Eaton ESR5-NO-21-24VDC User manual

Manual
ESR5-NO-21-24VDC
Emergency-Stop and protective door monitoring
11/23 MN049017EN

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owners.
Service
For service and support, please contact your local sales organisation.
Contact details
Eaton.com/contacts
Eaton.com/aftersales
Original operating manual
The German-language edition of this document is the original operating
manual.
Translation of the original operating manual
All editions of this document other than those in German language are trans-
lations of the original operating manual.
1. Edition 2023, publication date 11/23
See change log in chapter "About this manual“
© 2023 by Eaton Industries GmbH, 53105 Bonn
Translation: GlobalDocs
Editors: Antje Nonnen
All rights, including those of translation, reserved.
No part of this manual may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopy-
ing, micro-filming, recording or otherwise, without the prior written permis-
sion of Eaton Industries GmbH, Bonn.
Subject to alteration.

I
Before commencing the installation
• Disconnect the power supply of the device.
• Ensure that devices cannot be accidentally restarted.
• Verify isolation from the supply.
• Earth and short circuit.
• Cover or enclose neighbouring units that are live.
• Follow the engineering instructions (AWA/IL) of the
deviceconcerned.
• Only suitably qualified personnel in accordance with
EN 50110-1/-2 (VDE 0105 Part 100) may work on 
this device/system.
• Before installation and before touching the device ensure
that you are free of electrostatic charge.
• The functional earth (FE) must be connected to the
protective earth (PE) or to the potential equalisation. The
system installer is responsible for implementing this
connection.
• Connecting cables and signal lines should be installed so
that inductive or capacitive interference does not impair
the automation functions.
• Install automation devices and related operating elements
in such a way that they are well protected against
unintentional operation.
• Suitable safety hardware and software measures should
be implemented for the I/O interface so that a line or wire
breakage on the signal side does not result in undefined
states in the automation devices.
• Ensure a reliable electrical isolation of the low voltage for
the 24 volt supply. Only use power supply units complying
with IEC 60364-4-41 (VDE 0100 Part 410) or HD 384.4.41 S2.
• Deviations of the mains voltage from the rated value must
not exceed the tolerance limits given in the specifications,
otherwise this may cause malfunction and dangerous
operation.
• Emergency stop devices complying with IEC/EN 60204-1
must be effective in all operating modes of the automation
devices. Unlatching the emergency-stop devices must not
cause restart.
• Devices that are designed for mounting in housings or
control cabinets must only be operated and controlled
after they have been installed with the housing closed.
Desktop or portable units must only be operated and
controlled in enclosed housings.
• Measures should be taken to ensure the proper restart of
programs interrupted after a voltage dip or failure. This
should not cause dangerous operating states even for a
short time. If necessary, emergency-stop devices should
be implemented.
• Wherever faults in the automation system may cause
damage to persons or property, external measures must
be implemented to ensure a safe operating state in the
event of a fault or malfunction (for example, by means of
separate limit switches, mechanical interlocks etc.).
Eaton Industries GmbH Safety instructions
Danger!
Dangerous electrical voltage!

1ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
Table of contents
0 About this manual ................................................................... 3
0.1 List of revisions.......................................................................... 3
0.2 Target group .............................................................................. 4
0.3 Additional documents ................................................................ 4
0.4 Abbreviations and symbols........................................................ 5
1 Description ESR5-NO-21-24VDC............................................. 6
1.1 Intended use.............................................................................. 6
1.2 Possible signal encoders............................................................ 6
1.3 Contact type............................................................................... 6
1.4 Actuation.................................................................................... 7
1.5 Achievable level of safety integrity ............................................ 7
1.6 Other Features........................................................................... 7
1.7 Approvals ................................................................................... 7
1.8 Operator control and display elements...................................... 8
1.9 Function description................................................................... 9
1.10 Function and time diagrams..................................................... 10
1.11 Heat dissipation calculation...................................................... 11
1.12 Block diagram .......................................................................... 12
1.13 Derating ................................................................................... 13
1.13.1 Use at altitudes greater than 2000 m above sea level. NN...... 13
1.14 Load curve – resistive load....................................................... 14
1.15 Electrical lifespan ..................................................................... 15
2 Safety regulations.................................................................. 16
2.1 Basics ...................................................................................... 16
2.2 Mandatory requirements, personnel requirements ................. 18
2.2.1 Occupational safety ................................................................. 18
2.2.2 Personnel qualifications ........................................................... 18
2.2.3 Device documentation............................................................. 18
2.2.4 Installation, maintenance, and disposal ................................... 19
2.2.5 Prerequisites for proper operation ........................................... 19
2.3 Device-specific hazards............................................................ 20
2.3.1 Direct/indirect contact.............................................................. 20
2.3.2 Power supply units for 24 V supply ......................................... 20
2.3.3 Mismatching and polarity reversal of connections................... 20
2.4 In operation.............................................................................. 21
2.5 Defective devices .................................................................... 21

ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 2
2.6 Ensuring the safety of machinery or equipment ......................22
2.6.1 Elaborating and implementing a safety concept ......................22
2.6.2 Risk assessment, validation, and functional test ..................... 22
2.6.3 Achievable level of safety integrity ..........................................22
3 Installation ..............................................................................23
3.1 Prerequisites for the location of use ........................................24
3.2 Unpacking and checking the equipment supplied....................24
3.3 Mounting and disassembly ......................................................24
3.4 Connection ...............................................................................25
3.4.1 Pin assignment.........................................................................25
3.4.2 Wiring topic ..............................................................................26
3.4.3 Terminal models Signal encoder ..............................................27
3.4.4 Connection options Start and feedback circuit.........................27
4 Maintenance ...........................................................................28
4.1 Maintenance ............................................................................28
4.1.1 Proof-Test.................................................................................28
4.2 Storage and transport...............................................................29
4.2.1 Decommissioning and disposal................................................29
4.2.2 Device replacement and repair ................................................29
4.3 Diagnostics...............................................................................30
4.3.1 General states ..........................................................................30
4.3.2 Error Messages........................................................................30
5 Application examples ............................................................32
5.1 Dual-channel EMERGENCY STOP monitoring ......................... 32
5.2 Dual-channel protective door monitoring .................................33
6 Appendix.................................................................................34
6.1 Data sheet and ordering data ...................................................34
6.2 Technical specifications ...........................................................34
6.3 Interface type (ZVEI classification) ...........................................39
7 Glossary ..................................................................................42

0 About this manual
3ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
0 About this manual
This manual contains all the information you will need in order to use the
ESR5-NO-21-24VDC safely and effectively.
The ESR5-NO-21-24VDC manual is considered an integral part of the device
and must always be readily available in the device's close proximity so that
users have access to it.
This manual describes all lifecycle stages of the device: transport, installa-
tion, commissioning, maintenance, storage and disposal.
It assumes you have electrical engineering knowledge and skills.
0.1 List of revisions
The following significant amendments have been introduced since previous
issues:
￫Due to the fact that we cannot know the details of your specific
application, the information and examples in this document are
meant to provide you solely with general assistance in regard to
the use of safety control equipment to implement standards,
guidelines, and directives.
The information and examples in this document do not claim to
be exhaustive or legally binding.
For detailed information, please refer to the standards, guide-
lines, and directives that apply to your specific application.
Publication
date
Page Keyword New Modifi-
cation
Delete
d
10/23 – Initial issue – – –
11/23 – Second certification EN IEC 62061 – ✓–

0 About this manual
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 4
0.2 Target group
This manual is intended for qualified personnel that has appropriate electrical
training and:
•Plans and develops safety equipment for machines and systems or
•Installs and commissions this safety equipment and
•Is familiar with the applicable standards and regulations regarding acci-
dent prevention and occupational health and safety
Familiarity with the following is required:
•Machinery Directive/Machinery Regulation and functional safety
•Handling safety components
•Applicable EMC regulations
•Applicable accident prevention and occupational health and safety regu-
lations
0.3 Additional documents
ATTENTION
For further information, see the applicable documentation:
•IL049013ZU
•Safety relay data sheet ESR5-NO-21-24VDC, article no. 401061
￫The term "qualified personnel" refers to individuals who are
authorized, by the party responsible for the system's safety, to
perform the required activities and can identify and avoid the
corresponding potential hazards as a result of their training,
experience, and briefing and their familiarity with the applicable
standards, regulations, accident prevention regulations, and
operating conditions.
Make sure to always use the latest documentation for your
device. The latest edition of this documentation and the applica-
ble documents can be found on the Internet at Eaton.com/esr5.
￫

DANGER
CAUTION
WARNING
ATTENTION
0 About this manual
5ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
0.4 Abbreviations and symbols
The following symbols are used throughout this manual:
▶Indicates instructions to be followed.
Hazard warnings of personal injury
Hazard warnings of material damages
Tips
Warns of hazardous situations that result in serious injury or
death.
Warns of the possibility of hazardous situations that may possi-
bly cause slight injury.
Warns of the possibility of hazardous situations that could result
in serious injury or even death.
Warns about the possibility of material damage.
￫Indicates useful tips.

1 Description ESR5-NO-21-24VDC
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 6
1 Description ESR5-NO-21-24VDC
1.1 Intended use
The ESR5-NO-21-24VDC safety relay is used to monitor dual-channel signal
generators and drive actuators.
With the help of this ESR5-NO-21-24VDC, circuits are de-energized for safety
purposes. When the sensor circuit is broken, the safety relay brings about a
safe state.
Any other use must be discussed and agreed upon with the manufacturer in
advance.
The ESR5-NO-21-24VDC is approved for use in control cabinets or enclo-
sures with a minimum degree of protection of IP54..
The ESR5-NO-21-24VDC must be used only in locations for
which the device is approved: Make sure to read and Observe the markings
on the device, as well as section Approvals and standards in the appendix.
1.2 Possible signal encoders
•Emergency-stop pushbuttons
•Protective door monitoring
1.3 Contact type
•2 instantaneous enable current paths
•1 instantaneous signaling current path
The enable current paths and the signal current path will drop out without a
delay in conformity with Stop category 0 as defined in EN 60204-1.
￫Please note that we assume no liability for damages, conse-
quential damages, and/or accidents caused by the following:
•Failure to follow any applicable occupational health and
safety rules, standards, and/or regulations
•Device failures or function disturbances
•Improper use and/or handling
•Not following the instructions or observing the information
in the documentation for the device
•Alterations, changes, and repairs to the device

1 Description ESR5-NO-21-24VDC
7ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
1.4 Actuation
•Dual-channel
•Automatic start
1.5 Achievable level of safety integrity
•Suitable up to category 4, PL e (EN ISO 13849-1), SIL 3 (EN IEC 62061)
￫Section , "5 Application examples"
1.6 Other Features
•Cross-circuit detection
•Plug-in screw terminals
•22.5 mm housing width
1.7 Approvals
ID 0600000000
Product Safety
Functional
Safety

APPROVALS
13 2 3 31
14 24 32
ESR5-NO-21-24VDC
31 13 14
32 23 24
A1S34 S33 S11
S12 S21 S22 A2
Power
IN 1/2
K1
K2
LISTED
IND. CONT. EQ .
32FB
30 - 12 AW G
5 - 7 lbs-in s
Input: 24V ac/d c
Output: 240V ac/24V dc.
B300 Pilotdut y
R300 Pilotdut y
ESR5-NO-21-24VDC
①
②
③
⑪
⑩
⑨
⑧
⑦
⑥
⑤
④
1 Description ESR5-NO-21-24VDC
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 8
1.8 Operator control and display elements
Figure 1: ESR5-NO-21-24VDC
aMetal lock for installation on the mounting rail
bPlug-in screw terminals COMBICON
c13/14, 23/24 – enable current paths, non-delayed
d31/32 – signal current path
eLED status display, green – K2
fLED status display, green – K1
gLED status display, green – IN 1/2
hLED status display, green – Power
iA1, A2 – supply voltage connection
jS11/S12, S21/S22 – input circuits (channel 1, channel 2)
kS33/S34 – start circuit (automatic start)
￫The device's year of manufacture can be found underneath the
CE marking on the housing.
XX/XX = calendar week / year

1 Description ESR5-NO-21-24VDC
9ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
1.9 Function description
Dual-channel sensor circuit
The dual-channel sensor circuit is connected the same as for cross-fault
detection.
￫Section 1.4.3, "Anschlussvarianten Signalgeber", page29
Automatic start
The device will start automatically after the sensor circuit is closed.
￫Section 3.4.4, "Connection options Start and feedback circuit", page27
￫Section 1.10, "Function and time diagrams", page10
Safe shut-down
When the sensor circuit is opened, enable current paths S13/14 and 23/24
will be opened without delay.
When the enable current paths are open, the device will be in a safe state.
The signal current path closes.

13/14,
23/24
13/14,
23/24
1 Description ESR5-NO-21-24VDC
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 10
1.10 Function and time diagrams
Time diagram automatic start
Figure 2: Time diagram automatic start
Designation Explanation
A1/A2 Power Supply
S33/34 Automatic start circuit
S11/12 Input sensor circuit (channel 1)
S21/22 Input sensor circuit (channel 2)
13/14, 23/24 Enable current path, non-delayed
31/32 Signal current path, non-delayed

1 Description ESR5-NO-21-24VDC
11 ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
1.11 Heat dissipation calculation
Input heat dissipation
PInput = UB²/ (UN/IN)
Contact heat dissipation
At equal load currents.
PContact = n x IL²x 200 mΩ
At different load currents:
PContact = (IL1²+ IL2²+ … + ILn²) x 200 mΩ
Total heat dissipations
PTotal =PInput + PContact
now then
PTotal = UB²/ (UN/IN) + n x IL²x 200 mΩ
or
PTotal = UB²/ (UN/IN) + (IL1²+ IL2²+ … + ILn²) x 200 mΩ
￫The safety relay's total heat dissipation is yielded by the input
heat dissipation and the contact heat dissipation with equal or
different load currents.
PHeat dissipation in mW
UBApplied operating voltage
UNInput rated voltage
INInput current
nNumber of enable current paths used
ILContact load current

1 Description ESR5-NO-21-24VDC
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 12
1.12 Block diagram
Figure 3: Block diagram
Isolation co-ordination
Enclosure
material
A1/A2, Logic 13/14 23/24 31/32
Enclosure
material
- 4 kV BI 4 kV BI 4 kV BI 4 kV BI
A1/A2, Logic - - 6 kV ST 6 kV ST 6 kV ST
13/14 - - - 4 kV BI 6 kV ST
23/24 - - - - 6 kV ST
31/32 - - - - -
Legend: BI - basic insulation, ST - safe isolation
￫Basic insulation
(rated surge voltage 4 kV)
Mixing low voltage and SELV is not permissible. Connect
250 VAC to one of the enable contacts only if the neighboring
contact/enable current path is also carrying the same potential.
Safe isolation / reinforced insulation
(rated surge voltage 6 kV)
The reinforced insulation is designed one overvoltage category
higher than the basic insulation (e.g., with greater clearances
and creepage distances for the conductors). Accordingly, mixing
SELV circuits with V ≤25 VAC or V ≤60 VDC and circuits with a
higher voltage is possible.
Logic
IN 1/2
A1 13 23 31
S11 S12 S33S34
K1
K2
A2 S22 S21 14 24 32
U Logic
Power
24V DC
Designation Explanation
A1 Power supply 24 VDC
A2 Power supply 0 V
S11/S12 Input sensor circuit (channel 1)
S21/S22 Input sensor circuit (channel 2)
S33/S34 Start circuit automatic
13/14 Enable current paths, non-delayed 1
23/24 Enable current paths, non-delayed 2
31/32 Signal current path, non-delayed

T[
A°C]
I[A]
TH
22
10
20
30
40
0 10203040 50 60
0
45 55
50
60
70
80
32
72
1 Description ESR5-NO-21-24VDC
13 ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
1.13 Derating
The derating curves apply under the following conditions:
•Mounting on vertical or horizontal mounting rail
•Devices mounted without distance to each other
•with UNup to max. 26.4 V DC
•Imax² = I1² + I2² + I3²
Horizontal mounting position
Figure 4: Derating curve – horizontal mounting positions, without distance
Vertical mounting position
Figure 5: Derating curve – vertical mounting positions, without distance
1.13.1 Use at altitudes greater than 2000 m above sea level. NN
The use of the device ESR5-NO-21-24VDC at altitudes higher than 2000 m
above sea leveland up to a maximum of 4500 mabove sea level is
allowed provided that:
1. Rated input voltage VN: 24 VDC (-15%/+10%) is maintained and
2. The maximum switching voltage at the relay outputs for enable current
paths 13/14, 23/24, 33/34, 43/44: min. 10 V, max. 250 VAC
and signal current path 51/52: min 5 V, max. 250 VAC is not exceeded.
▶1.Reduce the maximum ambient temperature for operation by the corre-
sponding temperature derating factor as per the following table.
￫The following section describes the special conditions for the
use of an ESR5-NO-21-24VDC at altitudes greater than
2000 m abovesea level.
Make sure to observe the corresponding device-specific specifi-
cations (technical data, derating, etc.).

0
10
20
30
40
50
60
70
49 55
24 27
3
72
0 102030405060
T
A
[°C]
I
TH2
[A
2
]
27 °C x 0.906 ≈24 °C
55 °C x 0.906 ≈49 °C
Example
1 Description ESR5-NO-21-24VDC
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 14
▶2.If derating is required, shift all the points in the derating curve by the
temperature derating factor.
Calculation example for shifting the derating curve
Figure 6: Example: Shifted derating curve (blue) at altitude of 3000 m above sea level
1.14 Load curve – resistive load
I [A]
DC
U[V]
DC
0,1 0,20,512510
10
20
50
100
500
1000
200
Figure 7: Load curve of the relay – resistive load
Altitude above sea
level
Temperatur-Derating-Factor
2000 m 1
2500 m 0.953
3000 m 0.906
3500 m 0.859
4000 m 0.813
4500 m 0.766
￫Carry out the calculation and shift the derating curve as required
for your application
￫Section 1.13, "Derating"

1 Description ESR5-NO-21-24VDC
15 ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
1.15 Electrical lifespan
[A]
n
[A]
n
Figure 8: Number of switching cycles
AC-1
Figure 9: Number of switching cycles
DC-1
[A]
n
[A]
n
Figure 10: Number of switching cycles
AC-15
Figure 11: Number of switching cycles
DC-13

2 Safety regulations
ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com 16
2 Safety regulations
2.1 Basics
WARNING
WARNING
The device has been designed according to the state of the art and all gener-
ally accepted safety rules and standards. However, this alone cannot elimi-
nate all potential hazards, which is why it is necessary for you to be aware of
all hazards and residual risks.
Do not run the device unless it is in perfect technical condition. Make sure to
always operate it as specified in this document and for the intended purpose.
WARNING
Danger due to electric voltage!
Disregarding safety regulations may result in death, serious per-
sonal injury or damage to equipment!
Depending on the specific application in question, the improper
use of the device may pose serious hazards to the user or result
in serious property damage.
Please observe all safety standards, regulations, and instruc-
tions regarding electrical equipment, as well as those estab-
lished by the applicable employers' liability insurance associa-
tion!
Danger posed by the machine restarting automatically!
When dealing with controlled emergency (category 1) stop
applications, make sure that the higher-level control system will
not cause the machine to restart automatically!
Do not remove any protective covers from electrical switchgear
during operation!
Danger posed by faulty devices!
After a fault , the devices may be damaged, in which case
proper operation can no longer be guaranteed!
Turn off the device without fail after the first fault!
Repairs to the device, especially those involving opening the
housing, must be carried out exclusively by the manufacturer or
by a person authorized by the manufacturer to do so. Failure to
observe this requirement will void any and all warranties!

WARNING
ATTENTION
2 Safety regulations
17 ESR5-NO-21-24VDC 11/23 MN049017EN Eaton.com
Danger due to electric voltage!
During operation, parts of electrical switching devices carry haz-
ardous voltages!
During operation, the protective covers must not be removed
from the electric switchgear!
CAUTION 
UV LIGHT
Plastics will become brittle when exposed to UV light. 
This artificial aging will reduce the device's lifespan. Protect the
device from direct sunlight and other sources of UV radiation.
Risk of property damage posed by improper installation
In order to ensure safe operation, install the safety relay in an
enclosure protected from water sprays and limited dust ingress
(IP54).
Wire the device as required for the intended use.
￫Section 3, "Applikationsbeispiele", page35.
ATTENTION
Risk of property damage posed by emitted interference
When operating relay modules, the company operating the sys-
tem must ensure that the requirements for emitted interference
for electrical and electronic equipment (EN 61000-6-4) are met
on the contact side.
If necessary, corresponding measures must be taken.
ATTENTION
Follow the safety instructions for the ESR5-NO-21-24VDC!
The section on safety instructions must be read and understood
by everyone who will be working with the ESR5-NO-21-24VDC
before the actual work is performed Safety relays for Emer-
gency-Stop and protective door monitoring.