DOLD SAFEMASTER M BG 5913.08/ 0 Series User manual

1BG 5913.08/_0_ _ _ / 11.05.09 e
Safety Technique
Multi-Function Safety System SAFEMASTER®M
Input Module BG 5913.08/_0_ _ _, BH 5913.08/_0_ _ _
•According to EN 62 061, DIN EN ISO 13 849-1
•Category 4 to EN 954-1
•Input module for realization of
- 4 similar 2-channel inputs
- Emergency stop circuits
- Safety gate monitoring system
- Two-hand control type IIIA, IIIC acc. to DIN/EN 574
- Light curtain (LC type 4)
•The functions are selected via rotary switch
•8 safety inputs
•2 semiconductor outputs for status indication
•Broken wire and short circuit monitoring function with error indication
•LEDs for status indication
•Width
BG 5913.08/_0_ _ _: 22.5 mm
BH 5913.08/_0_ _ _: 45 mm
Block Diagram
0247337
Approvals and Marking
Realization of fail-safe control circuits for protection of people and ma-
chinery.
Note: This module is intended for applications in which mixed safety
functions affect one common output.
Further input modules with other combinations of functions are provided
(e.g. BG 5913.08/_1_ _ _, BG 5913.08/_2_ _ _, BG 5913.08/_3_ _ _ ,
BG 5914.08/_0_ _ _, BH 5914.08/_0_ _ _ or BG 5914.08/_1_ _ _).
Applications
Circuit diagrams
X1 S44 S42 S34 S32 S24 S22 S14 S12 X2 (-) 48 58(-)
input- module
PTC
input or control module
M8752_a
start-button
assignment
output
assignment
function management
en1 en2 run1 run2
X1 S
11 S 12 S 14 S 13 X2 X1 S 21 S 22 S 24 S 23 X2 X1 S 31 S 32 S 34 S 33 X2 X1 S 41 S 42 S 44 S 43 X2 (-) 48 58(-)
input- module
PTC
input or control module
M8753_a
start-button
assignment
output
assignment
function management
en1 en2 run1 run2
S12 S14 S22 S24
S32 S34 S42 S44
48
58
X1
X2
(-)
(-)
M8741
S12 S24 S32 S34 S42 S44
X1 X2
S14 S22
(-)(-)
48
58
A1+
A1+
BG 5913
BH 5913
BG 5913
BG 5913 BH 5913
ET Canada / USA
All data in this list are in correspondence with the technical equipment used at the time of this
version. We reserve the right to implement technical improvements and changes at any time.

2BG 5913.08/_0_ _ _ / 11.05.09 e
Circuit diagrams
S21S11 S22S12 S23S13 S24S14
S41S31 S42S32 S43S33 S44S34
X1
48
X1
58
X2
X1
X2
X1
(-)
X2
(-)
X2
M8742
S11 S31S14
(-)
S34S21
X1 X2 X1 X2 X1 X2 X1 X2 (-)
S41S22 S42S23 S43S24 S44S12 S32S13 S33
48
58
A1+
A1+
General information SAFEMASTER®M
The maximum configuration of the SAFEMASTER®M multi-function safety
system is as follows:
• the control unit BH 5911
• up to 3 input modules BG 5913, or BG/BH 5914, BG/BH 5915
• up to 3 output modules BG 5912
• 1 diagnostic module BG 5551 for CANopen, or
• 1 diagnostic module BG 5552 for Profibus-DP
The BH 5911 controls the whole system.
The input/output modules can be used to expand the control unit in a
modular way into a multi-functional safety system.
To transmit status messages of the individual modules to a monitoring or
control unit, one of the following diagnostic modules may be connected:
• BG 5551 for CANopen
• BH 5552 for Profibus-DP
Notes
In respect of function and settings, the modules BG 5913 and
BH 5913 are completely identical.
•The modules BG 5913 have 8 inputs with one common ground. This is
the ground of the overall system.They are suitable for all applications in
which volt free contacts are used, or where there is a common ground
(e.g. 2-channel light curtains). They need only 8 terminals and thus only
have an overall width of 22.5 mm.
•The modules BH 5913 have 8 completely DC-decoupled inputs. This
allows with setting 1 and 3 (4 lightcurtains) to connect also 4 two-channel
e-stop buttons with long connection wires with static signal potental.Here,
short-circuit monitoring is effected by a certain type of wiring according
to the application examples.
Indication
Green LEDs: on, when all inputs are present and start
button activated.
White LEDs Run1/
Run 2 and outputs
48 and 58: indicate the current status of the module.
Setting of the Module
The module is assigned to the start inputs and the safety outputs via the
DIP switches.
The combinations of individual functions are set via the rotary switches.
To prevent accidently adjustments, these elements are covered by a front
plate and are redundant.
plate
M2926_a
M8941_b
02
3
4
7
8
9
012
5
6
79
1
2
3
4
5
6
7
8
output
Mod3
Mod2
Mod1
Base
Mod3
Mod2
Mod1
Base
S1 S2
1
2
3
4
5
6
7
8
start
input
T1
T2
T3
T4
T1
T2
T3
T4
green LED "en 1"
green LED "en 2"
white LED
"run 1"
white LED
"run 2"
off on
• Settings to the unit must be performed by skilled personnel while
the unit is disconnected.
• Before the front cover is removed, antistatic precautions must be
observed.
Note:
BH 5913
When using setting 8 or 9 the user has to indicate clearly on the device
which type of 2-hand function is adjusted (IIIA or IIIC).
Setting of the Modules
Sw. Function
0 4 Emergency stop 2-channel, autostart
1 4 light curtains category 4, autostart
2 4 Emergency stop 2-channel, manual start
3 4 light curtains category 4, manual start
4 4 safety gates with 2 single contacts
5 2 safety gates with 2 changeover contacts
61 safety gate with 2 twin contacts and 1 single contact,
manual start (plastic injection moulding machines) to EN 201
71 safety gate with 3 twin contacts, manual start
(plastic injection moulding machines) to EN 201
8 4* two-hand control IIIA acc. to EN 574
9 2* two-hand control IIIC acc. to EN 574

3BG 5913.08/_0_ _ _ / 11.05.09 e
Function of the Two-Hand Control
Indication of System Errors:
These errors are indicated by flashing codes of the white LEDs Run 1 and/
or Run 2.The green LEDs and all outputs turn inactive.The system will only
restart after the supply voltage has been switched off and on again.
Error codes*
0) (both white LEDs are off):
Another input module indicates a system error.
1) To 4): not used
5) Incorrect setting of function:
The rotary switches have different or incorrect positions
6) LED Run 1 flashes: Undervoltage
LED Run 2 flashes: Overvoltage
7), 8) Not used
9) Connection error between the input modules
· No terminating connector available.
· Control or input module defective
10), 11), 12), 13) a. 14) Internal errors
* number of short flashing impulses, followed by a longer space
When the unit is set to monitor safety gates according to EN 201 switch
position 4, 5, 6 and 7, closing of the assigned safety outputs is only enabled,
if every gate has changed from open state (all contacts inactive) to closed
state within a maximum period of 3 sec on each gate.
When the system is powered up with some gates open and some closed
the open gates can be closed and the system can be started up by the
simulation button, simulating an open-close cycle of the previously closed
gates.
Only those gates are simulated, that had been closed before the system
was powered up.
Simulation is only possible once after the unit is powererd up. After that all
contacts of a gate have to be opened and reclosed to enable the outputs
again. When closing the gate all contacts of a gate have to close within
3 sec.
Simulation input for function of safety gates
Automatic start
Automatic start is performed only when supply voltage is switched on, or
when the emergency stop or stop function has been reset.
All other errors nevertheless require confirmation by a start input.
Manual Start
To start the system, do not keep the start key pressed for more than 3
seconds. A module may also be assigned several start keys.
With setting 6), it is imperative to use a voltfree contact for the single contact.
A static signal cannot be used.
One-channel input
Function of the Two-Hand Control
Up to 4 pairs of two-hand safety circuits can be connected with the two-
hand safety function. However, no more than one circuit may be activated.
To permit enabling of the assigned safety outputs, the following conditions
must be fulfilled:
1) First, none of the connected two-hands circuits must be activated.
2) Both buttons of a two-hand control must be pressed within 0.5 s.
3) When changeover contacts (type IIIC acc. to DIN / EN 574) are used
for the two-hand-safety buttons, they must effect changeover of con-
tacts within 50 ms.
4) As soon as a button of a second two-hand circuit is pressed, the
outputs are disabled, and condition 1) must be fulfilled once more
before a new enabling cycle can start.
5) The two-hand buttons habve to be released if an other function mo-
dule, also assigned to the same outputs disables the outputs.
6) Only one two-hand control module is allowed in one safemaster M
system.
The unit must be connected as specified in the application examples.When
the operating contacts are connected in parallel or in series, safe functioning
of the unit is cancelled.
The two-hand buttons must be designed and arranged in such a
way as to ensure that they cannot be disabled easily, or pressed
unintentionally.
The safety distance between the push buttons and the place of danger must
be large enough to insure that after releasing a button, the place of danger
can only be reached after the dangerous movement has stopped.
The safety distance “S” is calculated according to the following formula:
S = V x T + C, where
a) gripping velocity V = 1 600 mm/s
b) overtravel time T (s)
c) and safety factor C = 250 mm.
When any access into the dangerous area, with operating keys pressed,
is safely prevented, e.g. by a protective cover for the keys, the safety factor
C may be set to the value 0. Generally, the minimum safety distance must
be 100 mm. See also DIN/EN 574.
Safety gate function
The safety gate function always permits enabling if both contacts change
from inactive to active state within 3 seconds. If the second contact reacts
later, both changeover contacts must turn inactive before they can be
enabled again.
When activating the system, press the start button to simulate the compul-
sory opening and re-closing of safety gates which have been kept closed
since the system has started.
This simulation is possible only before enabling has been permitted for
the first time, and as long as both safety gate contacts remain closed as
well. As soon as a contact opens, simulation of the safety gate function is
no longer possible.
Emergency Stop or Light Curtain (LC) Function
In the Emergency stop or LC functions, both signals have to change from
inactive state into active state within 250 ms. If the second signal reacts
later, both changeover contacts must turn inactive before they can be
enabled again.
With manual start, all safety inputs must be active before the start button
can be pressed to trigger enabling. To start the system, do not keep the
start button pressed for more than 3 seconds. A module may also be as-
signed several start buttons.
Note: Connect only self-testing light curtains of the type 4 acc. to EN
61496 to the module. Short-circuit monitoring of the inputs for
the LC must be done in the LC.

4BG 5913.08/_0_ _ _ / 11.05.09 e
Indication
Function Error Indication
Function errors are indicated by the white LED Run 1 and by output 48;
the white LED Run 2 remains on. Output 58 is ON as long as the error is
pending; it flashes regularly, while waiting for the assigned start signal.
Error codes*
1) Normal interruption of function (e.g. Emergency stop)
2) Time error: (e.g. the second two-hand button is not pressed)
3) With gate monitoring: simulation input error (kept pressed for
too long)
4) Error at start input
5) Input error (short-circuit, interruption)
6) Error in the control unit (input or output error detected in
the control unit)
* number of short flashing impulses, followed by a longer space
Special with two-hand control:
When both two-hand buttons of the module are inactive while all other
functions are active and enabled either by autostart or via the start but-
ton, output 48 and the white LED Run 1 are permanently OFF, and out-
put 58 permanently ON.
Permanently OFF Pulsing Permanent ON
Output
48
all relays inactive
due to system
error
one input function
not available
Activation of the
assigned safety
outputs is
permissible
LED
Run 1
Two-hand control
not activated
(LED run 2 ON)
or all relays inac-
tive
due to
system error
one input function
not available
(LED run 2 ON) or
system error when
LED Run 2 is OFF
or flashing
Activation of
the assigned
safety
outputs is
permissible
Output
58
Activation of the
assigned safety
outputs is permis-
sible or system
error
Error exists no
more,
waiting for
Start input
one input
function
not available
LED
Run 2
all relays inactive
due to system
error
all relays inactive
due to system
error
No system error

5BG 5913.08/_0_ _ _ / 11.05.09 e
Function Diagramms
supply voltage
(A1/A2)
emergency stop contact 1
S11/S12
emergency stop contact 2
S13/S14
LED en1en2
(enabling K1, K2)
output 48, LED run 1
(error code)
output 58
(waiting for start)
: off : permanently
on
: flashing code
t<
250ms
t>
250ms
M8943_a
1111
(error code)
: off M8945_a
1
assigned start button
: constant flashing
t<
3s
supply voltage
(A1/A2)
emergency stop
LED en1en2
(enabling K1, K2)
output 48, LED run 1
output 58
(waiting for start)
: permanently
on
: flashing code
Emergency stop or light curtain, automatic start
Function Diagramms
supply
voltage
(A1/A2)
door 1S1
(X1/S12)
door 1S2
(X2/S14)
door 2S1
(X1/S22)
door 2S2
(X2/S24)
door 3S1
(X1/S32)
door 3S2
(X2/S34)
door 4S1
(X1/S42)
door 4S2
(X2/S44)
LED en1en2
(enabling K1,K2)
output 48,
LED run 1
(error code)
output 58
(waiting for start)
: off : permanently
on
: flashing code M8951_a
111121
assigned
start button
: constant flashing
t=3s
Safety gates (example: 4 gates with 2 single contacts each),
assigned start buttons are also suitable for gate simulation (setting 4 or 5)
Emergency stop or light curtain, manual start

6BG 5913.08/_0_ _ _ / 11.05.09 e
door S1, 1
(X1/S12)
door S1, 2
(X2/S14)
door S2, 1
(X1/S22)
door S2, 2
(X2/S24)
door S3
(X1/S32)
LED en1en2
(enabling K1,K2)
: off M8953_a
1121
simulation
button
t=3s
t<
3s
supply
voltage
(A1/A2)
assigned
start button
output 48,
LED run 1
(error code)
output 58
(waiting for start)
: permanently
on
: flashing code : constant flashing
Safety gate for plastic moulding machines
(example: 1 gate with double contacts + single
contact) (setting 6 or 7)
Function Diagramms
two-hands 1,
button 1
(X1/S12)
two-hands 1,
button 2
(X2/S14)
two-hands 2,
button 1
(X1/S22)
two-hands 2,
button 2
(X2/S24)
two-hands 3,
button 1
(X1/S32)
two-hands 3,
button 2
(X2/S34)
two-hands 4,
button 1
(X1/S42)
two-hands 4,
button 2
(X2/S44)
LED en1en2
(enabling K1, K2)
output 48,
LED run 1
(error code)
output 58
(waiting for start)
M8963_a
1211
t=0,5s
t<
0,5s
supply voltage
(A1/A2)
: off : constant flashing: permanently
on
: flashing code
Two-hand control

7BG 5913.08/_0_ _ _ / 11.05.09 e
Application examples
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
emergency stop 1 emergency stop 2 emergency stop 3 emergency stop 4
58 (-)48
waiting for start
error
error indication,
enabling active
M8947_a
BG5913
4 Emergency stop circuits, 2-channel, auto/manual start with short circuit monitoring; function: 0, 2
BG5913
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
Not-Aus 1 Not-Aus 2 Not-Aus 3 Not-Aus 4
58 (-)48
Warten auf Start
Fehler
Fehleranzeige,
Freigabe aktiv
M8824_a
L+
L-
BH5913
X1 X1 X1 X1S11 S21 S31 S41
(-)
S12 S22 S32 S42S14 S24 S34 S44S13 S23 S33 S43X2 X2 X2 X2
58 (-)48
M9322
emergency
stop 1
emergency
stop 2
emergency
stop 3
emergency
stop 4
waiting for start,
error
error indication,
enabling active
4 Emergency stop circuits, 2-channel, auto/manual start, short circuit monitoring by wiring; function 1, 3

8BG 5913.08/_0_ _ _ / 11.05.09 e
Application examples
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8949_b
L+
L-
LC 1LC2 LC 3LC4
--------
++++++++
waiting for start
error
error indication,
enabling active
trans-
mitter
trans-
mitter
trans-
mitter
trans-
mitter
OSSD OSSD OSSD OSSD
BG5913
4 light curtains, category 4, auto/manual start; function: 1,3
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8955_b
S1 S1 S1 S1S2 S2 S2 S2
open
open
open
open
closed
closed
closed
closed
safety gate 1 safety gate 2 safety gate 3 safety gate 4
waiting for start
error
error indication,
enabling active
BG5913
4 safety gates with 2 NO contacts; function: 4

9BG 5913.08/_0_ _ _ / 11.05.09 e
Application Examples
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8957_b
S1 S1S2 S2
waiting for start
error
error indication,
enabling active
open
open
closed
closed
safety gate 1 safety gate 2
BG5913
2 safety gates with 2 antivalent changeover contacts each; function: 5
1 safety gate with 2 twin/1 single contact, manual start (plastic injection moulding machines); function: 6
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8959_b
S1 S2
S3
simulation
open closed
safety gate 1
waiting for start
error
error indication,
enabling active
BG5913

10 BG 5913.08/_0_ _ _ / 11.05.09 e
Application examples
1 safete gate with 3 twin contacts, manual start (plastic injection moulding machines); function: 7
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8961_b
S1 S2
S3
simulation
open closed
safety gate 1
waiting for start
error
error indication,
enabling active
BG5913
4 two-hand controls type IIIA acc. to DIN/EN 574; function: 8
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
two-hand 1 two-hand 2 two-hand 3 two-hand 4
58 (-)48
M8965_b
T1 T1 T1 T1T2 T2 T2 T2
waiting for start
error
error indication,
enabling active
BG5913

11 BG 5913.08/_0_ _ _ / 11.05.09 e
2 two-hand controls type IIIC acc. to DIN/EN 574; function: 9
Application Examples
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M8967_b
T1 T1T2 T2
two-hand 1 two-hand 2
waiting for start
error
error indication,
enabling active
BG5913

12 BG 5913.08/_0_ _ _ / 11.05.09 e
Technical Data
Voltage Supply
Nominal voltage UN:DC 24 V (coming from the basic module
BH5911)
Voltage range:
with max. 5% residual ripple: 0.85 ... 1.15 UN
Nominal consumption: max. 60mA
(no load on semiconductor outputs)
Short-circuit protection
of the modules: internally with PTC
Input
Control voltage
via X1, X2, 48.58: DC 23 V at UN
Control voltage
via S12, S14, S22, S24,
S32, S34, S42, S44: 4.5 mA each at UN
Minimum voltage
on S12, S14, S22, S24,
S32, S34, S42, S44: DC 16 V
Semiconductor outputs
Output at terminal 48 and 58: Transistor outputs, plus-connected
Output nominal voltage: DC 24 V, max. 100 mA constant current,
max. 400 mA for 0.5 s
Internal short circuit, overtemperature, and
overload protection
Reaction times (time till reaction of the assigned output):
Typ. NO time with UN:
Input modules
BG 5913 Manual start Automatic start
First start Restart
Emergency stop max. 80 ms max. 850 ms max. 115 ms
Light barriers max. 80 ms max. 850ms max. 115 ms
Safety gates or simulation:
max. 80 ms
Gate closing:
max. 115 ms
Two-hand control max. 85 ms
Break time (reaction time):
Input modules
BG 5913
Emergency stop max. 33 ms
Light barriers max. 33 ms
Safety gates max. 33 ms
Two-hand control max. 33 ms
General Data
Operating mode: Continuous operation
Temperature range: ± 0 ...+ 50 °C
At an operating temperature of 50 °C
the modules must be mounted with
a distance of 3 - 5 mm.
Clearance and creepage
distances
rated impuls voltage /
pollution degree: 4 kV / 2 IEC 60 664-1
EMC
Electricstatic discharge: 8 kV (contact) IEC/EN 61 000-4-2
(corresponding to test severity level 3)
HF irradiation: 10 V / m IEC/EN 61 000-4-3
Technical Data
Fast transients:
on supply line A1-A2 2 kV IEC/EN 61 000-4-4
on signal and control lines: 2 kV IEC/EN 61 000-4-4
Surge voltages
between
wires for power supply: 1 kV IEC/EN 61 000-4-5
wire and ground: 2 kV IEC/EN 61 000-4-5
HF wire guided: 10 V IEC/EN 61 000-4-6
Radio interference
suppression: Limit value class B EN 55 011
Degree of protection
Housing: IP 20 IEC/EN 60 529
Terminals: IP 20 IEC/EN 60 529
Housing: Thermoplastic with V0 behavior
according to UL Subject 94
Vibration resistance: Amplitude 0.35 mm IEC/EN 60 068-2-6
Frequency 10…55 Hz,
Shock resistance
Acceleration: 10 g
Pulse duration: 16 ms
Number of shocks: 1000 per axis on three axes
Climate resistance: 0 / 050/ 04 IEC/EN 60 068-1
Terminal designation: EN 50 005
Wire connection: 1 x 2.5 mm2 stranded wire with sleeve, or
1 x 4 mm2 massive or
2 x 1.5 mm2 stranded wire with sleeve
DIN 46 228-1/-2/-3/-4
Wire fixing: Box terminal with wire protection, remov-
able terminal strips.
Mounting: on DIN rail IEC/EN 60 715
Weight:
BG 5913: 193 g
BH 5913: 255 g
Dimensions
Width x height x depth
BG 5913: 22.5 x 84 x 121 mm
BH 5913: 45 x 84 x 121 mm
Safety related data
nfo
Safety data for other variants are available on request
Standard type
BG 5913.08/00MF0 DC 24 V
Article number: 0055530
BH 5913.08/00MF0 DC 24 V
Article number: 0059242
E. DOLD & SÖHNE KG • D-78114 Furtwangen
e-mail: dold-relays @dold.com • internet: http://www.dold.com
• PO Box 1251 • Telephone (+49) 77 23 / 654-0 • Telefax (+49) 77 23 / 654-356