrated external actuators

Fig. 7/91EMERGENCY STOP circuit with integrated pneumatic valves

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

SupplycontactorKO

Circuit-breaker

Term

inat

ing

mod

ule

PM-E

DO DO DOPM-DF1

IM151

PM-X

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PLC

L1 L2 L3

24V

Category 4 acc. to EN 954-1 Cat 1

M~

DS

F kit-1

M~

RS

F kit-2

M~

DS

F kit-1

M~

Term

inat

ing

mod

ule

PM-E

DO DO DOPM-DF1

IM151

PM-X

PROFIBUS-DP

Mas

ter

L+M

A1+A2–

ONbutton

EMERGENCYSTOPbutton

PLC

L1 L2 L3

Category 4 acc. to EN 954-1 Cat 4

SupplycontactorKO

Circuit-breaker

This section shows you the possibili-ties of achieving Safety ClassesAK4/SIL2/Cat.3 and AK6/SIL3/Cat.4using the F I/O in S7-300F and S7-400F/FH.This information refers to the F I/O of the SIMATIC S7 range - this means F-SMs S7-300 and F modules ET 200S.

How is the safety class achieved for F inputs?

For F inputs, the required Safety Classis achieved by the type of transmitterevaluation.This means that SafetyClass AK4/SIL2/Cat.3 or AK6/SIL3/Cat.4. is defined by how the transmit-ter is connected-up.

777How is the Safety Class achievedwith F outputs?

For F outputs, the required SafetyClass is achieved by the way in whichthe test signals are connected tothe F I/O.

Evaluating transmitters for F digitalinputs

For F digital inputs, the requiredSafety Class is achieved by the type of transmitter evaluation.


Table: Safety Classes which can be achieved for F digital inputs

7.2 Controllers: Fail-safe controls

7.2.1 Circuit examples for S7-300F

Achieved by

Acc. to IEC 61508 Acc. to DIN V 19250 Acc. to EN 954-1 Transmitter evaluation

SIL2 AK4 Cat. 3 1-from-1 evaluation

SIL3 AK5,6 Cat. 4 2-from-2 evaluation

Safety Classes

Example: A transmitter connectedto an F-DI through 1 channel(AK4/SIL2/Cat.3)

The connection schematic for an SM326, DI 24 x 24V DC for a 1-from-1evaluation of the transmitter is shownin the following diagram.The transmit-ter is supplied from the F I/O.AK4/SIL2/Cat.3 can be achieved usingthis connection.

Example: A transmitter connectedto an F-DI through 1 channel(AK6/SIL3/Cat.4)

The connection schematic for an SM326, DI 24 x 24V DC for a 2-from-2evaluation of the transmitter is shownin the following diagram.The transmit-ter is supplied from the F I/O.AK6/SIL3/Cat.4 can be achieved usingthis connection as long as a suitablyqualified transmitter is used.

Example: A transmitter connectedto an F-DI through 2 channels(AK6/SIL3/Cat.4)

The connection schematic for an SM326, DI 24 x 24V DC for a 2-from-2evaluation of the transmitter is shownin the following diagram.AK6/SIL3/Cat.4 can be achieved usingthis connection.

Example: An antivalenttransmitter (2-channel) connectedto an F-DI (AK6/SIL3/Cat.4)

The connection schematic for an SM326, DI 24 x 24V DC with antivalenttransmitter (2-from-2 evaluation) isshown in the following diagram.AK6/SIL3/Cat.4 can be achieved withthis connection.


Example: Wiring schematic for a transmitter connected to an F-DI (2-from-2) through 2 channels)

Digital inputmodule

1L+

1M

Vs

DILeft: Channels 0…11

Right: Channels 0…11 Vs

DI

Example: Connection schematic for an anti-valent transmitter connected to an F-DI (2-from-2) through 2 channels

Digital inputmodule

1L+

1M

Vs

DI

DI

Left: Channels 0…11

Right: Channels 0…11

Example: Wiring schematic for a transmitter connected to an F-DI (1-from-1) through 1 channel

Digital inputmodule

1L+

1M

Vs

DI

Example: Wiring schematic for a transmitter connected to an F-DI (2-from-2) through 1 channel)

Left: Channels 0…11

Right: Channels 0…11

Digital inputmodule

1L+

1M

Vs

DI

DI

Mode of operation

Light curtains can be operated in themuting mode so that products orobjects can be brought into the haz-ardous area, monitored by the lightcurtain, without stopping the machine.It must be ensured that personnel can-not enter the hazardous area while thelight curtain is bypassed by using twoor four muting sensors as well as thecorrect integration into the productionsequence.It is extremely important to note thatthe interval in which the safety pro-gram is called (e.g. OB 35) must beless than the selected discrepancytime.

Schematic sequence of an error-freemuting operation using 4 mutingsensors(MS_11, MS_12, MS_21, MS_22)

1. If the inputs for the muting sensorsMS_11 and MS_12 are activated by theproduct within DISCTIM1, then the Fapplication block switches to MUTING.The enable signal Q remains at 1, alsoif the input FREE = 0 (the productinterrupts the light curtain).The outputMUTING goes to 1 to control the mut-ing lamp.

2. As long as the two inputs MS_11and MS_12 are still activated by theproduct, Q remains at 1 and MUTINGremains at 1 as a result of the MUT-ING function of the F application block (so that the product may pass throughthe light curtain without the machinestopping).

3.The inputs for the muting sensorsMS_21 and MS_22 must have beenactivated within DISCTIM2 and beforethe inputs for the muting sensorsMS_11 and MS_12 are switched intoan inactive state.This means that the F application block maintains the MUTING. (Q = 1, MUTING = 1).

777

4. After one of the inputs for the mut-ing sensors MS_21 and MS_22 = 0(the product enables the sensors), theMUTING function is exited (Q = 1,MUTING = 0).The MUTING functionmay be active for a maximum timeparameterized at the input TIME_MAX.


7.2.2 Function block for the S7-300F mutingfunction

Hazardous areaMS_21

MS_22

Transmitter

Receiver

MS_11

MS_12

1

Hazardous areaMS_21

MS_22

Transmitter

Receiver

MS_11

MS_12

2

Hazardous areaMS_21

MS_22

Transmitter

Receiver

MS_11

MS_12

3

Hazardous areaMS_21

MS_22

Transmitter

Receiver

MS_11

MS_12

4

Timing diagram for error-free muting using 4 muting sensors

DISCTIM1 and DISCTIM2 are discrep-ancy times for sensor pairs 1 and 2.


FREE

MS_11

MS_12

MS_21

MS_22

ACK

MUTING

Q

FAULT

ACK_REQ

t < DISCTIM2

t < TIME_MAX

t < DISCTIM1

777

Fig. 7/93Stop Category 0, 2-channel, with feedback circuit; Category 3 acc. to EN 954-1; Function with a motor coasting down

N/–

14

13

24

23

K1M3~

K1

A2

EMER-GENCYSTOP

A1

P24 V DCM DC

Y1 Y2

ON

L/+N/–

U2 V2 W2SIMOVERT MASTERDRIVES

ControlmoduleCU

PV

M

P24V

Option K80X533

X101

K1

L1L2L3PE

X: Digital input,assigned to OFF2P556i001 and i002

U1 V1 W1

Separatelyprotected routing

3TK

2824

1)

Loop in check-back signals fromprotective devices,e.g. door interlocks,light curtains

1)

1243

Communi-cationsmodule,e.g. CBP

X

Drive inverter

This section describes the circuitexamples using the drive systemsSIMOVERT MASTERDRIVES andSIMODRIVE 611 universal for applica-tions involving variable-speed driveswith AC motors.

These examples show possibilities of implementing the various solutions.The solution required for the machinemust be aligned to the particularmachine function.This results inindividual parameter assignments orcontrol commands for applicationsassociated with stop Category 1.

Using the “safe standstill” function,the drive pulses are cancelled thuspreventing the drive from undesirablystarting.

The solutions which are shown can,from the actual principle, also beimplemented using other drivesystems. However, the appropriateinformation/instructions in the docu-mentation describing the variousproducts must be carefully observed(also refer to the Certificate in Section8.6.3)

SIMOVERT MASTERDRIVES Vector Control Catalog DA 65.10

SIMOVERT MASTERDRIVES Motion Control Catalog DA 65.11

SIMODRIVE 611Catalog NC 60.1 and NC 60.2

7.3 Motion Control Systems: Safe Motion Control

7.3.1 Application exam-ples for EMERGENCYSTOP Category 0



Fig. 7/94Stop Category 1, 2-channel, with feedback circuit, Category 3 acc. to EN 954-1;Function where the motor is shut down along the torque limit in a controlled fashion.

13 23

14 24

N/–

32 44

31 43

54

53

K1

K1

Y11

A2Y21 Y22

EMER-GENCYSTOP

A1 Y12

24 V DCM DC

Y33

PE

PE

Y34

H1

ON

L/+N/–

X533

K1

L1L2L3PE

U1 V1 W1

Y10

3TK

2827

M3~

U2 V2 W2SIMOVERT MASTERDRIVES

ControlmoduleCU

PV

M

P24V

Option K80X533

X101


Loop in check-back signals fromprotective devices,e.g. door interlocks,light curtains

1)

1243

Communi-cationsmodule,e.g. CBP

1)

X

Y

Drive inverter


7.3.2 Application exam-ples for EMERGENCYSTOP Category 1

Structure acc. to EN 954-1 controlcategory 3 and EN1037

The drive is shut down according tothe stop function, Category 1 acc. toEN 60204-1.


777By implementing as a higher-levelcircuit using contacts, the “Safe stand-still” function is even guaranteed forerroneous behavior or if the PLC fails.For an EMERGENCY SWITCHING-OFF,the drive is electrically isolated fromthe line supply.For this type of connection, the inter-nal line contactor of the supply unitonly drops-out if the internal safetyrelay functions erroneously.

Fig. 7/95EMERGENCY SWITCHING-OFF and EMERGENCY STOP, Stop Category 1 acc. to EN 60204,2-channel with feedback circuit, control Category 3 acc. to EN 954-1

7.3.3 Application examplesfor EMERGENCY SWITCH-ING-OFF and EMERGENCYSTOP Category 1

Structure/design in accordancewith EN 954-1 control Category 3and EN1037

The drive is shut down in accordancewith stop function Category 1 acc. toEN 60204-1.


With this particular circuit principle, theinternal line contactor of the supplyunit only drops-out if one of the twointernal safety relays has an erroneousfunction.This circuit principle is suitable if indi-vidual drive groups must be selectivelyshut down.The circuit principle can be expandedto several drive groups.

7.3.4 Application examplefor EMERGENCY STOP,Category 1 for severaldrives

Fig. 7/96Emergency Stop, Stop Category 1 acc. to EN 60204, 2-channel with feedback circuit,control Category 3 acc. to EN 954-1


777

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