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kapitel 7
7.1 Safety-Related Low-Voltage Switchgear and Sensors
7.2 Controllers: Fail-safe controls
7.3 Motion Control Systems: Safe Motion Control
7.1 Safety-Related Low-Voltage Switchgear and Sensors
Supply
Fig. 7/1
EMERGENCY STOP switch with manual actuation or remote actuation via under-voltage
release
1-channel 2-channel
EMERGENCY EMERGENCY
STOP STOP Doors
control devices control devices
Open
Closed
Closed
Open
Fig. 7/7
Internal circuit diagram of the 3TK28 23
Function description
Y33 Y34 Y22 Y21 13 23 Power on;
Connect the power;
A1 The Power LED is lit, EMERGENCY STOP closed,
K1 K2
C1 is charged, press ON,
4 C1 starts to charge K1, V1 is energized,
K1
1 3 K2 starts, K1 + K2 latch,
2 Channel 1 and Channel 2 LEDs are lit.
K1
H1 H2 H3
K1 ON monitoring
ON is pressed fault!
C1 K1 K2
K2 EMERGENCY STOP is closed,
V1 V1 immediately starts K2, C1 is not charged
K2 K1 does not start.
K2 Only LED Channel 2 is lit.
Cross-circuit
A2 If EMERGENCY STOP 1 and EMERGENCY STOP 2 are
Y11 Y12 14 24 short-circuited, a current flows through the PTC fuse.
The PTC goes into a high-ohmic state.
None of the LEDs are lit.
Fig. 7/8
Function description of the 3TK28 23
Y2 Y1 13 23 (33) (41)
A1/A2 Power supply via
A1 EMERGENCY STOP pushbutton
Y1/Y2 ON
4
K1 K1 Feedback circuit
Fig. 7/9
Internal circuit diagram of the 3TK28 21/24
3TK28 21/24
K2
EMERGENCY SWITCHING-OFF
(EMERGENCY STOP) circuits M
Circuit diagrams
A2 14 24 (34) (42)
K3
K1 K2 K3 H1
Fig. 7/10 M
3TK28 21/24 for EMERGENCY STOP, N/ N/
Category 2, single channel,
with feedback circuit
24 V AC/DC L/+
ON
K1
K1
K2
K2
M
A2 14 24 (34) (42)
Fig. 7/11 K1 K2 H1
3TK28 21/24 EMERGENCY STOP,
N/ N/
Category 3 (4),
two-channel with feedback circuit
24 V AC/DC
L/+
K1
ON
K2
EMER- A1 Y11 Y12 Y33 Y34 13 23
GENCY
3TK28 23
STOP
K1
K2
Y21 Y22 A2 14 24 M
Fig. 7/12 K1 K2
3TK28 23 for EMERGENCY STOP,
N/ N/
Category 4, two-channel,
with feedback circuit, monitored start
L/+
ON STOP
K1
K2 K1 K2 K3
K3 M M M
K1 K2 K3 H1 H2
PE
N/ N/
Fig. 7/13 3TK28 25 EMERGENCY STOP, Category 2, single-channel, according to EN 954-1, monitored start
L/+
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
3TK28 25
EMER-
ON GENCY
K2
STOP
K1
K2 K1
M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52
K1 K2 H1 H2
PE
N/ N/
Fig. 7/14 3TK28 25 EMERGENCY STOP, Category 4, two-channel, according to EN 954-1, monitored start
L/+
L/+
STOP
K2 K1
ON
K1
M M
K2
Y33 Y34 PE A2 14 24 32 48 58
H1 K1 K2
N/
PE
N/
Fig. 7/15 3TK28 27 EMERGENCY STOP, Category 2, single-channel, according to EN 954-1, monitored start
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57
EMER-
GENCY
3TK28 27
STOP
ON K1
K1 K2
K2
Y33 Y34 PE A2 14 24 32 48 58
H1 K1 K2
Fig. 7/16
PE 3TK28 27 EMERGENCY STOP with
N/ N/ shutdown, Stop Category 1, for Category 3
according to EN 954-1, two-channel, with
feedback circuit, monitored start
24 V AC/DC
K1
ON
L/+
K5
A1 Y11 Y12 Y33 Y34 13 23 A1 13 23 33 43 51
EMER-
3TK2830
GENCY
3TK28 23
STOP
Y21 Y22 A2 14 24 A2 14 24 34 44 52
K1 K2 K3 K4 K5 Fig. 7/17
N/
3TK28 23 expanded with 3TK28 30 for
N/ EMERGENCY STOP, Category 4 acc. to
EN 954-1, two-channel, with feedback circuit
24 V AC/DC
3TK2830
ON
3TK28 25
EMER-
K1 GENCY
STOP
K5
K6
Y33 Y34 PE A2 14 24 34 42 52 A2 14 24 34 44 52
K1 K2 H1 H2 K3 K4 K5 K6
PE N/
N/ N/ N/
Fig. 7/18
3TK28 25 expanded by 3TK28 30 for EMERGENCY STOP, Category 4 acc. to EN 954-1, two-channel cc. to EN 954-1, monitored start
L/+
24 V AC/DC
GENCY
3TK28 27
ON
STOP
K1
K7
Y33 Y34 PE A2 14 24 32 48 58 A2 14 24 34 44 52
K1 K2 H1 K3 K4 K5 K6 K7
PE N/
N/ N/ N/
Fig. 7/19
3TK28 27 expanded by 3TK28 30 for EMERGENCY STOP, Category 4 (Category 3 for delayed
contacts), two-channel, monitored start
K16
0 3
ON
A1 Y11 Y12 Y32 Y32 13 23
5 K1
3TK28 41
7 EMERGENCY STOP K1
M 9 K7
3 10 1M
Backplane bus Y21 Y22 A2 14 24 K2
interface M
4 11 2L+
13
15 K9
17
M 19 K15
7 K2 K4 K6 K16
20 2M K15
K16
S7 300 For 3TK2825, additional
Channel number signaling output for PLC
Status display, green or via auxiliary contact
Fig. 7/20
EMERGENCY 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
L+
24V DC
K1
1 1L+ K2
EMERGENCY
0 3 STOP K8
ON
A1 Y1 Y2 13 23 33 41 K1
5 K1
3TK28 21/24
7
M 9 K4
3 10 1M
Backplane A2 14 24 34 42
M
bus interface M
4 11 2L+
13 K2
15 K5
Signaling contact
17 for PLC
M 19 K8
7
20 2M
M
K8
S7 300
Channel number
Status display, green
Fig. 7/21
EMERGENCY 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)
K1
K2
open closed
K3
A1 Y1 Y2 13 23 (33) (41)
3TK28 21/24
open closed
K1 K2 K3
M M M
K3 M
A1 Y1 Y2 13 23 (33) (41)
3TK28 21/24
K2
open
closed
M
Fig. 7/23
3TK28 21/24 for protective door monitoring A2 14 24 (34) (42) K3
with tumbler (2 protective doors are cascad- K1 K2 K3 H1
ed, each with 2 SIGUARD position switches M
with tumbler) Category 2 acc. to EN 954-1, N/ N/
single-channel, with feedback circuit,
autostart
K2
A1 Y1 Y2 13 23 (33) (41)
3TK28 21/24
open closed K1
K2
M
Fig. 7/24
A2 14 24 (34) (42) 3TK28 21/24 for protective door monitoring
K1 K2 H1
(2 protective doors are cascaded, each with
open closed
2 SIGUARD position switches), Category 3
N/ (4) acc. to EN 954-1, two-channel, with feed-
back circuit, autostart, ( for Category 4 -
N/ the cable has to be routed so that it is well
protected). Sensors must be fail-safe.
24 V AC/DC
L/+
K1
K2
open closed
K1
K2
M
Y21 Y22 A2 14 24 Fig. 7/25
K1 K2 3TK28 22 for protective door monitoring
(protective doors, each with 2 SIGUARD
N/ N/
position switches).
Category 4 acc. to EN 954-1,
two-channel, with feedback circuit, autostart
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
closed
open
3TK28 25
K1
K2
open closed K1 K2 K3
K3
M M M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52
K1 K2 K3 H1 H2
PE
N/
N/
Fig. 7/26
3TK28 25 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position
switch), autostart, Category 2 acc. to EN 954-1, single-channel, with feedback circuit
L/+
open closed
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
3TK28 25
K1
K1
K2
K2
M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52
K1 K2 H1 H2
PE
N/
N/
Fig. 7/27
3TK28 25 for protective door monitoring with 2 SIGUARD position switches, autostart,
Category 4 acc. to EN 954-1, two-channel, with feedback circuit
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57
closed
open
3TK28 28
K1 K2
K1
open closed
K2 M M
Y33 Y34 PE A2 14 24 32 48 58
H1 K1 K2
N/
PE
N/
Fig. 7/28
3TK28 28 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position
switch), Stop Category 1, Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart
L/+
L/+
K1
K1 open closed K2
K2
Y33 Y34 PE A2 14 24 32 48 58 M
H1 K1 K2
N/
PE
N/
Fig. 7/29
3TK28 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
L/+
3TK28 30
K1
K6
open closed
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52 A2 14 24 34 44 52
K1 K2 H1 H2 N/ K3 K4 K5 K6
PE
N/ N/ N/
Fig. 7/30
3TK28 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
24V AC/DC
L/+ L1 L2 L3
K1
K2
1 1
2 2
Magnetically- K2
operated switch
Y21 Y22 A2 14 24
K1 K2
N/- N/-
Fig. 7/31
Protective door monitoring with magnetically-operated switch,
Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart
br/br 21
bl/bl 14
4AT
S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 Y1 Y2 Y3 Y4 X4 L 14 24
Signaling outputs
to the PLC
START
0V
Magnetically operated Magnetically operated Magnetically operated Magnetically operated (C)1998
switch 1 switch 2 switch 3 switch 4
Fig. 7/33
A 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
voltage A2 N/
2 PTC fuse
Outputs 13, 14 Enable circuit 1 (NO contact)
23, 24 Enable circuit 2 (NO contact) 3 Control logic
1 2 31, 32 NC contact
41, 42 NC contact 4 Channel 1
3 4
Inputs Y11, Y12 Feedback circuit 5 Channel 2
Y21, Y22, Y23 Pushbutton S1
6 6 Safety circuit
Y31, Y32, Y33 Pushbutton S2
5
Fig. 7/34
Internal circuit diagram of the 3TK28 34 two-hand control device
L/+ L/+
S1
K1
K2
H1 signaling lamps
K1, K2 must be contactors with positively driven
contacts
K1
K2
K1 K2 H1
N/ S2 N/
Fig. 7/35
3TK28 34 two-hand control device, Category 4 acc. to EN 954-1
voltage A2 N/
Outputs 13, 14 Enable circuit (tool down)
23, 24 NO contact (tool up)
1 2 3 4 33, 34 NO contact (overtravel OK)
41, 42 NC contact (hydraulic pump on)
Inputs Y11, Y12, Y13, Y14 Feedback circuit (K4)
Y21, Y22 Position switch (S4) for test cam
Y31, Y32, Y33, Y34 Upper dead center, switch (S3)
Fig. 7/36
Internal circuit diagram of the 3TK28 35 overtravel tester
S0 L/+
S0 Main switch
L/+
S1, S2 Button on the two-hand
operating console
S3 Position switch at the
upper dead center
S1 S4 Position switch
for test cams
K3 S4
K4 S5 Hydraulic pump ON
S6 Tool UP
K4 (manual operation)
A1 Y11 Y12 Y21 Y22 Y23 13 23 31 41 A1 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41 K1 Contactor for the
hydraulic pump
3TK28 34
3TK28 35
K1 K2 Tool UP
K3, K4 Tool DOWN
H1 Signal lamp
S2 K4 K3 K2 H1 K1
N/
N/
Fig. 7/37
3TK28 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
A B C
Overtravel OK
Us
1 Power (Vs) on
S1, S2 2 S5 is pressed, K1 pulls in (latches).
3 S6 is pressed, K2 pulls in (the ram moves upwards in the manual mode).
3TK28 34 4 The upper dead center is reached, S3 is actuated.
23/24 (K4)
5 S6 is released, K2 drops out.
S3 6 S1 and S2 are pressed on the two-hand operating console, the two-hand
control device 3TK2834 outputs an enable signal, K3 and K4 pull in.
S4 7 The ram moves downwards, S3 is no longer actuated.
S5 8 Test cams are reached, S4 is actuated, K3 drops out.
S6 9 The ram remains stationary, S1, S2 are released, K4 drops out.
10 S1, S2 are pressed, K4 pulls in again, H1 lights up.
3TK28 35
11 S1, S2 are released, K4 drops out. K2 pulls in, the ram moves upwards.
13/14 (K3) S4 is no longer actuated.
23/24 (K2) 12 Upper dead center is reached, S3 is actuated.
33/34 (H1) 13 S1 and S2 are pressed; K2 drops out, K3 and K4 pull in.
41/42 14 The ram moves downwards, S3 is no longer actuated.
15 S1, S2 are released, K3 and K4 open. K2 pulls in.
K1 16 Points 14 to 16 are repeated at each stroke of the press.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fig. 7/39
K1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Fig. 7/40
S3
S S4
S
A B C D!
Fig. 7/41
Function schematic of the press control.
The permissible overtravel s corresponds to the length of the cam
which actuates position switch S4.
According to ZH 1/456, the press manufacturer must define s .
A2 14 24
Fig. 7/42
SIGUARD 3TK28 41, internal circuit diagram, standard electronic device
L+ ON
K1 K2
K1
EMERGENCY
STOP * * K2
K1 K2
Fig. 7/43
SIGUARD 3TK28 40, basic electronic device, EMERGENCY STOP, 2-channel,
Category 3 acc. to EN 954-1
K1
ON
3TK28 40
EMERGENCY
STOP
K1
M
Fig. 7/44
SIGUARD 3TK2840, EMERGENCY STOP, Category 2 acc. to EN 954-1, single-channel,
with feedback circuit
24V DC
L1 L2 L3
K1
K2
open closed
K2
K1 K2
M
Fig. 7/45
SIGUARD 3TK2840, protective door monitoring, Category 3 acc. to EN 954-1,
two-channel with feedback circuit
K2
3TK28 41
open closed
K2
K1 K2
M
Fig. 7/46
SIGUARD 3TK2841, protective door monitoring,
Category 4 acc. to EN 954-1, two-channel with feedback circuit, autostart
L+ K1 L1 L2 L3
K2
EMERGENCY STOP
ON K1
A1 Y11 Y12 Y33 Y34
3TK28 41
L1 L2 L3
K2
Y35 Y21 Y22 A2 14 24
K1 K2
M
Fig. 7/47
SIGUARD 3TK2841, EMERGENCY STOP,
Category 2 acc. to EN 954-1, one-channel, with feedback circuit, monitored start
K2
ON
A1 Y11 Y12 1 Y34
K1
3TK28 41
EMERGENCY STOP
K2
K1 K2
M
Fig. 7/48
SIGUARD 3TK2841, EMERGENCY STOP, Category 4 acc. to EN 954-1,
two-channel, with feedback circuit, monitored start with ON button
L+ L1 L2 L3
K1
K2
K2
K1 K2
M
Fig. 7/49
SIGUARD 3TK2841, light grid monitoring, Category 4 acc. to EN 954-1,
2-channel, with feedback circuit, autostart
K1
A1 Y11 Y12 Y32 1 Y34
3TK28 41
K2
EMERGENCY K1
STOP
K1 K2
M
Fig. 7/50
SIGUARD 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
L+
K1 L1 L2 L3
K2
K2
K1 K2
M
Fig. 7/51
SIGUARD 3TK2841, contact mat, Category 3 acc. to EN 954-1, 2-channel, autostart
K16
0 3
ON
A1 Y11 Y12 Y32 1 Y34
5 K1
3TK28 41
7 K1
EMERGENCY STOP
M 9 K7
3 10 1M
Backplane Y35 Y21 Y22 A2 14 24 K2
bus interface M
M
4 11 2L+
13
15 K9
17
7 M 19 K15
20 2M K2 K4 K6 K16
K15
K16
S7 300 Signal to the PLC
Channel number via auxiliary contact
Status display - green at K1..K16
Fig. 7/52
SIGUARD 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
L+
24V DC
1 1L+ K1 K10
K16 K16
0 3
ON
A1 Y11 Y12 Y32 1 Y34 A1 Y11 Y12 Y32 1 Y34
5 K1
3TK28 41
3TK28 41
7
EMERGENCY STOP
M 9 K7
3 10 1M
Backplane Y35 Y21 Y22 A2 14 24 Y35 Y21 Y22 A2 14 24
bus interface M
M
4 11 2L+
13
15 K9
17
7 M 19 K15
20 2M K2 K4 K6 K8 K10 K12 K14 K16
M
EMERGENCY STOP
Contactless device
S7 300 PLC/DO
Channel number M M M M M M M M
Status display - green
Fig. 7/53
SIGUARD 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)
K2
K1
A1 Y11 Y12 Y33 1 Y34
3TK28 42
K2
Fig. 7/54
SIGUARD 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
L+
K1 L1 L2 L3
K2
EMERGENCY STOP
ON
K1
A1 Y11 Y12 Y32 1 Y34
3TK28 42
K2
Fig. 7/55
SIGUARD 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
K2
ON
A1 Y11 Y12 Y32 1 Y34 K1
3TK28 42
EMERGENCY STOP
K2
Fig. 7/56
SIGUARD 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
L+
K1 L1 L2 L3
K2
ON K1
A1 Y11 Y12 Y32 1 Y34
EMERGENCY
3TK28 42
STOP
open
K2
K1 K2
M
Fig. 7/57
SIGUARD 3TK2842, EMERGENCY STOP and protective door monitoring,
Category 4 acc. to EN 954-1, 2-channel, with tumbler, monitored start
3TK28 41
K2 K1
EMERGENCY
STOP
K2
Protective door A1 Y11 Y12 Y32 1 Y34
3TK28 42
FU
M K1 K2
Fig. 7/58
SIGUARD 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
L+ L1 L2 L3
K1
K2
K2
K1 K2
M
Fig. 7/59
SIGUARD 3TK2842, light grid monitoring, 2-channel,
autostart, Category 4 acc. to EN 954-1
K2
K1
Contact mat A1 Y11 Y12 Y32 1 Y34
3TK28 42
K2
K1 K2
M
Fig. 7/60
SIGUARD 3TK2842, contact mat, Category 3 acc. to EN 954-1, 2-channel, autostart
K1
1 2
3 4
3TK2851
3TK2852
K2
3TK2850
14 34 44 14 32 44 14 24 34 44 54 72 84
Fig. 7/61
SIGUARD 3TK2850, 51, 52, internal circuit diagram, electronic basic unit with auxiliary
contactors, Category 3 acc. to EN 954-1
A1 Y33 Y34 13 23 33
Y11
Y21
Y22
Y12
K1
3TK28 50
open closed
K2
A2 14 24 34
N/-
Fig. 7/62
The electronic basic 3TK2850 device with auxiliary contactors,
protective door monitoring, 2-channel, autostart, Category 3 acc. to EN 954-1
L/+
A1 Y33 Y34 13 23 33
Y11
open closed
Y12
Y20
Y21
K1
3TK28 50
K2
A2 14 24 34
N/-
Fig. 7/63
The electronic basic 3TK2850 device with auxiliary contactors, protective door monitoring,
1-channel, autostart, Category 2 acc. to EN 954-1
ON
A1 Y33 Y34 13 23 33
Y11
Y21
Y22
Y21
EMERGENCY STOP
K1
3TK28 50
K2
A2 14 24 34
N/-
Fig. 7/64
The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,
1-channel, with additional ON button, Category 2 acc. to EN 954-1
L/+
ON
A1 Y34 Y33 13 23 33
Y11
Y21
Y22
Y12
EMERGENCY STOP
K1
3TK28 50
K2
A2 14 24 34
N/-
Fig. 7/65
The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,
2-channel, Category 3 acc. to EN 954-1
Y22
Y12
EMERGENCY STOP
K1
3TK28 53
K2
A2 2 14 34 44
N/-
Fig. 7/66
The electronic basic 3TK2850 device with auxiliary contactors, EMERGENCY STOP,
2-channel, Category 4 acc. to EN 954-1 SIL 3
24V
1 1L+ EMER-
GENCY
0 3 STOP ON
K1
5 K1
15 K9 3TK2850, 51, 52
L/+
17 N/M 14 24 34 44 54 72 84
7 M 19 K16 K16
20 2M
Signal to
the PLC
(3TK2852) K36
K21 K22 K23 K36
S7 300
Channel number
Status display - green
Fig. 7/67
3TK285.-.., EMERGENCY STOP, Category 4 acc. to EN 954-1, P-M switching in
conjunction with operational control of a standard PLC (SIMATIC S7 300/ET200M),
load current per enable circuit, 10 A
1 2
K1
4
K2
3
3TK2853
1 3 4 2 14 34 44
5 6 7
Fig. 7/68
3TK2853, internal circuit diagram, electronic basic device with auxiliary contactors,
Category 4 acc. to EN 954-1
L/+
Y22
Y21
K1
3TK28 53
open closed
K2
A2 2 14 34 44
N/-
Fig. 7/69
The electronic basic 3TK2853 device with auxiliary contactors, protective door
monitoring, 2-channel, autostart, Category 4 acc. to EN 954-1, SIL 3
Y22
Y21
open closed
K1
3TK28 53
K2
A2 2 14 34 44
N/-
Fig. 7/70
The electronic basic 3TK2853 device with auxiliary contactors,
protective door monitoring, 1-channel, autostart, Category 2 acc. to EN 954-1, SIL 3
L/+
ON
Y22
EMERGENCY STOP Y21
K1
3TK28 53
K2
A2 2 14 34 44
N/-
Fig. 7/71
The electronic basic 3TK2853 device with auxiliary contactors, EMERGENCY STOP,
1-channel, with additional EN button, Cat. 2 acc. to EN 954-1, SIL 3
Y22
Y12
K1
3TK28 53
OSSD 1 2
K2
A2 2 14 34 44
Fig. 7/73
The electronic basic 3TK2853 device with
auxiliary contactors, cascading EMERGENCY
N/- STOP and protective door monitoring,
2-channel, Cat. 4 acc. to EN 954-1, SIL 3
L/+
ON
Y22
Y12
EMERGENCY STOP
K1
3TK28 53
K2
A2 2 14 34 44
L/+
K1
3TK28 53
K2
A2 2 14 34 44
N
load feeder outgoing cables
EM
EM
CY
CY
1 2
STOP STOP
Six actuation units are monitored by
two EMERGENCY STOP switches
1 2 3 4 5 6 The actuation equipment can either
be individual de-activated or in groups
1 2 3 4 using the protective doors
During operation, the equipment is
Protective doors switched-over using a PLC or a pushbutton.
Conventional solution
Conventional wiring =>
approx. 160 different solutions
1 2
ER
GEN
ER
GEN Complex installation =>
EM
EM
CY
CY
STOP STOP
high costs => increased space
requirement
Frequent faults
No overload or short-circuit
protection
Feedback Feedback Feedback Feedback
circuit circuit circuit circuit
1 2 3 3 5 6
EM
CY
CY
STOP STOP
costs => compact design
3SB3 3SB3
Few faults due to the
"single wire connection"
Motor protection using a
24 V DC
M
protection circuit-breaker
3RA7 3RA7
1 2 3 4 5 6
open closed
K2
3TK2840
K1 K2
STOP
3SB3
K1
3TK2840
Y20 Y21 Y22 A2 14 24
K1
M
CY
STOP K1
Y22
3SB3 Y12
3TK2840
Y20 Y21 Y22 A2 14 24
K2
K1
M
Protective Devices
Contactor monitoring
6.3 AF
6.3 AF
1 AT
Restart inhibit
K2
Circuit examples for SIGUARD light 1 + 24 V + 24 V 1
Start
Safety
curtains 2 0V
3
0V 2
3
output K1
4 4 2-channel 1-channel
A1 enable enable
5 5
circuit circuit
Connection example, light curtain 6 6
(L+) S11 S33 S34 S35 S31 S22 13 23 31
7 PE PE 7
Category 4 connected to a standard Sender Receiver
+
evaluation unit 3RG7847-4BB SIGUARD
light curtain/grid k2
3RG7842 = CH1
Light curtain or light grid 3RG7842 s k1 k2 k1
connected through 2 channels to SIGUARD 3RG7847-4BB
CH2
the evaluation unit 3RG7847-4BB:
N.O.
N.O.
Category 4 acc. to EN 954-1 Use both contacts in
the enable circuit!
A2 (L-) S21 S12 14 24 32 K1 and K2 with positively
1)
driven contacts
Manual start with monitored K1
K2
1)
Contactor monitoring
Fig. 7/74
Connection example, light curtain Category 4 connected to a standard evaluation unit
3RG7847-4BB
Restart inhibit
2.5 AT
monitoring
Contactor
4
muting function 3RG7847-4BF: 4
M-Sensor 1
M-Sensor 2
M-Sensor 3
M-Sensor 4
5 5
k1
6 6
Category 4 acc. to EN 954-1
Start
7 PE PE 7
Sender Receiver 4 15 24 22 23 20 21 31 32 13 14 11 2
Integrated muting function SIGUARD
+ 24 V
muting sensors)
s
SIGUARD 3RG7847-4BF R-Output
Manual start with dynamically Diagn. State outputs Warn.
Muting
indicators State
k2
OSSD2 N.O.
Muting
Failure
S1-S2
1 2
k1 k2 k1
RS 232
9 19 33 30 28 29 7 6 10 1
1)
K1
1) Use both contacts in
K2
the enable circuit!
6 AT max.
Fig. 7/75
Connection example, light curtain Category 4 connected to an evaluation unit with muting
function
0V
evaluation unit 3RG7847-4BD
2.5 AT
monitoring
Restart inhibit
Contactor
A light curtain 3RG7841 connected
1 + 24 V + 24 V 1 L+ L-
to the evaluation unit 3RG7847-4BD: 2 2 Ph N
3 0V 0V 3 k2
4 Safety output
6 AT max.
4
Category 2 acc. to EN 954-1 5 5
k1
6 6
Cyclic testing of the light curtain 7 7
Start
8 8
4 15 24 22 23 13 14 11 2
Manual start with dynamically Sender Receiver
2-channel 1-channel
+ 24 V
SIGUARD
monitored start button light curtain/grid
3RG7841
T1 T2 S1 S2 enable
circuit
enable
circuit
EDM
Test AOPDs
RESET
Dynamic contactor monitoring Test input s
SIGUARD 3RG7847-4BD R-Output
k2
Diagn. State
OSSD1 N.O.
OSSD2 N.O.
k1 k2 k1
RS 232
0V
9 7 6 10 1
1)
K1
1) Use both contacts in
K2
h I the enable circuit!
6 AT max.
K1 and K2 with poitively
driven contacts
0V L- L+ 1) Provide suitable
N Ph arc quenching
Fig. 7/76
Connection example, light curtain Category 2 connected to a standard evaluation unit
3RG7847-4BD
Single-cycle
Two-cycle
contact
Only interventions longer
2 0V 0V 2 k
3 than 300 ms are accepted
3 for control.
Category 4 acc. to EN 954-1
Start
4 4
k Machine contacts close
5 5
to the upper end position
6 6
Automatic single or two-cycle 7 PE PE 7 4 15 24 22 23 20 21 13 14 11 2
open OSSDs and cancel
the entered cycles.
control Sender Receiver
+24 V
SIGUARD T1 T2 S1 S2
Select
2-channel 1-channel
Reset
Clear
enable enable
3RG7842
circuit circuit
monitored start button SIGUARD 3RG7847-4BH R-Output
OSSD1 N.O.
OSSD2 N.O.
k k k
9 19 7 6 10 1
1)
K1 Use both contacts in
1)
the enable circuit!
Signal outputs K2
K1 and K2 with poitively
6 AT max.
driven contacts
L- L+ 1) Provide suitable
N Ph arc quenching
Fig. 7/77
Connection example, light curtain Category 4 connected to an evaluation unit with cycle
control
Start
+24V 0V
+24 V IN OUT 0V
(int.) (int.)
External
TEST feedback
circuits
K1
Contactor
Fig. 7/78
1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3
L1
S
S
+24 V DC
A1 X1 X2 X3 X4 X5 X6 X7 X8 + 13 23 39 41
RESTART Relay
0V T3 Q3 T4 Q4 PM Indic. UB OUT
0V 0V
1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3
K4
K5
M
Sender Receiver Sender Receiver 3~
N
3RG... 3RG... 3RG... 3RG...
Fig. 7/79
X1
Neustartsperre
Fixed protective field pair 1
6.3 AF
6.3 AF
1.25 AmT
1 AT
k4
(24 V always present at connection 4)
k5
Safe output
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
CH1
K1
SIGUARD 3RG7847-4BB
CH2
N.O.
N.O.
K2
K4* K5*
LS4 SIGUARD laser scanner
0V
24 V DC
Receiver 3RG7855-1R Sender power
supply
wh gn bn A1(+) X1 X2 X3 13 23
3RG7857-1BD
K1 K1
K2 K2
12 V
controller
K1 K2
Safety-related
signal processing
K1 K2
A2() 14 24
Safety
outputs
Fig. 7/80
PM-X
Master
Terminating module
PM-D PM-D DS DS RS
F1 Power module PLC Circuit-
F1
breaker
DS Direct starter
PROFIBUS-DP IM
RS Reversing starter 151
Auxiliary contact block L+
F Kit (for the feedback circuit) M F kit-1 F kit-1 F kit-2
Supply
PM-X Connection module A1+ contactor
A2 KO
ON
button
EMERGENCY L1 L2 L3
STOP
button M M M
~ ~ ~ Terminating cover
Fig. 7/81
EMERGENCY STOP circuit with monitored start, Category 4 acc. to EN 954-1
PM-X
Master
Terminating module
PM-D PM-D DS DS RS
F1 Power module PLC Circuit-
F1
breaker
DS Direct starter 1
PROFIBUS-DP IM
RS Reversing starter 151 2
Auxiliary contact block L+
F Kit (for the feedback circuit) M F kit-1 F kit-1 F-Kit-2
EMERGENCY L1 L2 L3
STOP
button M M M
~ ~ ~ Terminating cover
Fig. 7/82
EMERGENCY STOP circuit with monitored start, Category 2 acc. to EN 954-1
Terminating module
PLC PM-D DS DS PM-D DS DS
RS
F1 F1 Circuit- Circuit-
breaker breaker
PROFIBUS-DP IM A1+A2-
151
L+
M F kit F kit FF-Kit
kit F-Kit
F kit
Supply Supply
A1+ contactor contactor
A2 KO2 KO2
ON
button
L1 L2 L3
EMERGENCY
STOP button
M M M M
~ ~ ~ ~ Terminating cover
Fig. 7/83
EMERGENCY STOP circuit in two groups
L1 L2 L3
EMERGENCY STOP 1
PM-X PM-X
EMERGENCY STOP 2
Master
Terminating module
PROFIBUS-DP IM A1+A2-
151
L+
M F kit F kit FF-Kit
kit F-Kit
F kit
Supply Supply
A1+ contactor contactor
A2 KO1 KO2
ON
button
L1 L2 L3
EMERGENCY
STOP button
M M M M
~ ~ ~ ~ Terminating cover
Fig. 7/84
EMERGENCY STOP circuit arranged in a cascade
Terminating module
PLC PM-D DS DS PM-D DS DS
RS
F1 F3 Circuit- Circuit-
breaker breaker
PROFIBUS-DP IM
151
L+
M F kit F kit F kit F kit
Supply Supply
A1+ contactor contactor
A2 KO1 KO2
ON
button
A2+A1-
L1 L2 L3
EMERGENCY
STOP button
M M M M
~ ~ ~ ~ Terminating cover
Fig. 7/85
EMERGENCY STOP circuit arranged in a cascade with delayed shutdown (Stop Category 1)
PM-X PM-X
Master
Terminating module
PLC PM-D PM-D DS DS DS DS
RS
F1 F2 Circuit-
breaker
PROFIBUS-DP IM
151
L+
M F kit F kit F kit F kit
Supply
A1+ contactor
A2 KO2
ON
button
EMERGENCY L1 L2 L3
STOP
button M M M M
~ ~ ~ ~ Terminating cover
Protective door
open closed
TM-PF30 S47-B1 TM-PF30 S47-B0
Fig. 7/86
EMERGENCY STOP combined with protective door
Terminating module
Terminating module
PLC PM-D DS DS PM-D DS DS
F1 Circuit- F4 Circuit-
breaker breaker
PROFIBUS-DP IM DF IM DF
151 151
L+ L+
M F kit F kit M F kit F kit
Supply Supply
A1+ contactor A1+ contactor
A2 KO1 A2 KO2
ON
button
EMERGENCY L1 L2 L3 L1 L2 L3
STOP
button M M M M
~ ~ Terminating cover ~ ~ Terminating cover
Fig. 7/87
One EMERGENCY STOP circuit for several ET 200S rails
A1+
PM-D PM-X PM-X
Master
Terminating module
PLC DS DS RS
Circuit-
ON breaker
button
PROFIBUS-DP IM
151
L+
M F kit-1 F kit-1 F kit-2
Supply
EMERGENCY A1+ contactor
STOP A2 KO
button AUX2
3TK2823 AUX3
L1 L2 L3
M M M
~ ~ ~ Terminating cover
Fig. 7/88
Integrated in an external EMERGENCY STOP circuit, Category 4 acc. to EN 954-1
Terminating module
PLC DS DS RS
Circuit-
ON breaker
button
PROFIBUS-DP IM
151
L+
M F kit-1 F kit-1 F kit-2
EMERGENCY A1+
STOP A2
button AUX2
3TK2823 AUX3
L1 L2 L3
M M M
~ ~ ~ Terminating cover
Fig. 7/89
Integrated in an external EMERGENCY STOP circuit, Category 2 acc. to EN 954-1
EMERGENCY
PM-D PM-X PM-X
STOP switch 1 AS-i
Safety
Monitor
Master
EMERGENCY
Terminating module
STOP switch 2 DS DS RS
PLC Circuit-
ON breaker
EMERGENCY
STOP switch 3 button
PROFIBUS-DP IM
151
EMERGENCY
Feedback circuit L+
STOP switch 4 M F kit-1 F kit-1 F kit-2
Shutdown circuit Supply
A1+ contactor
EMERGENCY A2 KO
STOP switch 5 AUX2
AUX3
A1+
L1 L2 L3
M M M
~ ~ ~ Terminating cover
Fig. 7/90
SIMATIC ET 200S SIGUARD and AS-i Safety at Work
Terminating module
PLC PM-D DS DS RS PM DO DO DO
F1 -E Circuit-
breaker
PROFIBUS-DP IM
151 24V
L+
M F kit-1 F kit-1 F kit-2
Supply
A1+ contactor
A2 KO
ON
button
EMERGENCY L1 L2 L3
STOP
button M M M
~ ~ ~
Fig. 7/91
EMERGENCY STOP circuit with integrated pneumatic valves
Terminating module
PLC PM-D DS DS RS PM DO DO DO
F1 -E Circuit-
breaker
PROFIBUS-DP IM
151
L+
M F kit-1 F kit-1 F kit-2
Supply
A1+ contactor
A2 KO
ON
button
EMERGENCY L1 L2 L3
STOP
button M M M
~ ~ ~
M
~
Fig. 7/92
EMERGENCY STOP circuit with integrated external actuators
1L+
Example: A transmitter connected Digital input
module
to an F-DI through 1 channel 1M
(AK6/SIL3/Cat.4)
Vs
The connection schematic for an SM
326, DI 24 x 24V DC for a 2-from-2 DI
Left: Channels 011
evaluation of the transmitter is shown
Right: Channels 011 DI
in the following diagram. The transmit-
ter is supplied from the F I/O.
AK6/SIL3/Cat.4 can be achieved using
this connection as long as a suitably Example: Wiring schematic for a transmitter connected to an F-DI (2-from-2)
through 1 channel)
qualified transmitter is used.
1L+
Example: A transmitter connected Digital input
module
to an F-DI through 2 channels 1M
(AK6/SIL3/Cat.4)
Vs
The connection schematic for an SM
326, DI 24 x 24V DC for a 2-from-2 DI
Left: Channels 011
evaluation of the transmitter is shown Right: Channels 011 Vs
in the following diagram.
AK6/SIL3/Cat.4 can be achieved using DI
this connection.
Example: Wiring schematic for a transmitter connected to an F-DI (2-from-2)
through 2 channels)
1L+
Digital input
module
Example: An antivalent 1M
transmitter (2-channel) connected
Vs
to an F-DI (AK6/SIL3/Cat.4)
The connection schematic for an SM DI
Left: Channels 011
326, DI 24 x 24V DC with antivalent Right: Channels 011 DI
transmitter (2-from-2 evaluation) is
shown in the following diagram.
AK6/SIL3/Cat.4 can be achieved with
this connection. Example: Connection schematic for an anti-valent transmitter connected to an F-DI
(2-from-2) through 2 channels
function
Mode of operation
Light curtains can be operated in the
muting mode so that products or
MS_12 Receiver MS_22
objects can be brought into the haz-
ardous area, monitored by the light
curtain, without stopping the machine.
It must be ensured that personnel can-
not enter the hazardous area while the 2
light curtain is bypassed by using two MS_11 Transmitter MS_21 Hazardous area
or four muting sensors as well as the
correct integration into the production
sequence.
It is extremely important to note that
the interval in which the safety pro-
gram is called (e.g. OB 35) must be
MS_12 Receiver MS_22
less than the selected discrepancy
time.
stopping).
3. The inputs for the muting sensors
MS_21 and MS_22 must have been 4. After one of the inputs for the mut-
activated within DISCTIM2 and before ing sensors MS_21 and MS_22 = 0
the inputs for the muting sensors (the product enables the sensors), the
MS_11 and MS_12 are switched into MUTING function is exited (Q = 1,
an inactive state. This means that the MUTING = 0). The MUTING function
F application block maintains the may be active for a maximum time
MUTING. (Q = 1, MUTING = 1). parameterized at the input TIME_MAX.
FREE
MS_11
MS_12
MS_21
MS_22
t < TIME_MAX
ACK
MUTING
FAULT
ACK_REQ
L1
L2
L3
PE
L/+
N/
P24 V DC
M DC K1
EMER-
GENCY U1 V1 W1
STOP
X533
1) Option K80
1
2 PV
4 P24V
K1 ON 3
A1 Y1 Y2 13 23
3TK2824
M
X101
Control
module
X CU
1)
Loop in check-
back signals from
Communi- protective devices,
cations e.g. door interlocks,
module, light curtains
e.g. CBP SIMOVERT MASTERDRIVES
A2 14 24 Drive inverter U2 V2 W2 X: Digital input,
assigned to OFF2
P556i001 and i002
M
K1 3~ Separately
N/
protected routing
Fig. 7/93
Stop Category 0, 2-channel, with feedback circuit; Category 3 acc. to EN 954-1;
Function with a motor coasting down
L1
L2
L3
PE
L/+
N/
24 V DC
M DC K1
U1 V1 W1
X533
1) 1 Option
X533 K80
2
4 PV
3 P24V
K1 ON
Y10
A1 Y11 Y12 Y33 Y34 13 23 31 43 53
3TK2827
X101
Control
X
module
EMER- 1)
GENCY Y CU Loop in check-
STOP back signals from
protective devices,
Communi- e.g. door interlocks,
cations light curtains
module,
e.g. CBP SIMOVERT MASTERDRIVES X: Digital input,
Y21 Y22 PE A2 14 24 32 44 54 Drive inverter U2 V2 W2 assigned to OFF2
P556i001 and i002
PE H1 K1 X: Digital input,
M
N/ 3~ assigned to OFF3
P559i001 and i002
Fig. 7/94
Stop 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.
Fig. 7/95
EMERGENCY 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
Fig. 7/96
Emergency Stop, Stop Category 1 acc. to EN 60204, 2-channel with feedback circuit,
control Category 3 acc. to EN 954-1