Honeywell FF-SRE6029 User manual

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HONEYWELL
FF-SRE60292

FF-SRE6029
Extension Module
Instructions for use
(pending)
(pending)
107137-20 -EN FR26 GLO 305 Printed in Germany 1
IMPROPER INSTALLATION
• Consult with US, Canadian and/or European safety
agencies and their requirements when designing a
machine control, interface and all control elements that
affect safety.
• Strictly adhere to all installation instructions.
Failure to comply with these instructions could result
in death or serious injury.
PRODUCT DESCRIPTION
The FF-SRE6029 Extension Module provides contact
multiplication for safety devices with External Device
Monitoring (EDM) capability (e.g. FF-SRS e-stop
modules, FF-SYB and FF-SB safety light curtains,
FF-SM safety mats).
This product has two safety relays with positive-guided
contacts to ensure redundancy and offers four NO and
one NC safety contact.
Its slim housing of only 22,5 mm (0.89 in) width allows
this safety control module to fit into most cabinets and
even helps to keep the overall cabinet size small.
APPROVALS
CE The product, packaging and documentation
of FF-SR Series products carry the CE
mark; the CE declaration of conformity is
attached on the last page.
cURus
(pending)
This product is currently being assessed
by Underwriters Laboratories Inc.
according to Canadian and U.S. safety
requirements.
DIRECTIVE COMPLIANCE
Machinery Directive 98/37/EC
Low Voltage Directive 73/23/EC
Electromagnetic Compatibility Directive 89/336/EC
REGULATION COMPLIANCE
Regulation Title
OSHA 29 CFR
1910.217
Requirements and
Safeguarding of Mechanical
Power Presses
STANDARD COMPLIANCE
Standard Title
EN 292 Safety of Machinery - Basic
Concepts, General Principles
for Design
EN 60204-1 Safety of Machinery - Electrical
Equipment of Machines
EN 954-1 Safety of Machinery - Safety
related parts of control system
ANSI B11.1 Construction, Care and Use of
Mechanical Power Presses
ANSI B11.2 Construction, Care and Use of
Hydraulic Power Presses
ANSI B11.19 Safeguarding Performance
Criteria for the Design,
Construction, Care and Use
ANSI/RIA R15.06 Safety Requirements for
Industrial Robots and Robot
Systems
UL 508 Industrial Control Equipment
NFPA79 Electrical Standard for Industrial
Machinery

2107137-20 -EN FR26 GLO 305 Printed in Germany
SPECIFICATIONS
Input
Nominal voltage 24 Vdc (-10 %, +10 %)
Nominal consumption dc: 1,5 W
Output
Contacts 4 NO, 1 NC (plus 1 NC for External Device Monitoring loop)
Contact type Safety relay, positive-guided
Response time Max. 15 ms (delay on de-energisation)
Delay on energisation Typ. 25 ms
Switching Capability Power factor = 1 with resistive load
Current Range (min. to max.) 10 mA to 5 A
Voltage Range (min. to max.) 0,1 to 250 Vac
Switching capability per
EN 60947-5-1
AC15: NO contact: 3 A/230 Vac, NC contact: 2 A/250 Vac
DC13: NO contact, NC contact: 8 A / 24 Vdc
Power factor = 1 at 230 Vac (see figure 1, note 1)
current operations current operations
0,5 A 5 500 000 2 A 1 000 000
Typical Electrical Life Expectancy
1 A 2 000 000 5 A 250 000
Limitation Factor F (see figure 2, note 2)
cos ϕF cos ϕ F
0,3 0,45 0,7 0,85
Typical Power Factor (cos ϕ)
0,5 0,7 1 1
Operating frequency 1200 operating cycles/h
Fuse rating 6 A time delayed (max.)
Mechanical life 20 000 000 operating cycles
General
Temperature range -15 °C to + 55 °C (5 °F to 131 °F) at 90 % humidity (max.)
Sealing Housing IP 40; Terminals IP 20
Housing material Thermoplastic
Vibration resistance
(IEC/EN 60 068-2-6)
Amplitude 0,35 mm; Frequency 10 to 55 Hz
Wire connection Solid wire: 1 x 4 mm2[12 AWG] or 2 x 2,5 mm2[14 AWG]
Stranded wire with sleeve: 1 x 2,5 mm2[14 AWG] or 2 x 1,5 mm2[16 AWG]
Wire/conductor attachment M3.5 screw terminals
Mounting Quick install rail mounting IEC/EN 60715 (width: 35 mm (1.38 in))
Weight 205 g (0.45 lb)
NOTE 1: Install arc suppressors
across load to avoid module contact
arcing and ensure specified contact life
expectancy.
NOTE 2: Total operations = operations
(power factor 1) x limitation factor F.
Example:
U = 230 Vac, I = 1 A,
power factor cos ϕ= 0,5
Switching power P = U x I = 230 VA
Contact life (cos ϕ= 1, P = 230 VA) =
2 000 000 operations (see Figure 1)
Limitation factor F (cos ϕ= 0,5) = 0,7
(see Figure 2)
Contact life (cos ϕ= 0,5, P = 230 VA) =
F x contact life (cos ϕ= , P= 230 VA) =
2 000 000 x 0,7 = 1 400 000 operations.
FIGURE 1. TYPICAL CONTACT
LIFE FOR 100 % RESISTIVE LOAD
(power factor cos ϕ= 1, note 1)
10
7
5
3
2
7
70,5 1,0 1,5 2,0
5
Operations
Switching power [kVA]
3
2
7
10
6
10
5
FIGURE 2. LIMITATION FACTOR FOR
INDUCTIVE LOADS
(power factor cos ϕ< 1, note 2)
Limitation factor F
Power factor

FIGURE 3. QUADRATIC TOTAL CURRENT LIMIT
107137-20 -EN FR26 GLO 305 Printed in Germany 3
20
40
60
80
100
120
010 20 30 40 50 60 T (˚C)
32 50 68 86 104 122 140 T (˚F)
Ambient temperature
Quadratic total current (A
2
)
I2(A2)
Figure 3 shows the maximal recommended safety
contact currents at a certain ambient temperature to
avoid overheating of the safety module.
To use this curve, do the following:
1. Square the currents in each safety contact branch
and sum the square currents to obtain the total
square limit (in A²).
2. Determine the maximal recommended external
temperature at the total square current limit:
Example: 5 A current per normally open contact:
Total square current limit :
∑Ι2= (5A)2+ (5A)2+ (5A)2 +(5A)2 =100 A²
Max. external temperature: T = 39 °C (102 °F).
If the module is located in a higher temperature
environment, the lifetime of the electronic components
may be reduced. Ventilation of the cabinet may be
required.
MECHANICAL INSTALLATION
The FF-SRE6029 must be installed inside an IEC IP 54
(NEMA 3) rating enclosure or better. The module can be
clipped easily onto a 35 mm (1.38 in.) width rail (see
figure 5 for installation and removal).
FIGURE 4. MOUNTING DIMENSIONS
(for reference only)
Rail
c
b
a
a Width: 22,5 mm / 0.89 in.
b Height: 90 mm / 3.55 in.
c Depth: 121 mm 4.77 in.
FIGURE 5. INSTALLATION DIAGRAM
FSR1
FSRE5929 6
CONTROL RELIABILITY
“Control Reliability” essentially means that “the device,
system or interface shall be designed, constructed and
interfaced such that any single component failure within
the device, interface or system shall not prevent normal
stopping action from beeing applied but shall prevent the
initiation of a successive operation until the failure is
corrected”.
OSHA 29 CFR 1910.217 states that “the device shall be
constructed so that a failure within the system does not
prevent the normal stopping action from being applied to
the press when required, but does prevent initiation of a
successive stroke until the failure is corrected. The
failure shall be indicated by the system.”
SAFETY CATEGORY OF INTERFACES
The safety category of the interface is depending on the
safety category of the main safety device (emergency
stop module, safety light curtain, safety mat, etc.) and
the way of interconnecting it to the FF-SRE6029
Extension module.
Refer to the important application warnings (page 5)
for more details concerning safety.
FIGURE 6. INTERNAL CIRCUITRY
13 23 33 43 51 Y1
M8561
14 24 34 44 52 Y2
A1(+) A2(-)
A3(+) A4(-)
K1
K2
24V
24V
AL6029

ELECTRICAL INSTALLATION
4107137-20 -EN FR26 GLO 305 Printed in Germany
ELECTRICAL SHOCK
Remove power from FF-SR Series control modules and
machine during installation.
Failure to comply with these instructions could
result in death or serious injury.
Multiple wiring configurations are possible for the
FF-SRE6029 extension control module and only general
guidelines are provided in this installation manual.
Refer to the important application warnings (page 5)
and the application examples (pages 6 through 7) for
more details.
FIGURE 7. TERMINAL ARRANGEMENT
FUNCTIONAL DESCRIPTION
In the case of an emergency stop condition, the safety
device connected to the FF-SRE6029 module is actuated
and the internal safety relays K1 and K2 de-energise. The
normally open safety contacts (13/14…43/44) will open
and the normally closed safety contacts (51/52) will close.
The emergency stop condition is signalled to the
machine
control circuitry by the module’s safety contacts to stop the
hazard and remove power.
As soon as the safety device is released, power is applied
to A1(+)/A2(-), A3(+)/A4(-) and the relays K1 and K2
energise. The normally open contacts will close and the
normally closed contact will open.
Both relays K1 and K2 must be energized to have the
normally open contacts in a closed condition. If one of the
safety relays de-energizes, the normally open contacts will
open.
One or more FF-SRE6029 Extension Modules can be
cascaded or external contactors with positive guided
safety contacts can be used to increase the number of
contacts.
If multiple safety contacts are used in parallel with one
load, the maximum admissible current can be increased.
LED INDICATORS
The FF-SRE6029 module has two green LED status
indicators (K1 and K2) as illustrated in Figure 8.
Illuminated K1 and/or K2 LEDs indicate(s) that the
corresponding internal safety relay is energized.
FIGURE 8. MODULE FRONT PANEL
13
14
23
24 34 44
A3
(+)
A4
(-)
Y1 Y2
33 43
A1
(+)
A2
(-)
51 52
K1
13 23 33 43 51
52
Y1
14 24 34 44 Y2
K2
Honeywell
FF-SRE60292
FSRE6029 10

APPLICATION WARNINGS
IMPROPER INPUT CONNECTIONS
• To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the
safety relay inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.
• When safety devices with relay outputs are used, always connect them using different potentials to A1(+)/A2(-) and
A3(+)/A4(-), in order to be able to detect cross-faults.
CONTACT WELDING
Always protect all safety contacts with correctly rated fuses. These fuse ratings must never exceed the max. safety
output switching currents of the FF-SRE6029 to prevent contact welding (see specifications page 2).
IMPROPER EXTENSION MODULE MONITORING
• Only connect the FF-SRE6029 extension module to safety devices offering the External Device Monitoring (EDM)
capabilities (e.g. FF-SYB, FF-SB, FF-LS safety light curtains, FF-SM safety mats, FF-SRS emergency stop
modules).
• Do NOT connect the FF-SRE6029 extension module to safety devices WITHOUT the EDM function (e.g. FF-SYA,
FF-SG, FF-SLG or FF-SLG30).
• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each
FF-SRE6029 activation and is able to detect failures of the internal relays (e.g. welded safety relay contacts).
• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring
(EDM) loop of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM.
• If the FF-SRE6029 is not activated often, the customer should perform additional test procedures of the safety
components. This testing may be done every day by removing the power from the FF-SRE6029 at machine power
up.
IMPROPER ARC SUPPRESSOR INSTALLATION
• NEVER install an arc suppressor across the safety output contacts of the extension module.
• ALWAYS install arc suppressors across the coils of external safety relays.
Failure to comply with these instructions could result in death or serious injury.
107137-20 -EN FR26 GLO 305 Printed in Germany 5

APPLICATION EXAMPLES
FIGURE 9. CONNECTION OF AN FF-SRS59352 EMERGENCY STOP MODULE
A2(-)
A1(+) S11 S12 S22
S21
PE
S33 S34
13 23 33 41
Honeywell
FF-SRS59352
14 24 34 42
Power
K2
K3
S1
S2
Internal
switches
Fuse
24 Vdc
A1(+) A3(+) 13 23
A2(-) A4(-) 14
33 43 51
52
24 34 44
Y1
Y2
Honeywell
K1
K2
Machine control
Restart push-
button
1 NO and 1 NC
safety contacts 4 NO
and 1 NC
safety
contacts
Emergency stop
push-button (A)
(A)
0 Vdc
FF-SRE60292
FUNCTIONAL DESCRIPTION:
After activation of the safety device (see application note (A)), the normally open safety contacts of the FF-SRS59352
dual channel emergency stop module (13/14 to 33/34) and the connected FF-SRE6029 extension module (13/14, 23/24,
33/34, 43/44) will open. The normally closed contacts (41/42, 51/52) will all close. The LED relay output indicators (K2,
K3 and K1, K2) of both modules go off indicating that the internal safety relays are de-energized.
After removing the emergency stop condition, press and release the restart push-button to restart the FF-SRS59352
emergency stop module. If the FF-SRE6029 extension module is operating properly, the normally closed contact
(Y1/Y2) for the External Device Monitoring is closed and both safety modules are energising their internal safety relays.
The normally open contacts will close and the normally closed contacts will open. The LED relay output indicators all
illuminate. This action will allow the machine to operate.
FSRE6029_12
APPLICATION NOTES
Note (A): Dual channel output safety devices with relay outputs or safety switches (examples)
This may be a safety device with dual output safety switching devices (OSSD)
• emergency stop push-button
• safety limit or interlock switches (e.g. CPS, GK, GSS)
IMPROPER INPUT CONNECTIONS
• To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the
safety relay inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.
• When safety devices with relay outputs are used, always connect them using different potentials to A1(+)/A2(-) and
A3(+)/A4(-), in order to be able to detect cross-faults.
IMPROPER EXTENSION MODULE MONITORING
• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each
FF-SRE6029 activation and is able to detect failures of the internal relays (e.g. welded safety relay contacts).
• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring
(EDM) loop of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM monitoring.
Failure to comply with these instructions could result in death or serious injury.
6107137-20 -EN FR26 GLO 305 Printed in Germany

107137-20 -EN FR26 GLO 305 Printed in Germany 7
FIGURE 10. CONNECTION OF AN FF-SYB TYPE 4 SAFETY LIGHT CURTAIN
(+24 Vdc)
(0 Vdc)
FF-SYB
Receiver
FF-SYB
emitter
OSSD1
(B)
(A)
OSSD2
Fuse
8
3
56
5
4 (-)
2 (+)
1
1
7
2
M O NB P
#01
Rec
M : Manual
O : NC output
NB: No blanking
Towards
PLC input
Restart / EDM
Optional reset P/B
Optional
test input
Dual channel machine
control circuit
(recommended circuit)
A1(+) A3(+) 13 23
A2(-) A4(-) 14
33 43 51
52
24 34 44
Y1
Y2
Honeywell
K1
K2
FF-SRE60292
FUNCTIONAL DESCRIPTION:
After interrupting the sensing field of the FF-SYB safety light curtain, both static safety oututs (5, 6) of the receiver switch off.
Then, the normally open contacts of the connected FF-SRE6029 extension module (13/14, 23/24, 33/34, 43/44) will open and
the normally closed contacts (51/52, Y1/Y2) will close. The LED relay output indicators (K1, K2) of the module go off indicating
that the internal safety relays K1 and K2 are de-energized.
After clearing the sensing field of the FF-SYB safety light curtain, press and release the restart push-button to restart the
receiver. If the FF-SRE6029 extension module is operating properly, the normally closed contact (Y1/Y2) for the External Device
Monitoring (EDM) is closed and the static safety outputs of the FF-SYB receiver are energising. The normally open contacts of
the FF-SRE6029 module will close and the normally closed contacts will open. The LED relay output indicators K1 and K2
illuminate. This action will allow the machine to operate.
FSRE6029_13
APPLICATION NOTES
Note (A): Dual channel output safety devices with static safety outputs AND External Device Monitoring (EDM) function (e.g.
FF-SYB safety light curtains).
Note (B): CONFIGURATION CARDS
Various mode settings are possible with the FF-SYB safety light curtain (e. g. start / restart, muting, floating blanking) using
configuration cards. The example above uses the factory setting configuration card for the receiver (#1: manual start, no muting,
no blanking). Refer to the FF-SYB installation manual for more information.
IMPROPER INPUT CONNECTIONS
To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the safety relay
inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.
IMPROPER EXTENSION MODULE MONITORING
• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each FF-SRE6029
activation and is able to detect failures of the internal relays (e.g: welded safety relay contacts).
• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring (EDM) loop
of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM monitoring.
Failure to comply with these instructions could result in death or serious injury.

FIGURE 11. FF-SRE6029 TROUBLESHOOTING FLOW DIAGRAM
Machine Down
Yes
Apply correct voltage AND/
OR check for correct
operation of previous
connected safety device.
Replace the
safety module.
Yes
Are K1 AND K2
LEDs ON?
No
No
Yes
The problem
is external to
the module.
Check for
external
causes
(wiring, etc.).
Damaged
contacts. Ensure
maximum load is
specification.
Replace module.
Are the
outputs contacts
13/14, ..., 43/44
closed?
Are K1 AND K2
LEDs OFF?
Are the contacts
51/52 AND Y1/Y2
closed ?
Replace safety
module and
activate restart
circuitry.
Is
voltage between
A1/A2 AND A3/A4 present
AND within
specifications?
Yes
Machine
Working
Is the problem
resolved?
No
Yes
Yes
No
No
No
within
FSRE6029_14
8107137-20 -EN FR26 GLO 305 Printed in Germany

WARRANTY AND REMEDY
Honeywell warrants goods of its manufacture as being free
of defective materials and faulty workmanship. Contact
your local sales office for warranty information. If
warranted goods are returned to Honeywell during the
period of coverage, Honeywell will repair or replace without
charge those items it finds defective. The foregoing is
Buyer’s sole remedy and is in lieu of all other warranties,
expressed or implied, including those of
merchantability and fitness for a particular purpose.
Honeywell
21, chemin du Vieux Chêne
38240 Meylan
France
While we provide application assistance, personally and
through our literature and the Honeywell Website, it is up to
the customer to determine the suitability of the product in
the application.
Specifications may change at any time without notice. The
information we supply is believed to be accurate and
reliable as of this printing. However, we assume no
responsibility for its use.
TELEPHONE
+ 61 (0) 2 9370 4500 Australia
+ 33 (0) 1 60 19 80 40 France
+ 49 (0) 69 8064 444 Germany
+ 34 91 313 61 00 Spain
+ 1-815-235-6847 International
+ 44 (0) 1698 481 481 UK
+ 1-800-537-6945 USA & Canada
FAX
+ 61 (0) 2 9370 4525 Australia
+ 33 (0) 1 60 19 81 73 France
+ 49 (0) 69 8064 442 Germany
+ 34 91 313 61 29 Spain
+ 44 (0) 1698 481 676 UK
+ 1-815-235-6545 USA & Canada
INTERNET
http://www.honeywell.com/sensing/
[email protected]
© 2005 Honeywell International Inc.
All rights reserved.
ORDER GUIDE
FF-SRE6029
2 = 24 Vac/dc