System Manual Safety Relays ESM - Euchner · System Manual ESM 4 Function The safety relays ESM…...

More than safety.

GBSystem ManualSafety Relays

ESM

System Manual ESM

�

ContentsCorrect use 3Exclusion of liability and warranty 3General safety instructions 3Function 4Safety relay ESM-BL2.. 5Application 6Technical data 8Safety relay ESM-BA2.. 10Application 11Technical data 14Accessories 15Safety relay ESM-BA3 16Application 17Technical data 19Accessories �1Safety relay ESM-BA7 22Application �3Technical data �6Accessories �8Safety relay ESM-BT4.. 29Application 30Technical data 3�Safety relay ESM-2H... 34Application 35Principle of operation 35Example circuits 36Technical data 37Function diagram 38Contact expansion ESM-ES.. 39Application 40Technical design 41Technical data 41Contact expansion ESM-TE.. 43Application 44Technical design 45Technical data 46Connection examples safety relays ESM 48Safety relay ESM-BL.. 48Safety relays ESM-BA../ESM-BT.. 49Safety relay ESM-�H�.. 51Safety contact expansion ESM-ES../ESM-TE.. 5�Inspection and service 53Service 53Declaration of conformity 54

System Manual ESM

3

Correct useThe safety relay ESM... is used to evaluate safety-related signals in safety cir-cuits according to EN 60�04-1. With this unit safety category 4 according to EN ISO 13849-1 can be achieved (exception: ESM-BL... up to category 3). The devices are not allowed to be opened, tampered with, or modified. The permissible operating parameters are to be observed during operation (see section “Technical data”).

Before the safety relay is used, a risk assessment must be performed on the machine in accordance with:

EN ISO 13849-1, Safety of machinery. Safety related parts of control systems. General principles for design, Annex B

EN ISO 141�1, Safety of machinery. Principles for risk assessment

IEC 6�061, Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems

Correct use includes compliance with the relevant requirements for installation and operation, particularly

EN 60�04-1, Safety of machinery. Electrical equipment of machines. General requirements

Exclusion of liability and warrantyIn case of failure to comply with the conditions for correct use stated above, or if the safety instructions are not followed, or if any servicing is not performed as required, liability will be excluded and the warranty void.

General safety instructionsThe device is only allowed to be installed and placed in operation by authorized personnel

who are familiar with the correct handling of safety components,

who are familiar with the applicable regulations on health and safety

and who have read and understood the operating instructions and the system manual.

The safety function of the system while the machine is in operation can no longer be ensured if the device is connected incorrectly or used incorrectly. Fatal injuries may result.

Important!

Prior to use read the operating instructions and the system manual, and keep these in a safe place. Ensure the operating instructions and the system manual are always available during mounting, setup and servicing. EUCHNER cannot provide any warranty in relation to the readability of the CD for the storage period required. For this reason you should also archive a printed copy of the system manual. If you should lose the operating instructions or the system manual, you can download these documents from www.EUCHNER.de.

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FunctionThe safety relays ESM… are used to evaluate connected safety components and to safely interrupt safety circuits.

The devices have inputs for the connection of safety components. The safety contacts are switched as a function of the input signals. Subsequent parts of the safety circuit can be monitored using a feedback loop.

Different device states can be signaled using monitoring outputs.

If one of the safety components (e.g. an emergency stop) is actuated, the safety relay opens its contacts immediately or after a time delay. If additional expansion devices are used, these also receive a signal to open their contacts. The system can be started either manually using a start button or automatically using a jumper.

System Manual ESM

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Safety relay ESM-BL2..STOP category 0

Up to safety category 3

� positively driven safety contacts with redundancy and cyclical monitoring of the internal components

Single-channel or dual-channel control without error monitoring

According to EN 60 �04-1 and EN ISO 13849-1

The EUCHNER ESM-BL�.. safety relay is an emergency stop safety relay for all ap-plications in which there is the risk of minor injuries or in which there is no frequent or continuous presence in the danger area. Shutdown is performed by isolating the power supply. Internal error monitoring is then performed when the start button is used for switching back on.

Safety precautions

All relevant safety regulations and standards are to be observed.

Failure to observe the safety regulations can result in death, serious injury and serious damage.

Assembly and electrical connection must be performed only by authorized personnel.

As per EN 60�04-1 the device is intended for installation in control cabinets with a minimum degree of protection of IP 54.

The electrical connection is only allowed to be made with the device and wiring isolated.

The wiring must comply with the instructions in this user information, otherwise there is a risk that the safety function will be lost.

The tightening torque on the connection terminals must be 0.6 to 0.8 Nm.

It is not allowed to open the device, tamper with the device or bypass the safety devices.

The device is maintenance-free when used correctly.

Caution!

In the event of a fault (e. g. short circuit) in the load circuit, excessively high currents may flow through the safety contacts. For protection against welding, each contact must be individually protected with an external fuse.

To enable a ground fault monitoring, S10 must be connected with PE (protective earth) on devices with an operating voltage of �30 V AC or 115 V AC. Acc. to EN 60�04-1, devices with an operating voltage of �4 V DC must be grounded on the power supply and S10 may not be connected with PE addition-ally.

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ApplicationIn case of danger, the ESM-BL�.. safety relay can quickly and safely shutdown the relevant parts of the machine by isolating the power supply to all main circuits using positively driven, redundant relay contacts, i.e. using relay contacts with double safety. Additionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).

Preferred applications include emergency stop circuits and guard monitoring.

The requirements in particular in EN 60 �04-1 on switch off, STOP and EMERGENCY STOP functions were taken into consideration for the safety relay.

Stop category 0 is achieved with the technology used. The occurrence of a single failure in the device does not result in the loss of the safety function; the failure will be detected on or before the next demand for the safety function. Faults in the supply cables to the safety relay are not monitored.

The ESM-BL�.. safety relay complies, along with the requirements in EN 60 �04-1, also with the requirements for safety category 3 as per EN ISO 13849-1.

Two-channel emergency stop circuit(without error monitoring for the emergency stop button and the supply cables)

The emergency stop button with two normally closed contacts is inserted in the wiring for the power supply, A1 and A�.

A single failure in the emergency stop button does not result in the loss of the safety function, however the failure will not be detected by the safety relay. This behavior is permissible up to safety category 3 as per EN ISO 13849-1. The start button for controlling the switching back on of the device connects terminals S11 and S�1.

S21

ϑ

(nur 24V)

A2

A1

(nur 24V)

S11

K2

K1+

+

14 24

13 23

UB

(electro-mechanical safety functions)Relay Control and Error Monitoring

Emergency Stop

Start

Power Supply

Pin assignment UB A1 A2 DC +UB 0 V AC L1 N

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Single-channel emergency stop circuitSafety category 1 as per EN ISO 13849-1 is achieved when the ESM-BL�.. safety relay is operated as an emergency stop circuit with single-channel control. In this case only the power supply to A1 is isolated by the (single-channel) emergency stop button. The start button for controlling the switching back on of the device connects terminals S11 and S�1.


S21

ϑ

(nur 24V)

A2

A1

(nur 24V)

Emergency Stop

S11

Start

K2

K1+

+

14 24

13 23

Power Supply

UB


Sliding guard monitoringThis circuit variant uses the same principle as the emergency stop circuit (see above), however the emergency stop button is replaced by one or two limit switches that monitor the position of the sliding guard. At least one of these limit switches must have positively driven contacts, i.e. isolate the electrical connection by means of the active application of force.

S21

(nur 24V)

A2

(nur 24V)

ϑ

Safety guardclosed

A1 S11

+K2

K1+

14 24

13 23

UB


Start

Power Supply


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Technical data Parameter Value Unit

min. nom. max.

Housing material Polyamide PA 6.6

Dimensions 114 x 99 x ��.5 mm

Weight 0.�3 kg

Ambient temperature

at UB = AC/DC �4 V - 15 - + 60°C

at UB = AC 115/�30 V - 15 - + 40

Degree of protection according to EN 605�9 IP �0

Degree of contamination �

Mounting 35 mm DIN rail according to DIN EN 500��-35

Type of connection Screw terminals

Terminals 0.14 - �.5 mm²

Operating voltage UB

ESM-BL�01 �4 ± 10% 1) V AC/DC

ESM-BL�0� 115 ± 10%V AC

ESM-BL�03 �30 ± 10%

Rated supply frequency 50 - 60 Hz

Power consumption approx. 4 VA

Control voltage for start button (S11) 18.6 �4 �6 V DC

Control cable length (with cross-section 0.75 mm�) - - 1,000 m

Control current for start button (S11) approx. 40 mA

Safety contacts � NO contacts

- Switching voltage AC - - �50 V AC

- Switching voltage DC - - �4 V DC

- Switching current at �4 V �0 - - mA

- Utilization category according Ue Ie S Ieto EN 60947-5-1 AC-1� �50 V 6 A

1� AAC-15 �30 V 4 A

DC-1� �4 V 1,�5 A

DC-13 �4 V � A

- Breaking capacity according to UL 6 A �50 V AC / � A �4 V DC

External contact fuses (safety circuit)according to EN 60�69-1

10 AgG (T6A / F8A)

Contact material AgNi-10

Mechanical life 1 x 107 operating cycles

Electrical life 1 x 105 operating cycles

Reverse polarity protection at version UB = DC �4 V

Rated impulse withstand voltage Uimp

�.5 kV

Leakage path/air gap acc. to DIN VDE 0110-1:1997-04 4 kV

In compliance with EN 60�04-1/ EN ISO 13849-1

LEDs �, Status displays for relays K1 and K�

1) All the electrical connections must either be isolated from the mains supply by a safety transformer according to EN 61558-�-6 with limited output voltage in the event of a fault, or by other equivalent isolation measures.Ue = Switching voltage Ie = Maximum switching current per contact S Ie = Maximum switching current per all safety contacts (cumulative current)

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Dimension drawing

114

99

22,5

23 13

14 24 A2 S11

S21

2414

K1K2

2313

ESM-BL2

A1

Suitable for 35 mm DIN railaccording to DIN EN 500��-35

Block diagram

2313S11S21

2414

Inputs

K2

K1

A1 A2

~-

--

Start

Powersupply

System Manual ESM

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Safety relay ESM-BA2..STOP category 0



Single-channel or dual-channel control

Short circuit monitoring and/or earth fault monitoring

According to EN 60�04-1 and EN ISO 13849-1

The EUCHNER ESM-BA�.. safety relay is an extremely compact universal emergency stop safety switching device and safety door monitor. It is intended for use in safety circuits designed in accordance with EN 60�04-1. Due to the flexible connection options, the safety relay can be used for almost all applications, despite its very compact dimensions. Depending on the external circuit, safety category 4 can be achieved.

Safety precautions










Caution!



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11

ApplicationIn case of danger, the ESM-BA�.. safety relay can quickly and safely shutdown the relevant parts of the machine by switching off all main circuits via a control circuit using positively driven, redundant relay contacts, i.e. using relay contacts with double safety. Additionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).

Preferred applications include single and dual-channel emergency stop circuits and guard monitoring.

The requirements in particular in EN 60�04-1 on switch off, STOP and EMERGENCY STOP functions were taken into consideration for the safety relay.

Stop category 0 is achieved with the technology used. The occurrence of a single failure in the device does not result in the loss of the safety function; the failure will be detected on or before the next demand for the safety function. As well as the requirements of EN 60�04-1, the safety relay also fulfills the requirements for the safety category 4 as per EN ISO 13849-1.

Two-channel emergency stop circuit with short circuit monitoring and earth fault monitoringS11 and S14 must be connected to activate the short circuit monitoring. The emer-gency stop button is inserted in the wires S11–S1� and S10-S13. The start/reset button connects S1� and S�1. After connecting the power supply to A1 and A�, the safety contacts can be closed using the start button.

S21

(nur 24V)

A2 S10

ϑ

A1 S11 S14

K2+

K1+

2414

S12 S13 2313


Emergency Stop

Start

Power Supply


System Manual ESM

1�

Two-channel emergency stop circuit with earth fault monitoring (no short circuit monitoring)This circuit makes it possible to achieve an immediate shutdown on an earth fault in the control cables, however the short circuit monitoring is deactivated. Contacts S10 and S13 are bridged; the emergency stop button is inserted in the wires S11–S1� and S11–S14.

The start/reset button connects S1� and S�1.

S21

ϑ

A2 S10 S13

(nur 24V)

A1 S11

K2

+K1

+

2414

S12 S14 2313


Emergency Stop

Start

Power Supply


Single-channel emergency stop circuitThe safety relay can also be used as an emergency stop circuit with single-channel control, provided this usage is permitted by a risk assessment in accordance with EN ISO 13849-1. For this purpose, the contacts S10 and S13 as well as S1� and S14 need to be connected. The single-channel emergency stop button is inserted in the wire S11–S1�/S14.

S21

(nur 24V)

A2 S10 S13

ϑ

A1 S11

+K2

+K1

2414

S12 S14 2313


Emergency Stop

Start

Power Supply Pin assignment UB A1 A2 DC +UB 0 V AC L1 N

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Two-channel sliding guard monitoring with short circuit and earth fault monitoring

This circuit variant uses the same principle as the dual-channel emergency stop circuit, however the emergency stop button is replaced by two limit switches that monitor the position of the sliding guard. At least one of these limit switches must have positively driven contacts, i.e. isolate the electrical connection by means of the active application of force.

S21

Start

Safety guardclosed

(nur 24V)

A2 S10

ϑ

A1 S11 S14

K2+

K1+

2414

S12 S13 2313


Power Supply


Monitored start / auto startAdditional monitoring of the start button can be realized by integrating the start button between S11 (instead of S1�) and S�1.

Replacing the Start button between terminals S1� and S�1 with a bridge pro-duces an auto start when the input signal is reset.

Time behavior of the relay in „auto start“ operating mode (bridge S21-S12)

If the signal at S1� is produced before the signal S13 or S14:

the maximum time difference between S1� and S13 or S14 must not exceed 50 ms.

If the signal at S13 or S14 is produced before the signal S1�:

any time difference between S1� and S13 (infinite).

System Manual ESM

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min. nom. max.



Weight 0.�3 kg

Ambient temperature

at UB = AC/DC �4 V - 15 - + 60°C

at UB = AC 115/�30 V - 15 - + 40







ESM-BA�01 �4 ± 10% 1) V AC/DC

ESM-BA�0� 115 ± 10%V AC

ESM-BA�03 �30 ± 10%






Safety contacts � NO contacts





1� AAC-15 �30 V 4 A

DC-1� �4 V 1,�5 A

DC-13 �4 V � A



10 AgG (T4A / F6A)






�.5 kV





System Manual ESM

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Dimension drawing

114

99

22,5

23 13

14 24 A2 S10S13S12

S11 S14 S21

2414

K1K2

2313

ESM-BA2

A1


Block diagram

2313S21

2414

S10

Inputs

K2

K1

A1 A2

~-

--

Start

Powersupply

S11 S12 S13 S14

Accessories(only for versions with plug-in connection terminals)

To connect the ESM modules you will need appropriate connection terminals that are not included with the modules.

Connection setThe connection set is available with either screw terminals or with spring termi-nals:

Items supplied with connection set with screw terminals4 plug-in screw terminals

� jumpers

Coding pins

Items supplied with connection set with spring terminals4 plug-in spring terminals

� jumpers

Coding pins

You can obtain additional installation material or spare parts from EUCHNER.

System Manual ESM

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Safety relay ESM-BA3STOP category 0


3 positively driven safety contacts with redundancy and cyclical monitoring of the internal components




The EUCHNER ESM-BA3.. safety relay is a compact, universal emergency stop safety switching device with 3 safety paths that can be loaded with up to 8A. In addition, there is a door auxiliary contact that can be loaded with up to �A. This is a normally closed contact. The device complies with the requirements of EN 60�04-1 for safety circuits. Despite its very compact dimensions, the safety relay can be used for almost all applications up to the highest category, safety category 4.

Safety precautions










Caution!



System Manual ESM

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ApplicationIn case of danger, the ESM-BA3.. safety relay can quickly and safely shutdown the relevant parts of the machine by switching off all main circuits via a control circuit using positively driven, redundant relay contacts, i.e. using relay contacts with double safety. Additionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).







S21

Start

42

41

A2 S10

ϑ

A1 S11 S14

K2+

K1+

2414 34

Emergency Stop

S12 S13 2313 33

System Manual ESM

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S21

42

41

S13A2 S10

ϑ

A1 S11

Start

+K1

+K2

14 24 34

S12 S14

Emergency Stop

13 23 33


Relay Control and Error Monitoring(electro-mechanical safety functions)

S21

A2 S10

ϑ

S13

A1 S11

Start

+K2

+K1

2414 4234

Emergency Stop

S12 S14 2313 4133

System Manual ESM

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Two-channel sliding guard monitoring with short circuit and earth fault monitoringThis circuit variant uses the same principle as the dual-channel emergency stop circuit, however the emergency stop button is replaced by two limit switches that monitor the position of the sliding guard. At least one of these limit switches must have positively driven contacts, i.e. isolate the electrical connection by means of the active application of force.

S21

Start

42

41

Safety guardclosed

A2 S10

ϑ

A1 S11 S14


K2+

K1+

2414 34

S12 S13 2313 33









min. nom. max.



Weight 0,�3 kg

Ambient temperature - 15 - + 40 °C







ESM-BA301 �4 ± 10% 1) V AC/DC

ESM-BA30� 115 ± 10%V AC

ESM-BA303 �30 ± 10%


System Manual ESM

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Safety contacts 3 NO contacts

- Cumulative current of all contacts acc. to UL 15 A




- Utilization category according to EN 60947-5-1 Ue Ie S Ie

ESM-BA301 AC-1� �50 V 8 A

15 A �)

AC-15 �50 V 3 A

DC-1� �4 V � A

DC-13 �4 V � A

ESM-BA30� AC-1� �50 V 8 A

ESM-BA303 AC-15 �50 V 3 A

DC-1� 50 V 8 A

DC-13 �4 V 3 A

- Breaking capacity according to UL

ESM-BA301 8A �50V AC / �A �4 V DC per contact

ESM-BA30� ESM-BA303 8A �50V AC / 3A �4 V DC per contact

Auxiliary contact 1 NC contact



- Utilization category according Ue Ieto EN 60947-5-1 AC-1� �50 V � A

AC-15 �30 V � A

DC-1� �4 V 1,�5 A

DC-13 �4 V 1,�5 A

- Breaking capacity according to UL

ESM-BA301 � A �50 V AC / 1.5 A �4 V DC

ESM-BA30� ESM-BA303 � A �50 V AC / � A �4 V DC


10 AgG (T6A / F8A)

Contact material

ESM-BA301 AgNi-10

ESM-BA30� ESM-BA303 AgSnO�





�.5 kV


In compliance with EN 60�04-1 / EN ISO 13849-1


1) All the electrical connections must either be isolated from the mains supply by a safety transformer according to EN 61558-�-6 with limited output voltage in the event of a fault, or by other equivalent isolation measures.�) With a housing distance of 10 mm. 8 A closely spaced at 40 °C.Ue = Switching voltage Ie = Maximum switching current per contact S Ie = Maximum switching current per all safety contacts (cumulative current)

System Manual ESM

�1

Dimension drawing

114

99

22,5

23 13

14 24 A2 S10S13S12

S11 S14 S21

ESM-BA3

A1

42

13 23 33 41

K2K1

24 3414

4133

34 42


Block diagram

2313S21

2414

S10

Inputs

K2

K1

A1 A2

~-

--

Start

Powersupply

S11 S12 S13 41

42

33

34

S14





� jumpers

Coding pins


� jumpers

Coding pins


System Manual ESM

��

Safety relay ESM-BA7STOP category 0


7 positively driven safety contacts with redundancy and cyclical monitoring of the internal components



According to EN 60�04-1, EN ISO 13849-1

4 Auxiliary contacts

� monitoring outputs

The EUCHNER ESM-BA7... safety relay is a compact, universal emergency stop safety switching device with 7 safety paths that can be loaded with up to 8 A. In addition, there are � monitoring outputs (semiconductor PNP) and 4 door auxiliary contacts which can be loaded with up to 8 A. These are normally closed contacts. The device complies with the requirements of EN 60�04-1 for safety circuits. Despite its very compact dimensions, the safety relay can be used for almost all applications up to the highest category, safety category 4.

Safety precautions










Caution!



System Manual ESM

�3

ApplicationIn case of danger, the ESM-BT7.. safety relay can quickly and safely shutdown the relevant parts of the machine by switching off all main circuits via a control circuit using positively driven, redundant relay contacts, i.e. using relay contacts with double safety. Additionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).






System Manual ESM

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System Manual ESM

�5

Two-channel sliding guard monitoring with short circuit and earth fault monitoringThis circuit variant uses the same principle as the dual-channel emergency stop circuit, however the emergency stop button is replaced by two limit switches that monitor the position of the sliding guard. At least one of these limit switches must have positively driven contacts, i.e. isolate the electrical connection by means of the active application of force.








OutputsThe ESM-BA7 safety relay features 7 positively driven, redundant safety contacts (13-14 to 73-74, NO contacts) and 4 auxiliary contacts (81-8�, 91-9�, 101-10�, 101-11�, NC contacts). Internally, two K1A/K1B relays and two K�A/K�B relays each work in parallel.

The monitoring outputs actively switch +�4V (internally). The terminal 0V is the reference potential.

O1 conducting: device ready, Pwr (UB) connected

O� conducting: both relay channels K1, K� switched on

Warning!

With an AC�4V connection, 0V must not be connected to A�!

System Manual ESM

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min. nom. max.


Dimensions 114 x 99 x 45 mm

Weight 0,35 kg







Operating voltage UB �4 ± 10% 1) V AC/DC





Control current for start button (S11) - - 100 mA



- Switching voltage DC - - 50 V DC


- Utilization category according to EN 60947-5-1 Ue Ie S Ie

AC-1� �50 V 8 A

35 A �)AC-15 �50 V 3 A

DC-1� 50 V 8 A

DC-13 �4 V 3 A

- Breaking capacity according to UL 8 A �50V AC / � A �4 V DC per contact

Auxiliary contact 4 NC contacts



- Utilization category according Ue Ieto EN 60947-5-1 AC-1� �50 V 8 A

AC-15 �50 V 3 A

DC-1� 50 V 8 A

DC-13 �4 V 3 A

- Breaking capacity according to UL � A �50 V AC / 1.5 A �4 V DC

Monitoring outputs �, p-switching, max. 30 mA, short-circuit-proof


10 AgG (T6A / F8A)

Contact material AgSnO�





�.5 kV

System Manual ESM

�7

Leakage path/air gap acc. to DIN VDE 0110-1:�003-11 4 kV


LEDs 3, Status display operating voltage (Pwr) and status displays for relays K1 and K�

1) All the electrical connections must either be isolated from the mains supply by a safety transformer according to EN 61558-�-6 with limited output voltage in the event of a fault, or by other equivalent isolation measures.�) With a housing distance of 10 mm. �5 A closely spaced at 40 °C.Ue = Switching voltage Ie = Maximum switching current per contact S Ie = Maximum switching current per all safety contacts (cumulative current)

Dimension drawing

5343O1 O2 A1101

63 7333S21 S14S11

13 23 81

K1

K2

92

91

34

33 81

8224

2313

K2K1

14 54

53 63

6444

43 73

74 112

101

102

44A20V112

64 74

ESM-BA701

34S12 S13 S10 92

2414

91

Pwr

99

54102

82

45 114


Block diagram2313S21

2414

S10

Inputs

K2

K1

A1 A2

~-

--

Start

Powersupply

S11 S12 S13 33

34

81

82

91

92

6353

6454

43

44

101

102 112

73

74

S14

O10V

monitoringoutputs

O2

System Manual ESM

�8





� jumpers

Coding pins


� jumpers

Coding pins


System Manual ESM

�9

Safety relay ESM-BT4..STOP category non-time-delay 0, time-delay 1


4 positively driven safety contacts, time-delayed or non-time-delayed (various combinations: 3 nd/1 d, � nd/� nd, 1 nd/3 d)

Continuously adjustable time delay (1 ... 30 s)

Redundancy and cyclical monitoring of the internal components




The EUCHNER ESM-BT4.. safety relay is a compact, universal emergency stop safety switching device with 4 safety paths that can be loaded with up to 8A. Depending on the device type, the safety contacts are either time-delayed or non-time-delayed. The safety contacts delayed by up to 30 s permit, for instance, the resetting of the machine to a defined initial state or the braking of over-traveling machine parts. The device complies with the requirements of EN 60�04-1 for safety circuits. Despite its very compact dimensions, the safety relay can be used for almost all applications up to the highest category, safety category 4.

Safety precautions










Caution!



System Manual ESM

30

ApplicationIn case of danger, the ESM-BT4.. safety relay can quickly and safely shutdown the relevant parts of the machine by isolating the power supply to all main circuits using positively driven, redundant relay contacts, i.e. using relay contacts with double safety.

The ESM-BT4.. safety relay also features integrated safety contacts with time-delayed deactivation designed, e.g., for the resetting of the machine to a defined initial state or the braking of over-traveling machine parts.

The time-delayed contacts are activated at the same time as the non-time-delayed contacts; however, when the emergency stop button is pressed, the contacts are only deactivated after the time delay set on the potentiometer (1 ... 30 s).

Additionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).



The occurrence of a single failure in the device does not result in the loss of the safe-ty function; the failure will be detected on or before the next demand for the safety function. The safety relay complies, along with the requirements in EN 60�04-1, also with the requirements for safety category 4 as per EN ISO 13849-1.

The unit is designed as per EN 60�04-1 to be used in switch cabinets with the minimum degree of protection IP54.

Two-channel emergency stop circuit with short circuit monitoring and earth fault monitoringS11 and S14 must be connected to activate the short circuit monitoring. The emergency stop button is inserted in wires S11–S1� and S10-S13. The start/reset button connects S1� and S�1. After connecting the power supply to A1 and A�, the safety contacts can be closed using the start button.

System Manual ESM

31



Single-channel emergency stop circuitThe safety relay can also be used as an emergency stop circuit with a single-channel control if permitted by the risk assessment according to EN ISO 13849-1 . For this purpose, the contacts S10 and S13 as well as S1� and S14 need to be bridged. The single-channel emergency stop button in inserted in the wire S11–S1�/S14.








System Manual ESM

3�


min. nom. max.



Weight 0.�5 kg







Operating voltage UB �4 ± 10% 1)) V AC/DC


Power consumption approx. 4.6 VA

Verzögerungszeit einstellbar 1 - 30 s




Safety contacts 4 NO contacts (non-time-delayed/time-delayed)





15 A �)AC-15 �30 V 3 A

DC-1� 50 V 8 A

DC-13 �4 V 3 A

- Breaking capacity according to UL 6 A �50 V AC / � A �4 V DC per contact


10 AgG (T6A / F8A)

Contact material AgSnO�





�.5 kV



LEDs 4, Status displays for relays K1 bis K4

1) All the electrical connections must either be isolated from the mains supply by a safety transformer according to EN 61558-�-6 with limited output voltage in the event of a fault, or by other equivalent isolation measures.�) With a housing distance of 10 mm. 9 A closely spaced at 40 °C.Ue = Switching voltage Ie = Maximum switching current per contact S Ie = Maximum switching current per all safety contacts (cumulative current)

System Manual ESM

33

Dimension drawing

22,5

473713 S11 S14 S21A1

27

t

ESM-BT401

4838S12 S13 S10 A2

28 14

114

99


Block diagram

2313S21

2414

S10

Inputs

K1

K2

A1 A2

~-

--

Start

Powersupply

S11 S12 S13 37

K3

K4

47S14

38 48

2313S21

2414

S10

Inputs

K1

K2

A1 A2

~-

--

Start

Power supply

S11 S12 S13 33

K3

K4

47S14

34 48

2713S21

2814

S10

Inputs

K1

K2

A1 A2

~-

--

Start

Powersupply

S11 S12 S13 37

38

K3

K4

47

48

S14

ESM-BT401 ESM-BT411 ESM-BT4�1

System Manual ESM

34

Safety relay ESM-2H...STOP category 0

Up to safety category 4 / IIIC

Dual-channel control


Short circuit monitoring

Complies with EN 60 �04-1, EN 574 and EN ISO 13849-1

The ESM-�H�.. �-hand safety relay is an extremely compact, universal two-hand safety switching device. It complies with EN 574, type III C, and is intended for use in safety circuits that are designed in accordance with EN 60�04-1, e.g. on presses, punches and bending tools. Due to the internal error monitoring, the �-hand safety relay can, despite its very compact dimensions, be used for all applications up to the highest category, safety category 4 in accordance with EN ISO 13849-1 or type III C in accordance with EN 574.

Safety precautions










Caution!



System Manual ESM

35

ApplicationThe ESM-�H�.. �-hand safety relay is suitable for setting up and monitoring two-hand circuits and is used to protect the operators. Dangerous work steps can only be triggered when both two-hand buttons connected are operated simultaneously, i.e. within 0.5 s.

The buttons in the two-hand circuit must be arranged and be such that accidental operation is prevented and the protective effect cannot be easily bypassed. Here the regulations in the applicable standards, in particular EN 574-1 and EN 999, are to be observed. The �-hand safety relay is intended for the connection of two-hand buttons each with one normally closed contact and one normally open contact.

The feedback loop X1/X� enables monitoring of external contactors or relays for increasing the number of contacts or increasing the rating of the contacts . Ad-ditionally, on each on/off cycle automatic function monitoring is performed; this feature ensures that on the failure of a safety circuit, switch on is not possible (self-monitoring).

The occurrence of a single failure in the device does not result in the loss of the safety function; the failure will be detected on or before the next demand for the safety function. The �-hand safety relay complies, along with the requirements in EN 60�04-1 and EN 574, also with the requirements for safety category 4 in EN ISO 13849-1. As per EN 60�04-1 the device is intended for installation in control cabinets with a minimum degree of protection of IP 54.

Principle of operationWhen the operating voltage is applied to A1-A� and the feedback loop X1/X� is closed, the �-hand safety relay is ready for use. To be able to initiate a switching operation, the output relays must be de-energized. The output relays only switch to the energized position when the two-hand buttons T1 and T� are operated simultaneously, i.e. within 0.5 s.

The output relays are not switched if:

The two-hand buttons are not operated simultaneously or the time between the operation of the two-hand buttons is greater than 0.5s.

The feedback loop is open.

Another error (short circuit, cable break, error in the switching device) has oc-curred.

When T1 and/or T� are/is released, the output relays are de-energized immediately. In order to trigger a new operation, both two-hand buttons must first be released and the feedback loop must first be closed.

System Manual ESM

36

Without external contactors or expansion modules, X1-X� is to be connected.

N

KA KB

A1 A2 13

14

23

24

S11 S12 S13 S21 S22 S23 X1 X2

L1F1 F2

K1

K2

KA KB

K1

K2

Control Logic

Channel 1 Channel 2(control-, relay-, time-circuit)

K1 K2

T1 T2

ESM-2H2..

Example circuitsSingle-channel (1S) and dual-channel control (2S) of external con-tactorsThe type of circuit to be used is dependent on the safety level required for the control system, a risk analysis must be performed in accordance with EN ISO 13849-1.

KA KB

X1 X2 13 23

14 24

F1 F2

KA KB

L1

N

KA

KBESM-2H2..

X1 X2

KA KB

13

14

KA KB

L1

N

F1

ESM-2H2..

System Manual ESM

37


min. nom. max.



Weight 0.�3 kg








ESM-�H�01 �4 ± 10% 1) V AC/DC

ESM-�H�0� 115 ± 10%V AC

ESM-�H�03 �30 ± 10%


Power consumption AC approx. 4 VA

Power consumption DC approx. � W

Control voltage for start button (T1 + T�) 18.6 �4 �6 V DC


Control current for start button (T1 + T�) approx. 40 mA

Synchronization time - - 0.5 s

Release time for the safety relais (response time) - - �0 ms

Safety contacts � NO contacts (redundant)




- Utilization category Ue Ie S Ieaccording to EN 60947-5-1 AC-1� �50 V 6 A

8,4 AAC-15 �30 V 4 A

DC-1� �4 V 1,�5 A

DC-13 �4 V � A



10 AgG (T6A / F8A)






�,5 kV


In compliance with EN 60�04-1/ EN 574/ EN ISO 13849-1



System Manual ESM

38

Dimension drawing

114

13 23 A1

ESM-2H2

13 23

K2K1

14 24

S13S12S11

S21 S22 S23 A2 24 14

X1 X2

22,5

99


Block diagram

2313S11

2414

S12

Inputs

K2

K1

A1 A2

~-

--

Powersupply

S13 S21 S22 S23

X1 X2

Feedbackloop

Channel 1 Channel 2

Function diagram

Error:F1: T1 and/or T� on before UB F�: Synchronous activation error t > 0.5 sF3: Fault in feedback loop

No effectt0: UB must be applied before T1 or T� t1: Simultaneity t1 < 0.5 s = tst�: Working cycle is terminated by T1 or T�t3: X1-X� must be closed before T1 and/or T� are/is activated

101010101010

t0 t1 t2 t2t1t3 F1 F2 F3

ts

ErrorNormal working cycleOperating voltage UB

Two-hand button T1

Two-hand button T�Simultaneity monitoring ts(synchronous operation)

Feedback loop X1-X�(open: 0, closed: 1)

Output contacts 13-14, �3-�4(floating)

System Manual ESM

39

Contact expansion ESM-ES..

STOP category 0

Up to safety category 4 (within an electrical connection space)

Control and monitoring using ESM-B... safety relay

3 positively driven safety contacts and redundancy

Earth fault monitoring


Using the ESM-ES3.. safety expansion in conjunction with any ESM-B... safety relay, up to 3 additional safety paths can be created per expansion. In this way an existing system can be modularly expanded as required. Control is via a safety contact on the safety relay; the safety expansion provides auxiliary contacts for error monitoring.

Safety precautions










Caution!



System Manual ESM

40

ApplicationThe ESM-ES3.. safety expansion is connected to the ESM-B... safety relay using only 4 wires: a safety contact in the safety relay controls the relay in the expan-sion, two wires are needed for the feedback/error monitoring. Earth faults in the control cables are detected as well as internal errors.

Any number of expansions can be connected to a safety relay such that the number of safety contacts can be adapted to suit the specific requirement. Thus, for ex-ample, on the expansion of a system with components that represent an additional danger area, it is very straightforward to ensure that people remain protected by adding an expansion.

The safety expansion was designed so that in conjunction with an ESM-B... safety relay, it complies with the requirements of EN 60�04-1 EMERGENCY STOP de-vices, STOP category 0, as well as the stipulations of EN ISO 13849-1 up to safety category 3. Independent operation without a safety relay is not possible. As per EN 60�04-1, the device is intended for installation in control cabinets with a minimum degree of protection of IP 54.

Connection of an expansion to a safety relayOne of the safety contacts on the safety relay is connected to connections S11 and S15/S16 on the ESM-ES3.. safety expansion, the auxiliary contacts S�3-S�4 are connected in series with the start button.

34


S10A2

ϑA1

Start

S21S14S11

K2 +

K1+

14 24

S12 S13

EmergencyStop

13 23 33 S16

(nur 24V)

S10

(nur 24V)

42 A2

K1+

41 A1 S11

K2+

342414

S24S23S15 13 3323

Power Supply

Pin assignment UB A1 A2 DC +UB 0V AC L1 N

Connection of several expansions to a safety relayIf further ESM-ES... safety expansions are to be integrated in the system, S11 and also connections S10 and connections S15/S16 must be connected in parallel on all expansions.

ESM-ES...

14

13

ESM-B...

S21S12

S10

S15S11

EinOn

S10

S11S24S16

S23

ESM-ES...

S16S15 S23

S24

System Manual ESM

41

Technical designThe ESM-ES3.. safety expansion has relays with positively driven contacts so that error states can be detected by the safety relay via the auxiliary contacts S�3-S�4. The relay is controlled using terminals S15 and S16. A further function unit generates a control voltage of �4V at terminal S11; this voltage is connected to the controlling safety contact on the safety relay. The power supply is provided using terminals A1 and A�.

S16

S10A2

K1+

(nur 24V)

A1

ϑ

S11

K2+

14 24 34

S24S23S15 2313 33

Power Supply



min. nom. max.



Weight 0.�3 kg

Ambient temperature

at UB = AC/DC �4 V - 15 - + 60°C

at UB = AC 115/�30 V - 15 - + 40







ESM-ES301 �4 ± 10% 1) V AC/DC

ESM-ES30� 115 ± 10%V AC

ESM-ES303 �30 ± 10%





- Cumulative current of all con-tacts according to UL - - 10.5 A





1� AAC-15 �30 V 4 A

DC-1� �4 V 1,�5 A

DC-13 �4 V � A

- Breaking capacity according to UL 6A �50 V AC / �A �4 V DC per contact

System Manual ESM

4�

Auxiliary contact 1 NC contact AC/DC �4 V, 500 mAuse only as monitoring contact for safety relay


10 AgG (T6A / F8A)






�.5 kV


In compliance with EN 60�04-1 / EN ISO 13849-1



Dimension drawing

114

99

22,5

23 13

14 24 A2 S10S24S23

S11 S15 S16

ESM-ES3

A1

34

13 23 33 S23

K2

K1

14 24 S24

33

34


Block diagram

2313S10

2414

S11

Inputs

K2

K1

A1 A2

~-

--

Powersupply

S15 S16 33

34

S23

S24

System Manual ESM

43

Contact expansion ESM-TE..

STOP category 1

Up to safety category 4 (within an electrical connection space)

Control and monitoring using ESM-B... safety relay

3 time-delayed (1 ... 30 s adjustable), positively driven safety contacts and redundancy

Earth fault monitoring


The ESM-TE3.. safety timer relay expansion is operated in conjunction with a ESM-B... safety relay and enables parts of machines to be shutdown after a time delay. This can be necessary, for example, when it is safer to first move a tool to the starting position instead of shutting down the drive immediately. Expansions with and without time delay can be combined as required such that a complete system with different times and the specific number of safety contacts required can be realized.

Safety precautions










Caution!



System Manual ESM

44

ApplicationThe ESM-TE3.. safety timer relay expansion is connected to the ESM-B... safety relay using only 4 wires: a safety contact on the safety relay controls the relay in the expansion, two wires are needed for the feedback/error monitoring. Earth faults in the cables are detected as well as internal errors.

When the safety relay is activated, the output relays on the expansion switch on immediately. If the EMERGENCY STOP button is pressed, the safety relay switches off immediately, however the expansion only switches off after the time set on the rotary knob. The power supply must remain present during this time.

The safety timer relay expansion was designed so that in conjunction with a ESM-B... safety relay, it complies with the requirements of EN 60�04-1 EMERGENCY STOP devices, STOP category 0, as well as the stipulations of EN ISO 13849-1 up to safety category 3. Independent operation without a safety relay is not possible. As per EN 60�04-1, the device is intended for installation in control cabinets with a minimum degree of protection of IP 54.

Connection of an expansion to a safety relayOne of the safety contacts on the safety relay is connected to connections S11 and S15/S16 on the ESM-TE3.. safety timer relay expansion, the auxiliary contacts S�5-S�6 are connected in series with the start button.

34

Relay Control and Error Monitoring

S10A2

K2 +

14 24

K1+

A1 S21S14S11

Start

S12 S13 13 23 33

EmergencyStop

S1042 A2

(24V)

K1+

K2

382818

+

S16

(24V)

41 A1 S11 S26S15 S25 17 3727

Power Supply


Connection of several expansions to a safety relayIf further ESM-TE3... safety timer relay expansions are to be integrated in the system, connections S11 and also connections S10 and connections S15/S16 must be connected in parallel on all expansions.

ESM-TE...

14

13

ESM-B...

S21S12

S10

S15S11

EinOn

S10

S11S26S16

S25

ESM-TE...

S16S15 S25

S26

System Manual ESM

45

Technical designThe ESM-TE3.. safety timer relay expansion has relays with positively driven contacts so that error states can be detected by the safety relay via the auxiliary contacts S�5-S�6. The relay is controlled using terminals S15 and S16.

By using electronic components, very high reproducibility of the time set is achieved. To achieve the required failure safety, all function units are duplicated and realized in technically diverse manners.

A further function unit generates a control voltage of �4V at terminal S11; this volt-age is connected to the controlling safety contact on the safety relay. The power supply is provided using terminals A1 and A�.

K2

(24V)

A2 S10

K1+

A1

ϑ

S11 S16

+

2818 38

S25S15 S26 2717 37

Power Supply


System Manual ESM

46


min. nom. max.



Weight 0.�3 kg

Ambient temperature

at UB = AC/DC �4 V - 15 - + 60°C

at UB = AC 115/�30 V - 15 - + 40







ESM-TE301... �4 ± 10% 1) V AC/DC

ESM-TE30� 115 ± 10%V AC

ESM-TE303 �30 ± 10%



Delay time adjustable 1 - 30 s

Delay time fixed ESM-TE301-05S 0.5 s



- Cumulative current of all contacts 10.5 A at 1�0 V / 6 A at �50 V

- Cumulative current according to UL - - 10.5 A





10,5 AAC-15 �50 V 4 A

DC-1� �4 V 1,�5 A

DC-13 �4 V � A

- Breaking capacity according to UL 6 A �50 V AC / � A �4 V DC per contact

Auxiliary contact 1 NC contact AC/DC �4 V, 500 mAuse only as monitoring contact for safety relay


10 AgG (T4A / F6A)






�.5 kV





System Manual ESM

47

Dimension drawing

114

99

22,5

27 17

18 28 A2 S10S26S25

S11 S15 S16A1

t

ESM-TE3

38 S26

37

38

2818

K1

K2

S25372717


Block diagram

2717S10

2818

S11

Inputs

K2

K1

A1 A2

~-

--

Powersupply

S15 S16 37

38

S25

S26

System Manual ESM

48

Connection examples safety relays ESM

Safety relay ESM-BL..Automatic start without integration of the feedback loop

S11 S21

Manual start without integration of the feedback loop

S11 S21

S

Automatic start with integration of the feedback loop

KA

KB

S11 S21 13 23

KAKB

14 24

+

Manual start with integration of the feedback loop

KA

KB

S11 S21 13 23

KAKB

S

14 24

+

System Manual ESM

49

EMERGENCY STOP/safety circuitSTOP

A1 A2

UB

A1 A2

UB

1-channel �-channel

STOP

Safety relays ESM-BA../ESM-BT..Monitored start without integration of the feedback loop

S12(S14)

S11 S21

Un-monitored start without integration of the feedback loop

S12(S14)

S11 S21

Automatic start without integration of the feedback loop

S12(S14)

S11 S21 13 23

KAKB

14 24

+

Monitored start with integration of the feedback loop

S11 S21 13 23

KAKB

14 24

+KA

KB

S

System Manual ESM

50

Un-monitored start with integration of the feedback loop

KA

KB

S12 S21S11 13 23

KAKB

S

14 24

+

Automatic start with integration of the feedback loop

KA

KB

S12 S21S11 13 23

KAKB

14 24

+

1-channel EMERGENCY STOP/safety circuit

S10S11 S12 S13 S14

STOP

Important!

Earth connection notes for the respective device are to be observed.

2-channel EMERGENCY STOP/safety circuit with ground fault/short circuit detection

S10S11 S12 S13 S14

STOP

Important!

Earth connection notes for the respective device are to be observed.

System Manual ESM

51

Safety relay ESM-2H2..Monitoring a 2-hand control

S13S11 S12

T1

S23S21 S22

T2

With integration of the feedback loop

KA

KB

X1 X2 13 23

KAKB

14 24

+

Without integration of the feedback loop

X1 X2 13 23

KAKB

14 24

+

System Manual ESM

5�

Safety contact expansion ESM-ES../ESM-TE..Integration of the contact expansion

S15

ESM-ES /ESM-TE

S1614

K2

K1

13 S11

ESM-B...

Connection of the contact expansion with automatic start and with integration of the feedback loop

S15

ESM-ES /ESM-TE

S1614

K2

K1

13 S11ESM-BA.../ESM-BT...

S11 S23

S24S12(S14)

13 23

KAKB

14 24

+

KA KB

Connection of the contact expansion with manual start and with integration of the feedback loop

S15

ESM-ES /ESM-TE

S1614

K2

K1

13 S11ESM-BA.../ESM-BT...

S11 S23

S24S12(S14)

13 23

KAKB

14 24

+

KA KB

S

System Manual ESM

53

Inspection and service

Warning!

Loss of the safety function because of damage to the device.In case of damage the related module must be replaced. The replacement of individual parts in a module is not permitted.

Regular inspection of the following is necessary to ensure trouble-free long-term operation:

Check the switching function

Check the secure fastening of the devices and the connections

Check for soiling (e.g. the ventilation slots on the housing)

No servicing is required. Repairs to the device are only allowed to be made by the manufacturer.

ServiceIn case of a need for service, contact:

EUCHNER GmbH + Co. KG

Kohlhammerstraße 16

D-70771 Leinfelden-Echterdingen

Service telephone:

+49 (0) 7 11 / 75 97 - 301

E-mail:

[email protected]

Internet:

www.eucher.de

System Manual ESM

54

Declaration of conformityAs per the requirements of the Low voltage directive �006/95/EC, the EMC directive �004/108/EC and the Machinery directive 98/37/EC, we declare the conformity of the products listed below with the following European standards:a: EN 50081-1Electromagnetic Compatibility (EMC). Generic emission standard. Part 1: Residential, commercial and light industry

b: EN 50081-2Electromagnetic Compatibility (EMC). Generic emission standard, Part �: Industrial environment

c: EN ISO 13849-1Safety of machinery. Safety related parts of control systems. General principles for design

d: EN 60204-1Safety of machinery. Electrical equipment for machines. Part 1: Specification for general requirements

e: EN 60 439-1Low-voltage switchgear and controlgear assemblies. Part 1: Type-tested and partially type-tested assemblies

f: EN 61558-1Safety of power transformers, power supply units and similar. General requirements and tests

g: EN 60 695-2-4/0Fire hazard testing. Part �: Diffusion type and premixed type flame test methods

h: EN 60 947-1Specification for low-voltage switchgear and controlgear. Part 1: General rules

i: EN 60 947-5-1Specification for low-voltage switchgear and controlgear. Part 5-1: Control circuit devices and switching elements. Electromechanical control circuit devices

j: EN 60 947-7-1Specification for low-voltage switchgear and controlgear. Part 7: Ancillary equipment. Terminal blocks for copper con-ductors

k: EN 574Safety of machinery. Two-hand control devices. Functional aspects. Principles for design

The products are marked with the - marking as per the machinery directive.

Product Series Conformity with EN standards

Safety relay ESM-... a, b, c, d, e, f, g, h, i, j, k

Safety module ESM-F-... a, b, c, d, e, f g, h, i, j

The use of these products in a machine or system does not guarantee the entire machine or system complies with the European directives.

Leinfelden, March �009 Dipl.-Ing. Stefan Euchner Director

System Manual ESM

55

More than safety.

Euchner GmbH + Co. KGKohlhammerstraße 16D-70771 [email protected]

Issue:098853-08-07/09Title: System Manual Safety Relays ESM(Translation of the original operating instructions)Copyright:© EUCHNER GmbH + Co. KG, 07/�009

Subject to technical modifications,all data supplied without liability.

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