DOLD SAFEMASTER M User manual

107.10.15 en / 477
Safety Technique
Multi-Function Safety System SAFEMASTER M
Input Module
BG 5913.08/_2_ _ _
•According to
- Performance Level (PL) e and category 4 to EN ISO 13849-1: 2008
- SIL Claimed Level (SIL CL) 3 to IEC/EN 62061
- Safety Integrity Level (SIL 3) to IEC/EN 61508
•Input module for combination of 4 of the following functions to be set
via rotary switch:
- safety gate monitoring function (2 x 2 changeover contacts)
- Light curtain (LC type 4) with manual or automatic start
- Emergency stop (2-channel) with manual or automatic start
- Two-hand controls type IIIC acc. to DIN/EN 574
•Functions can be selected via rotary switches
•8 inputs for safety sensors
•Broken wire and short circuit monitoring function with error indication
•2 semiconductor outputs for status indication
•LEDs for status indication
•Width: 22.5 mm
Block Diagram
0247383
Approvals and Markings
Circuit Diagram
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
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+
Realization of fail-safe control circuits for protection of people and machinery.
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/_0_ _ _, BG 5913.08/_1_ _ _ , BG 5913.08/_3_ _ _,
BG 5914.08/_0_ _ _, BH 5914.08/_0_ _ _, BG 5914.08/_1_ _ _,
BG 5915/_1_ _ _ or BH 5915.08/_1_ _ _).
Applications
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/BH 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
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.
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.

207.10.15 en / 477
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:
Setting of the Modules
Sw. Function at Terminals Start behavior of the LC
/ E-Stop
S12-S14 S22-S24 S32-S34 S22-S24
0 Gate Gate E-Stop LC Autostart
1 Gate Gate E-Stop LC Manual Start
2 E-Stop E-Stop E-Stop E-Stop Autostart Enabling
only
when
all other
modules
permit
enabling
3 E-Stop E-Stop E-Stop E-Stop Manual Start
4 E-Stop E-Stop E-Stop E-Stop Autostart
5 E-Stop E-Stop E-Stop E-Stop Manual Start
6 E-Stop E-stop Two-hand IIIC Autostart
7 E-Stop E-stop Two-hand IIIC Manual Start
8 Gate Gate Two-hand IIIC Autostart
9 Gate LC Two-hand IIIC Autostart
Function of the Two-Hand Control
Each function activates an enabling signal in the module software. The
control unit is permitted to enable the assigned safety outputs only after
all 3 (for two-hands control) or 4 enablings have been given.
With the exception of two-hand control, each function works indepen-
dently. The assigned safety outputs are enabled if the precondition for
enabling has been met for all functions.
Functional Principle of Combined Inputs
This function will only work when the other two functions have already per-
mitted enabling. To provide for enabling, the two buttons must be pressed
within 0.5 s. As soon as one of the other function reacts, the two buttons
must turn inactive before the others can be enabled again. Only after that,
the buttons can be activated once more from an inactivated state.
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 with easily, or pressed unintentionally.
The safety distance between the push buttons and the place of danger must
be large enough to make sure 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 danger 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. In this respect, also see DIN/EN 574.
The two-hand control must be released when another function module
which affects the same outputs does not permit enabling.
The system may comprise only one function module with two-hand control.
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.

307.10.15 en / 477
Indication of System Errors:
E-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.
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.
Special behaviour on e-stop (function setting 2 or 3):
Initial state: all e-stop buttons are not activated and the start button has
been pressed correctly on manual start. An other module gives no en-
abling signal independent of the assigned output module. Output 48 and
the white run LED 1 are off and output 58 is continuously on.
In this state the module will give the enabling signal automatically as
soon as all other modules give their enabling signals together.
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
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 for channel 1 and 2 has different or
incorrect positions
- The setting of the 4 upper Dip-switches (channel 1) are not
identically to the 4 lower Dip-switches (channel 2)
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

407.10.15 en / 477
Function Diagrams
Note: The times specified in a pulse diagram also apply to the same function in other applications.
gate, changeover
contact 1NC contact
gate, changeover
contact 1NO contact
gate, changeover
contact 2NO contact
gate, changeover
contact 2NC contact
gate recognized
as closed
status: 1
gate is
fully open
2
gate closes
regularly
t<3s
3
gate is
correctly
closed
12
gate closes,
one contact signal missing
t=3s
error,
status 1
is expected
again
4
gate opens, is
recognized at the
first edge at one of
the4contacts
(now, status1is expected)
M8987_b
123
error has been
corrected
two-hand 1,
NC contact
two-hand 1,
NO contact
two-hand 2,
NO contact
two-hand 2,
NC contact
two-hand
recognized as
operated
status: 1
two-hand
not pressed
2
operation of the
two buttons correct
t<0,5s
3
two-hand
is pressed
12
button2has been
confirmed too late
t=0,5s
error,
status1is
expected again
4
release of the,
button is recognized
at the first edge at
one of the4contacts
(now, status1is expected)
123
error has been
corrected
M8989_b
emergency stop,
LC, signal 1
emergency stop,
LC, signal 2
emergency stop
recognized as closed
status: 1
emergency
stop pressed
2
contacts
close correctly
t<0,250s
3
emergency
stop
deactivated
12
emergency stop is
deactivated,aline
is interrupted
t=0,250s
error,
status1is
expected again
4
operation of the
emergency stop is
recognized at the
first edge at one of
the2contacts
(now, status1is expected)
123
error has been
corrected
M8991
Emergency stop or light curtains
Safety gate control
Two-hand control type IIIC

507.10.15 en / 477
Function Diagrams
Note: The times specified in a pulse diagram also apply to the same function in other applications.
supply
voltage
(A1/A2)
gate closed,
changeover
contact 1
gate closed,
changeover
contact 2
emergency stop,
contact1S32
emergency stop,
contact2S34
LC, input 1
S42
LC, input 2
S44
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
M8993_a
11113 22
32
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
t<3s t<3s t<3s t<3s t<
250ms
t<
250ms
t=
250ms
t=3s
M8995_a
1122
32
t<3s t<3s t<
250ms
t<
250ms
t=
250ms
supply
voltage
(A1/A2)
gate,
changeover
contact 1
gate,
changeover
contact 2
emergency stop,
contact1S32
emergency stop,
contact2S34
LC, input 1
S42
LC, input 2
S44
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
1 Safety gate, 1 Emergency stop, 1 light curtain, Autostart; function: 0
1 Safety gate, 1 Emergency stop, 1 light curtain, manual start; function: 1

607.10.15 en / 477
Function Diagrams
Note: The times specified in a pulse diagram also apply to the same function in other applications.
emergency stop 2
S22-S24
emergency stop 3
S32-S34
emergency stop 4
S42-S44
enabling of the
other modules
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
M8997_b
2222 22 23
assigned
start button
: dark
t<
250ms
t=
250ms
supply
voltage
(A1/A2)
emergency stop 1,
contact1S12
emergency stop 1,
contact2S14
: permanently
on
: flashing code
M8999_a
222222 2
supply
voltage
(A1/A2)
emergency stop 1,
S12-S14
emergency stop 2,
S22-S24
emergency stop 3,
S32-S34
emergency stop 4,
S42-S44
enabling of the
other modules
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
4 Emergency stop, Autostart, only enabling when all the other modules are enabled; function: 2
4 Emergency stop, manual start, only enabling when all the other modules are enabled; function: 3

707.10.15 en / 477
Function Diagrams
Note: The times specified in a pulse diagram also apply to the same function in other applications.
M9001_b
2222 2232
t<
250ms
t=
250ms
emergency stop 2
S22-S24
emergency stop 3
S32-S34
emergency stop 4
S42-S44
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
assigned
start button
supply
voltage
(A1/A2)
emergency stop 1,
contact1S12
emergency stop 1,
contact2S14
: dark : permanently
on
: flashing code
M9003_a
222222
supply
voltage
(A1/A2)
emergency stop 1,
S12-S14
emergency stop 2,
S22-S24
emergency stop 3,
S32-S34
emergency stop 4,
S42-S44
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
4 Emergency stop, Autostart; function: 4
4 Emergency stop, manual start; function 5

807.10.15 en / 477
Function Diagrams
Note: The times specified in a pulse diagram also apply to the same function in other applications.
two-hand 1
S32-S34
two-hand 2
S42-S44
enabling of the other
modules assigned
to the same output
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
M9005_a
22 3
t<
0,5s t=0,5s
supply
voltage
(A1/A2)
emergency stop 1,
S12-S14
emergency stop 2,
S22-S24
: dark : permanently
on
: flashing code : constant flashing
M9007_a
222
two-hand 1
S32-S34
two-hand 2
S42-S44
enabling of the other
modules assigned
to the same output
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
supply
voltage
(A1/A2)
emergency stop 1,
S12-S14
emergency stop 2,
S22-S24
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
2 Emergency stop, Autostart, 1 two-hand control type IIIC; function: 6
2 Emergency stop, manual start, 1 two-hand control type IIIC; function: 7 or 9

907.10.15 en / 477
Application Example
BG 5913.08/_2_ _ _, 1 safety gate, 1 Emergency stop, 1 light curtain; functions: 0 or 1
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M9011_c
S1 S2
LC
--
++
L+
L-
trans-
mitter
emergency stop
open
closed
safety gate
waiting for start
error
error indication,
enabling active
OSSD
BG5913
M9009_a
111
gate, changeover
contact 1 S12-S14
gate, changeover
contact 2 S22-S24
t<
0,5s
t<
0,5s
t<3s
supply
voltage
(A1/A2)
two-hand 1
S32-S34
two-hand 2
S42-S44
enabling of the other
modules assigned
to the same output
enabling
LED en1en2
output 48,
LED run 1
(error code)
output 58
(error)
assigned
start button
: dark : permanently
on
: flashing code : constant flashing
1 Safety gate, 1 two-hand control type IIIC; function: 8
Function Diagram

10 07.10.15 en / 477
BG 5913.08/_2_ _ _, 2 Emergency stop; 1 two-hand control type IIIC functions: 6 or 7
Application Examples
BG5913
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M9015_b
T1 T2
two-hand
waiting for start
error
error indication,
enabling active
emergency
stop 2
emergency
stop 1
BG 5913.08/_2_ _ _, 4 Emergency stop; functions: 2, 3, 4 or 5
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M9013_a
emergency stop 1 emergency stop 2 emergency stop 3 emergency stop 4
waiting for start
error
error indication,
enabling active
BG5913

11 07.10.15 en / 477
Application Examples
BG 5913.08/_2_ _ _, 2 light curtains, 1 two-hand control type IIIC (EN 574); function: 9
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M9019_c
T1 T2
LC 1LC2
----
++++
L+
L-
two-hand
waiting for start
error
error indication,
enabling active
trans-
mitter
trans-
mitter
OSSDOSSD
BG5913
X1
(-)
X2S12 S14 S22 S24 S32 S34 S42 S44
58 (-)48
M9017_b
S1 S2
T1 T2
two-hand
waiting for start
error
error indication,
enabling active
open
closed
safety gate
BG5913
BG 5913.08/_2_ _ _, 1 safety gate, 1 two-hand control type IIIC (EN 574); function: 8

12 07.10.15 en / 477
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. 1 s max. 115 ms
Light barriers max. 80 ms max. 1 s 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 impulse voltage /
pollution degree: 4 kV / 2 (basis insulation) IEC 60 664-1
EMC: IEC/EN 61 326-3-1, IEC/EN 62 061
Radio interference suppression: Limit value class A EN 55011
Remark: This device is designed for industrial ambient conditions.
When used in other environment, it is possible that wire bound or
radiated interference occurs.
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,
Technical Data
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: DIN rail IEC/EN 60 715
Weight: 193 g
Dimensions
Width x height x depth: 22.5 x 84 x 121 mm
Safety Related Data for E-STOP
Values according to EN ISO 13849-1:
Category: 4
PL: e
MTTFd: 812,8 a
DCavg: 96,0 %
dop: 365 d/a (days/year)
hop: 24 h/d (hours/day)
tZyklus: 3600 s/Zyklus
=1 /h (hour)
Values according to IEC EN 62061 / IEC EN 61508:
SIL CL: 3 IEC EN 62061
SIL 3 IEC EN 61508
HFT*): 1
DCavg: 96,0 %
SFF 99,2 %
PFHD: 2,34E-10 h-1
Safety Related Data for light curtains ,safety gates or two-hand
Values according to EN ISO 13849-1:
Category: 4
PL: e
MTTFd: 2697,1 a
DCavg: 96,0 %
dop: 220 d/a (days/year)
hop: 12 h/d (hours/day)
tZyklus: 138 s/Zyklus
Values according to IEC/EN 62061 / IEC/EN 61508:
SIL CL: 3 IEC/EN 62061
SIL 3 IEC/EN 61508
HFT*): 1
DCavg: 96,0 %
SFF 99,2 %
PFHD: 2,34E-10 h-1
)HFT = Hardware-Failure Tolerance
nfo
The values stated above are valid for the standard type.
Safety data for other variants are available on request.
The safety relevant data of the complete system has to be
determined by the manufacturer of the system.
Standard Type
BG 5913.08/02MF0 DC 24 V
Article number: 0056805
E. DOLD & SÖHNE KG • D-78114 Furtwangen
e-mail: dold-relays @dold.com • internet: http://www.dold.com
• POBox1251•Telephone(+49)7723 / 654-0 • Telefax (+49) 77 23 / 654-356