EUCHNER ESM-F Series User guide

GB
More than safety.
System Manual
Modular Safety System
ESM-F

System Manual ESM-F
2
Contents
Correct use 3
Exclusion of liability and warranty 3
General safety instructions 3
Function 4
Status LEDs and pin assignment 5
Status LEDs and connections on the base units 5
Status LEDs and connections on the input modules 5
Status LEDs and connections on the output modules 5
Technical data 6
General technical data 6
Items supplied 14
Items supplied, base units 14
Items supplied, input modules 14
Items supplied, output modules 14
Accessories 14
Connection set 14
Mounting and replacing modules 15
Mounting 15
Replacing modules 16
Electrical connection 17
Starting behavior 18
Connecting safety inputs 19
Connecting safety contacts and feedback loop 22
Connecting base unit monitoring outputs 23
Connecting group outputs 23
Connecting expansion modules 24
Connecting input modules 24
Connecting output modules 26
Expanding time-delay output modules 27
Forming safety groups 28
Forming a group with the outputs GO1 and GO2 on an input module 28
Forming a group with the outputs GO1 and GO2 on a base unit 29
Response times of the ESM-F system 29
Setup 30
Trouble shooting 31
Status table 31
Inspection and service 34
Service 34
Declaration of conformity 35

System Manual ESM-F
3
Correct use
The base unit ESM-F-B... is used to evaluate safety-related signals in safety circuits
according to EN 60204-1. With this unit safety category 4 according to EN 954-1
can be achieved. The base unit can only be expanded using expansion devices in
the modular safety system ESM-F from EUCHNER. The device is not allowed to be
opened, tampered with, or modified. The permissible operating parameters are
to be observed during operation (see section “Technical data”).
Before the safety module is used, a risk assessment must be performed on the
machine in accordance with:
EN 954-1, Safety of machinery. Safety related parts of control systems. Gene-
ral principles for design, Annex B
EN 1050, Safety of machinery. Principles for risk assessment
IEC 62061, Safety of machinery - Functional safety of safety-related electrical,
electronic and programmable electronic control systems
Correct use includes compliance with the relevant requirements for installation
and operation, particularly
EN 60204-1, Safety of machinery. Electrical equipment of machines. General
requirements
Exclusion of liability and warranty
In case of failure to comply with the conditions for correct use stated above, or
if the safety instructions are not followed, or if any servicing is not performed as
required, liability will be excluded and the warranty void.
General safety instructions
The device is only allowed to be installed and placed in operation by authorized
personnel
who are familiar with the correct handling of safety components,
who are familiar with the applicable regulations on health and safety
and who have read and understood the operating instructions and the system
manual.
The safety function of the system while the machine is in operation can no longer
be ensured if the device is connected incorrectly or used incorrectly. Fatal injuries
may result.
Important!
Prior to use read the operating instructions and the system manual, and keep
these in a safe place. Ensure the operating instructions and the system manual
are always available during mounting, setup and servicing. EUCHNER cannot
provide any warranty in relation to the readability of the CD for the storage period
required. For this reason you should also archive a printed copy of the system
manual. If you should lose the operating instructions or the system manual, you
can download these documents from www.EUCHNER.de.








System Manual ESM-F
4
Function
The modules in the ESM-F system are used for the evaluation of the safety com-
ponents connected and the safe interruption of a safety circuit.
The base unit ESM-F-B... is part of the ESM-F system from EUCHNER. The ESM-F
system comprises at least one base unit.
The base unit has several inputs for the connection of safety components. The
safety contacts are switched as a function of the input signals. Subsequent parts
of the safety circuit can be monitored using a feedback loop.
Different device states can be signaled using monitoring outputs.
The base unit can be expanded with additional inputs and outputs using expansion
modules. The individual modules are connected together using a special connector
system. Power is supplied and safety signals are sent via the connector system.
If one of the safety components (e.g. an emergency stop) is actuated, the base
unit opens its contacts immediately. If additional output modules are used, these
also receive a signal to open their contacts. The system is designed such that
failures will not result in the loss of the safety function. The occurrence of failures
is detected by cyclic self-monitoring at the latest on the next demand to close
the safety contacts (e.g. on starting). The system can be started either manually
using a start button or automatically using a jumper. Safety groups with varying
safety levels can be formed using appropriate configurations (see section Forming
safety groups).

System Manual ESM-F
5
Status LEDs and pin assignment
All modules in the ESM-F system have status LEDs for the important module sta-
tes. The significance of the individual LED states is given in the section Trouble
shooting.
Status LEDs and connections on the base units
23
13
SI SA OV
SO
33 A1
14 24
Y2
Y1OY
O14
34 A2
ESM-F Basic
Pwr
In1 1 2
In2 1 2
In B G
Rx Tx
OG
OI
S23 S21 S22 S24
O2
O1
GO2 GI2
S13
S14
S12S11
GO1 GI1
Out 1
Out 2
Feedb
Out B
Status LEDs and connections on the input modules
ESM-F Input
Pwr
In1 1 2
In2 1 2
Rx Tx
O2
O1 GO2 GO1
S14
S12
S23
S24
S22S21
S13 S11
ESM-F Input
Pwr
In1 1 2
In2 1 2
In3 1 2
Rx Tx
O3
S33 S31 S32 S34
O2
O1
S14
S12
S23
S24
S22S21
S13 S11
Status LEDs and connections on the output modules
ESM-F Output
44
34
24
14
43
33
Y1
Y2
13 23
Pwr
Out 1
Out 2
Feedb
ESM-F Output
32
44
24
14
31
43
Y1
Y2
13 23
Pwr
Out 1
Out 2
Feedb
ESM-F Output
48
38
28
18
47
37
Y1
O17
Y2
17 27
Out 1 2
Pwr
Feedb
t
ESM-F Output
48
38
28
18
47
37
Y1
O17
Y2
17 27
Out 1 2
Pwr
Feedb
ESM-F-BSN-2C2O2
ESM-F-BMN-2C2O2
ESM-F-OSN-O3M1
ESM-F-OSN-O4 ESM-F-OT05NO4 ESM-F-OTNO4
ESM-F-I3I-3C2
ESM-F-ISI-6C1
ESM-F-IMI-3C2
ESM-F-ILI-3C2
ESM-F-ISI-2C2

System Manual ESM-F
6
Technical data
General technical data
Parameter Value Unit
Housing material Polyamide PA6.6
Dimensions ESM-F-B.. ESM-F-I.. ESM-F-O..
114 x 99 x 45 114 x 99 x 22.5 114 x 99 x 22.5 mm
Weight Approx. 0.26 Approx. 0.13 Approx. 0.18 kg
Connection type Plug-in connection terminals
Terminals 0.14 … 2.5 mm²
Ambient temperature
at UB= 24 V DC -15 ... +55 °C
Degree of protection to EN IEC 60529
IP 20
Degree of contamination
2
Mounting Expansion connector on DIN rail 35 mm
according to DIN EN 50022-35
Life Mechanical 1 x 107operating cycles
Electrical 1 x 105operating cycles
Connection data, base units ESM-F-B...
Parameter Value Unit
Operating voltage 24 ± 10% 1) V DC
Reverse polarity protection Yes
Power consumption Approx. 3.5 VA
Control voltage
at start button 18.6 … 26 V DC
Control cable length max.
(cross-section 0.75 mm²) 1000 m
Current consumption, max.
140without monitoring outputs mA
with monitoring outputs 320
External contact fuses
(safety circuit)
according to EN IEC 60269-1
10 AgG (T6A / F8A)
Rated impulse withstand voltage 2.5 kV
Leakage path and air gap acc. to
DIN VDE 0110-1:1997-04 4 kV
Cumulative therm. current for all
contacts 10 A
Safety contacts
Switching current, min., at 24 V DC 20 mA
Maximum switching voltage 50 V DC
250 V AC
Utilization category according to UeIeSIe
EN IEC 60947-5-1 AC-12 250 V 8 A
10 A
AC-15 250V 3 A
DC-12 50 V 8 A
DC-13 24 V 3 A
LEDs 13, diagnostics and status
Monitoring outputs (semiconductor)
Short circuit-proof Yes
Continuous current max. 30 mA
Output voltage 24 V DC
Inputs
Circuit ESM-F-BSN… 2 inputs, NC contact/NC contact, 2-channel
with short-circuit monitoring and earth fault monitoring
ESM-F-BMN… 2 inputs, NC contact/NO contact, 2-channel
with short-circuit monitoring and earth fault monitoring
1) All the electrical connections must either be isolated from the mains supply by a safety transformer according to EN IEC 61558-
2-6 with limited output voltage in the event of a fault, or by other equivalent isolation measures.
Ue= Switching voltage Ie= Maximum switching current per contact
SIe= Maximum switching current per all safety contacts (cumulative current)

System Manual ESM-F
7
Dimension drawing
Suitable for 35 mm DIN rail
according to DIN EN 50022-35
99
45 114
23
13
SI SA OV
SO
33 A1
14 24
Y2
Y1OY
O14
34 A2
ESM-F Basic
Pwr
In1 1 2
In2 1 2
In B G
Rx Tx
OG
OI
S23 S21 S22 S24
O2
O1
GO2 GI2
S13
S14
S12S11
GO1 GI1
Out 1
Out 2
Feedb
Out B
Block diagram ESM-F-B...
2313
24
14
Inputs
K2
K1
33
34
S23 S24
Y1 Y2
SO SI SA
O1 O2 OI OG O14 OY
Monitoring outputs
GI1 GI2
A1 A2
-
-
-
-
GO1
0V GO2
Group signal
Expansion connector
S11 S12 S13 S14 S21 S22
Expansion connector
Power
supply
Start function Input circuit 1 Input circuit 2
Feedback
loop

System Manual ESM-F
8
Connection data, input modules ESM-F-I
Parameter Value Unit
Operating voltage 24 ± 10% 1) V DC
Reverse polarity protection Yes
Power consumption Approx. 4.2 VA
Control cable length max.
(cross-section 0.75 mm²) 1000 m
Current consumption, max.
100
without monitoring outputs
mA
with monitoring outputs 160 (ESM-F-ISI-2C2)
190 (ESM-F-I3I-3C2, ESM-F-ISI-6C1,
ESM-F-IMI-3C2, ESM-F-ILI-3C2)
LEDs 9, diagnostics and status
Monitoring outputs (semicon-
ductor)
Short circuit-proof Yes
Continuous current max. per
output 30 mA
Output voltage 24 V DC
Inputs
Circuit ESM-F-I3I-3C2 3 inputs, NC contact/NC contact, 2-channel
with short-circuit monitoring and earth fault monitoring
ESM-F-ILI-3C2 3 inputs, NC contact/NC contact, 2-channel
without short-circuit monitoring and earth fault monitoring
ESM-F-ISI-2C2
2 inputs, NC contact/NC contact, 2-channel
with short-circuit monitoring and earth fault monitoring
outputs for forming a group
ESM-F-ISI-6C1 6 inputs, NC contact/NC contact, 1-channel
with short-circuit monitoring and earth fault monitoring
ESM-F-IMI-3C2
3 inputs, NC contact/NO contact, 2-channel
with short-circuit monitoring and earth fault monitoring
for the connection of safety switches
with NO contact/NC contact combination (e.g. CMS from
EUCHNER)
1) Supplied via expansion connector

System Manual ESM-F
9
Dimension drawing
99
22,5 114
ESM-F Input
Pwr
In1 1 2
In2 1 2
Rx Tx
GO2GO1
O2
O1
S14
S12
S23
S24
S22S21
S13 S11
99
22,5 114
ESM-F Input
Pwr
In1 1 2
In2 1 2
In3 1 2
Rx Tx
O3
S33 S31 S32 S34
O2
O1
S14
S12
S23
S24
S22S21
S13 S11
Block diagram ESM-ISI-2C2
S14 S21
Inputs
S22 S23 S24
GO1
Group
signal
S11 S12
S13
O1 O2
Monitoring
outputs
Input circuit 1 Input circuit 2
Expansion connector Expansion connector
GO2
Block diagram ESM-I3I-3C2, ESM-F-IMI-3C2 and ESM-F-ILI-3C2
S14 S21
Inputs
S22 S23 S24 S31 S32
S11 S12
S13
O1 O3 O2
Monitoring
outputs
S33 S34
Input circuit 1 Input circuit 3Input circuit 2
Expansion connector Expansion connector
Block diagram ESM-I..-6C1
S14 S21
Inputs
S22 S23 S24 S31 S32
S11 S12
S13
O1 O3 O2
Monitoring
outputs
S33 S34
Input circuit 1 Input circuit 2 Input circuit 3 Input circuit 4 Input circuit 5 Input circuit 6
Expansion connector Expansion connector
Suitable for 35 mm DIN rail
according to DIN EN 50022-35

System Manual ESM-F
10
Connection data, output modules ESM-F-O...
Parameter Value Unit
Operating voltage 24 ± 10% 1) V DC
Reverse polarity protection Yes
Power consumption Approx. 2.4 VA
Current consumption, max. 100 mA
External contact fuses
(safety circuit)
according to EN IEC 60269-1
10 AgG (T6A / F8A)
Rated impulse withstand voltage 2,5 kV
Leakage path and air gap acc. to
DIN VDE 0110-1:1997-04 4 kV
Cumulative therm. current for all
contacts 10 A
Safety contacts
Switching current, min.,
at 24 V DC 20 mA
Maximum switching voltage 50 V DC
250 V AC
Utilization category according to UeIeSIe
EN IEC 60947-5-1 AC-12 250 V 8 A
10 A
AC-15 250 V 3 A
DC-12 50 V 8 A
DC-13 24 V 3 A
LEDs 4, diagnostics and status
Auxillary contact
(on ESM-F-OSN-O3M1)
Switching current, min.,
at 24 V DC 20 mA
Maximum switching voltage 50 V DC
250 V AC
Utilization category according to UeIe
EN IEC 60947-5-1 AC-12 250 V 8 A
AC-15 250 V 3 A
DC-12 50 V 8 A
DC-13 24 V 3 A
1) Power supplied via expansion connector
Ue= Switching voltage Ie= Maximum switching current per contact
SIe= Maximum switching current per all safety contacts (cumulative current)

System Manual ESM-F
11
Dimension drawing ESM-F-O...
22,5
99
114
ESM-F Output
44
34
24
14
43
33
Y1
Y2
13 23
Pwr
Out 1
Out 2
Feedb
22,5
99
114
ESM-F Output
32
44
24
14
31
43
Y1
Y2
13 23
Pwr
Out 1
Out 2
Feedb
Block diagram ESM-F-OSN-O4
2313
24
14
K2
K1
43
44
Y1 Y2 31
32
Expansion connector Expansion connector
Feedback
loop
Block diagram ESM-F-OSN-O3M1
2313
24
14
K2
K1
43
44
Y1 Y2 31
32
Expansion connector Expansion connector
Feedback
loop
Suitable for 35 mm DIN rail
according to DIN EN 50022-35

System Manual ESM-F
12
Connection data output modules ESM-F-OT..
Parameter Value Unit
Operating voltage 24 ± 10% 1) V DC
Reverse polarity protection Yes
Power consumption Approx. 2.4 VA
Time-delay
ESM-F-OTN… 1 … 30 (adjustable) s
ESM-F-OT05N… 0.5 (fixed) s
Current consumption, max.
100without monitoring output mA
with monitoring output 130
Leakage path and air gap acc. to
DIN VDE 0110-1:1997-04 4 kV
Cumulative therm. current for all
contacts 10 A
Safety contacts
Switching current, min.,
at 24 V DC 20 mA
Maximum switching voltage 50 V DC
250 V AC
Utilization category according to UeIeSIe
EN IEC 60947-5-1 AC-12 250 V 8 A
10 A
AC-15 250 V 3 A
DC-12 50 V 8 A
DC-13 24 V 3 A
LEDs 4, diagnostics and status
Monitoring output
(semiconductor)
Short circuit-proof Yes
Continuous current max. 30 mA
Output voltage 24 V DC
1) Supplied via expansion connector
Ue= Switching voltage Ie= Maximum switching current per contact
SIe= Maximum switching current per all safety contacts (cumulative current)

System Manual ESM-F
13
Dimension drawing ESM-F-OT...
22,5
99
114
t
ESM-F Output
48
38
28
18
47
37
Y1
O17
Y2
17 27
Out 1 2
Pwr
Feedb
22,5
99
114
ESM-F Output
48
38
28
18
47
37
Y1
O17
Y2
17 27
Out 1 2
Pwr
Feedb
Black diagram ESM-F-OT...
2717
28
18
K2
K1
37
38
Y1 Y2 47
48
O17
Monitoring
output
Expansion connector Expansion connector
Feedback
loop
Suitable for 35 mm DIN rail
according to DIN EN 50022-35

System Manual ESM-F
14
Items supplied
Check whether all parts are complete. The connection terminals must be ordered
separately. The following parts are supplied:
Items supplied, base units
1 base unit ESM-F-B...
2 expansion connectors
2 terminal plugs with jumpers (already connected)
Operating instructions (please retain!)
CD with system manual (please retain!)
Items supplied, input modules
1 input module ESM-F-I...
1 expansion connector
Operating instructions (please retain!)
Items supplied, output modules
1 output module ESM-F-O...
1 expansion connector
Operating instructions (please retain!)
Warning!
Only use plug connectors from EUCHNER for connection and mounting. On the
use of parts not approved by EUCHNER, the safety function may be lost or the
device damaged.
Accessories
To connect the ESM-F modules you will need appropriate connection terminals that
are not included with the modules.
Connection set
The connection set is available with either screw terminals or with spring termi-
nals:
Items supplied with connection set with screw terminals
4 plug-in screw terminals
2 jumpers
Coding pins
Items supplied with connection set with spring terminals
4 plug-in spring terminals
2 jumpers
Coding pins
You can obtain additional installation material or spare parts from EUCHNER.


















System Manual ESM-F
15
Mounting and replacing modules
Mounting
The ESM-F system must be installed in a control cabinet that has a degree of pro-
tection of at least IP 54. For fastening, the expansion connectors must be clipped
to a horizontally mounted DIN rail. The technical data given only apply in this
installation position. The individual modules are fitted to the expansion connectors
and clipped onto the DIN rail.
Proceed as follows:
Connect the two expansion connectors for the base unit. If you use additional
expansion modules, you must use a new expansion connector for each mo-
dule.
Important!
Input modules must always be connected to the left of the base unit. Output
modules must always be connected to the right of the base unit. Each safety
group is only allowed to contain one base unit.
Connect a terminating plug at each of the ends.
Important!
For the ESM-F system to work, a terminal plug must be fitted on the end of the
first and last expansion connector. The jumpers on the terminal plug are not
allowed to be removed or the connections changed. The jumpers on the terminal
plug must be connected between terminal 1and 3(see figure above).
Clip the connected expansion connector to the DIN rail.
Connect the modules in the correct sequence to the expansion connector.
Ensure the modules engage with the DIN rail.
The mounting of the modules is complete.
1.
2.
3.
4.

Termial plug
Jumpers Jumpers
Contact spring
Expansion connector

System Manual ESM-F
16
Replacing modules
Any expansion modules can be removed from a safety group at any time. The
remaining modules will continue to function without limitations.
Warning!
The safety function will be lost if safety modules are removed while the system
is in operation. People may be placed in danger and the module or system may
be damaged.
Disconnect the power supply and secure the system against restart before
starting the maintenance job.
Proceed as follows:
Disconnect power.
If the inputs and outputs on the module are already connected, disconnect the
plug-in connection terminals from the module you want to remove.
Unlock the catch with a screwdriver and tip the module up and away.
Fit the new module to the expansion connector. Ensure the modules engage
with the DIN rail.
Caution!
If the connection terminals are connected incorrectly, malfunctions and damage
to the device or the system may result. Code the connection terminals using the
coding pins included in the connection set.
Re-connect the specified terminals.
Connect power.
Check the system functions correctly before you release the system for ope-
ration.
1.
2.
2.
3.
4.
5.
6.

System Manual ESM-F
17
Electrical connection
Warning!
The device is only allowed to be installed and placed in operation by authorized
personnel who are familiar with the correct mounting of safety components.
Caution!
Excessively high loads may cause damage to the base unit.
Comply with the operating values in the section Technical data. On the use of
several expansion modules the total current consumption must not be more
than 3 A.
Observe the requirements on connections in these operating instructions.
Power supply
The power supply of DC 24 V is supplied to the base unit. All expansion modules
for the ESM-F are supplied with DC 24 V via the expansion connector.
Caution!
Only use terminal A2 for the earth connection and not terminal 0V. The terminal
0V is only used as a reference potential for the semiconductor outputs and is
not designed for high loads. An incorrect connection will cause damage to the
unit.
Terminal
plug
Base
0V
A2
A1
+24 V
0 V
PE
Terminal
plug
A2 and 0V are
connected to-
gether internally
PE must be
connected to A2 for the
earth fault detection
Figure 1: Power supply
Important!
For the earth fault monitoring, the terminal A2 must be connected to the protec-
tive earth (PE) on the machine.

System Manual ESM-F
18
Starting behavior
The base unit can be placed in operation either using the autostart mode or by
starting it manually.
Connection for monitored, manual start
For monitored, manual start, a start button must be connected between the termi-
nals SO and SI. The monitoring will detect, e.g. a sticking start button.
Base
SA
SI
SO
Figure 2: Monitored, manual start
The safety contacts close immediately when the start button is pressed and all
safety circuits connected are closed.
Important!
The start button is only allowed to be pressed approx. 300 ms after power on.
If the start button is pressed earlier, the unit will switch to the fault state and
only LED Out1 will illuminate. This fault also occurs if the start button is pressed
while the safety inputs are activated (see section Trouble shooting).
A sticking start button is only detected if a signal has been deactivated on one
of the safety inputs for more than approx. 500 ms.
Connection for manual start (not monitored)
Warning!
Start button faults will not be detected in case of un-monitored, manual start.
Base
SA
SI
SO
Figure 3: Un-monitored, manual start

System Manual ESM-F
19
For un-monitored, manual start, a start button must be connected between the
terminals SI and SA.
The safety contacts close immediately when the start button is pressed and all
safety circuits connected are closed.
Connection for automatic start
Warning!
Impairment of the safety function because of improper connection. Pay attention
to sections 5.4 and 5.5 in the standard EN 954-1 if you want to start the ESM-F
system automatically.
Base
SA
SI
SO
Figure 4: Automatic start
For the autostart mode, a jumper must be connected between the terminals SI
and SA.
The safety contacts close immediately if all safety circuits connected are
closed.
Connecting safety inputs
The base unit is, depending on the version, equipped with two safety inputs for the
connection of two normally closed contacts (ESM-F-BSN...) or for the connection
of one normally closed contact and one normally open contact (ESM-F-BMN...).
The version ESM-F-BMN... is therefore suitable for the connection of diverse safety
switches (e.g. CMS, from EUCHNER). All safety inputs have short circuit and earth
fault monitoring.
Important!
Unused normally closed contact safety inputs must be fitted with jumpers (see
Figure 6 and Figure 8). For the earth fault monitoring, the terminal A2 must be
connected to the protective earth (PE) (see Figure 1).

System Manual ESM-F
20
Inputs on the base unit ESM-F-BSN...
You can connect two dual-channel safety switches (e.g. two emergency stops) to
the base unit. In the example below (Figure 6) only one safety switch has been
connected, jumpers must therefore be fitted to the remaining safety inputs.
Base
S14
S12
S11
S13
S24
S22
S21
S23
Safety
component
Safety
component
Figure 5: Safety inputs on the ESM-F-BSN... (both inputs connected)
Base
S14
S12
S11
S13
S24
S22
S21
S23
Safety
component
Figure 6: Safety inputs on the ESM-F-BSN... (one input connected, jumper fitted
to unused input)