Leuze MSI-SR4B User manual

MSI-SR4B
Safety Relays
Original operating instructions
EN 2022/03/29 - 50124419
We reserve the right to make technical changes

© 2022
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]

Leuze electronic GmbH + Co. KG MSI-SR4B 3
1 About this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Intended use and foreseeable misuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Responsibility for safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Device overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.1 Terminal assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7.2 Circuit diagram examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8 Starting up the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.1 Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2 Start/restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2.1 Unlocking start/restart interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
9 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.1 Before the initial start-up and following modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.1.1 Checklist – initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9.2 To be performed periodically by a competent person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.3 To be performed daily by the operating personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3.1 Check list – daily or at change of shift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
11 Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
12 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
13.2 Interference emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
13.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
14 Order guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

About this document
Leuze electronic GmbH + Co. KG MSI-SR4B 4
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Table 1.2: Other symbols
Table 1.3: Terms and abbreviations
1.2 Checklists
The checklists (see chapter 9 "Testing") serve as a reference for the machine manufacturer or supplier.
They replace neither testing of the complete machine or system prior to the initial start-up nor their periodic
testing by a competent person. The checklists contain minimum testing requirements. Depending on the
application, other tests may be necessary.
Symbol indicating dangers to persons
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger
avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger avoid-
ance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures for danger
avoidance are not followed.
DANGER Signal word for life-threatening danger
Indicates dangers with which serious or fatal injury is imminent if the measures for
danger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
AOPD Active Optoelectronic Protective Device
Active Opto-electronic Protective Device
EDM External Device Monitoring
OSSD Output Signal Switching Device
SSD Secondary Switching Device
RES Start/REStart interlock
PFHDProbability of a dangerous failure per hour
Probability of dangerous Failure per Hour
MTTFdMean time to dangerous failure
(Mean Time To dangerous Failure)
PL Performance Level

Safety
Leuze electronic GmbH + Co. KG MSI-SR4B 5
2 Safety
Before using the safety relay, a risk assessment must be performed according to valid standards (e.g.
EN ISO 12100, ISO 13849-1, EN/IEC 61508, EN/IEC 62061). The result of the risk assessment deter-
mines the required safety level of the safety relay (see table 13.3). For mounting, operating and testing,
this document as well as all applicable national and international standards, regulations, rules and direc-
tives must be observed. Relevant and supplied documents must be observed and handed to the affected
personnel.
Before working with the safety relay, completely read and understand the documents applicable to your
task.
In particular, the following national and international legal regulations apply for the start-up, technical
inspections and work with safety relays:
• Machinery directive 2006/42/EC
• Low voltage directive 2014/35/EU
• Electromagnetic compatibility 2014/30/EU
• Use of work equipment directive 2009/104/EC
•OSHA 1910 Subpart 0
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and employment protection act
• Product safety law (Produktsicherheitsgesetz)
2.1 Intended use and foreseeable misuse
2.1.1 Intended use
NOTE
For safety-related information you may also contact local authorities (e.g., industrial inspec-
torate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
DANGER
Electrically live systems pose a risk of electric shock!
During all conversions, maintenance work and inspections, make certain that the voltage sup-
ply is interrupted and protected against being restarted again.
Only have work on the electrical system and electronics performed by a competent person.
WARNING
A running machine may result in serious injury!
Make certain that the safety relay is correctly connected and that the protective function of the
protective device is ensured.
Make certain that, during all conversions, maintenance work and inspections, the system is
securely shut down and protected against being restarted.

Safety
Leuze electronic GmbH + Co. KG MSI-SR4B 6
Only if the safety relay is correctly connected and correctly started up is the protective function of the
protective device ensured. To prevent misuse and resulting dangers, the following must be observed:
• These operating instructions are included in the documentation of the system on which the protective
device is mounted and are available to the operating personnel at all times.
• The safety relay is used as a safety monitoring device in combination with safety sensors, switches
and command devices for guarding danger zones or points of operation in machines and systems.
• The safety relay must only be used after it has been selected in accordance with the respectively
applicable instructions and relevant standards, rules and regulations regarding labor protection and
safety at work, and after it has been installed, connected, checked and commissioned by a compe-
tent person.
• The safety relay must only be connected and commissioned in accordance with its specifications
(technical data, environmental conditions, etc.).
• The "Reset" acknowledgment button for unlocking the start/restart interlock must be located outside
of the danger zone.
• The entire danger zone must be visible from the installation site of the acknowledgment button.
• The safety relay must be selected so that its safety-related capability meets or exceeds the required
Performance Level PL ascertained in the risk assessment (see table 13.3).
• The machine or system control must be electrically influenceable so that a switch command sent by
the safety relay results in the immediate shutdown of the dangerous movement.
• The construction of the safety relay must not be altered. When manipulating the safety relay, the pro-
tective function is no longer guaranteed. Manipulating the safety relay also voids all warranty claims
against the manufacturer of the safety relay.
• The safety relay must be tested regularly by a competent person (see chapter 9 "Testing").
• The safety relay must be exchanged after a maximum of 20 years. Repairs or the exchange of wear
parts do not extend the mission time.
2.1.2 Foreseeable misuse
Any use other than that defined under the "Approved purpose" or which goes beyond that use is consid-
ered improper use.
Alone, the safety relay is not a complete protective device. It is not suitable for use in the following cases:
• in explosive or easily flammable atmospheres.
• on machines or systems with long stopping times.
2.2 Competent persons
Prerequisites for competent persons:
• They have a suitable technical education.
• They know the rules and regulations for labor protection, safety at work and safety technology and
can assess the safety of the machine.
• They know the instructions for the safety relay and the machine.
• They have been instructed by the responsible person on the mounting and operation of the machine
and of the safety relay.
2.3 Responsibility for safety
Manufacturer and operating company must ensure that the machine and implemented safety relay func-
tion properly and that all affected persons are adequately informed and trained.
The type and content of all imparted information must not lead to unsafe actions by users.
The manufacturer of the machine is responsible for:
• Safe machine construction.
• Safe implementation of the safety relay.
• Imparting all relevant information to the operating company.
• Adhering to all regulations and directives for the safe starting-up of the machine.

Safety
Leuze electronic GmbH + Co. KG MSI-SR4B 7
The operator of the machine is responsible for:
• Instructing the operating personnel.
• Maintaining the safe operation of the machine.
• Adhering to all regulations and directives for labor protection and safety at work.
• Regular testing by competent persons.
2.4 Exemption of liability
Leuze electronic GmbH + Co. KG is not liable in the following cases:
• Safety relay is not used as intended.
• Safety notices are not adhered to.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Proper function is not tested (see chapter 9 "Testing").
• Changes (e.g., constructional) are made to the safety relay.

Device description
Leuze electronic GmbH + Co. KG MSI-SR4B 8
3 Device description
The MSI-SR4B E-Stop relay is used as a connecting element between optoelectronic protective devices
of type 3 or 4 as well as a sequential device for 1- or -2-channel protective-door and E-Stop monitors and
the machine control.
The safety relay is intended for installation on the DIN rail in the cabinet and is wired via the 16 terminals.
All connection terminals are pluggable. The individual terminal blocks are mechanically coded to prevent
swapping or skewed plug in. The safety relays are available with screw terminals or spring-cage terminals.
Figure 3.3: Internal circuit diagram of the MSI-SR4B
Figure 3.1: MSI-SR4B with screw terminals Figure 3.2: MSI-SR4B with spring-cage terminals
N.O.
N.O.
13 23 33
14 24 34
S33
K1
K2
A1 (+24V)
A2 (0V)
CH1
CH2
~
=
+
S34 S35 S22S31
S12
MSI- SR4B
N.O.
42
41

Device description
Leuze electronic GmbH + Co. KG MSI-SR4B 9
3.1 Device overview
• 1- or 2-channel E-Stop circuit
• Cross-circuit detection
• Monitoring of external contactors in the button circuit
• Monitored start button (cross connections between the button contacts and earth faults in the button
circuit are detected.)
• Automatic and manual start
• 3 release circuits, 1 NC contact as auxiliary power circuit
• LED displays Power, K1 and K2, Reset
• Operating voltage 24 V AC/DC
• Housing width 22.5 mm
• Removable connection terminal blocks (screw terminals, spring-cage terminals)
3.2 Display elements
The display elements of the safety relay simplify start-up and fault analysis.
1 "Supply" LED
2"K1" LED
3"K2" LED
4 "Reset" LED
Figure 3.4: Display elements of the MSI-SR4B
Table 3.1: Meaning of the LEDs
1
2
3
4
LED Color Description
Supply Green Supply voltage on
K1 Green Relay K1 picked up
K2 Green Relay K2 picked up
Reset Yellow Restart interlock locked

Functions
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4 Functions
Single-channel E-Stop circuit, manual start
see figure 7.3
After applying the supply voltage to A1 and A2 and with the E-Stop button not actuated, relays K1 and K2
of the MSI-SR4B pick up upon actuation of the start button and lock. The release circuits 13-14, 23-24 and
33-34 close, signal circuit 41-42 opens. Upon actuation of the E-Stop button, K1 and K2 go dead and drop
out. The release circuits open, the signal circuit closes. With one-channel E-Stop wiring, up to category 2
acc. to EN ISO 13849-1:2015 is achieved. Earth faults in the button circuit are detected.
Two-channel E-Stop circuit, manual start
see figure 7.1
Function/operating principle as described above. In addition, contactor contacts K3, K4 are looped into the
start circuit (reset) (EDM).
With two-channel E-Stop wiring, up to category 4 acc. to EN ISO 13849-1:2015 is achieved.
Downstream safety circuit for optoelectronic protective devices type 4, IEC 61496-1:2020
see figure 7.1, see figure 7.2
Optionally, light beam safety devices of type 4 can be connected with relay outputs or with fail-safe semi-
conductor outputs. When calculating the safety distance, the regression delay of the MSI-SR4B of 10 ms
must be included. As an alternative to the manual start, a bridge can be placed between S34 and S35 for
automatic start. With this operating mode, it must not be possible to reach or step behind the protective
sensor.
Two-channel sliding safety guard monitoring
see figure 7.3
Based on the specified signal sequence, when using two, forced position switches, the direction-depen-
dent actuation of the contacts, e.g. of a safety guard, is monitored. For automatic start (bridge S34 - S35),
reaching or stepping behind must not be possible.
Signal sequence monitoring
The function expects the first signal at S22 and the second signal at S12. The time offset is arbitrary. If,
due to, e.g., misalignment of a contact actuator, the times of the signals are swapped, this is tolerated up
to max. 20 ms. Afterwards, the release circuits of the MSI-SR4B close. Signal sequence monitoring is only
active if automatic start is used.
Monitoring of the sensor inputs
In the event of a cross circuit at inputs S12 and S22 or a short to ground at input S12, output relays K1 and
K2 of the MSI-SR4B are switched off via an electronic fuse. The MSI-SR4B is again ready for operation
approx. 2 s after the cause of the malfunction has been eliminated.
Start button monitoring during manual start
To detect static faults or blocking of the start button, the button function is monitored for signal changes.
Enabling occurs when the button is released (1/0 signal change). This function is deactivated during auto-
matic start.
Contactor monitoring (EDM) with manual start
see figure 7.1
For function monitoring of the external contactors, their NC contacts are looped into start circuit S35 with
start button in series.
Contactor monitoring (EDM) with automatic start
For function monitoring of the external contactors, their NC contacts are looped in between S34 and S35
in series.

Applications
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5 Applications
• Single-channel E-Stop circuit, (up to category 2, EN ISO 13849-1:2015)
• Two-channel E-Stop wiring with cross-circuit recognition (up to category 4, EN ISO 13849-1:2015)
• Single-channel protective door monitoring (up to category 2, EN ISO 13849-1:2015)
• Two-channel protective door monitoring (up to category 4, EN ISO 13849-1:2015)
• Sequential circuit for safety sensor semiconductor outputs (two-channel, self-testing)
Figure 5.1: Guarding a robot area with S400 safety hinge switch and MSI-SR4B safety relay

Mounting
Leuze electronic GmbH + Co. KG MSI-SR4B 12
6 Mounting
The safety relay is intended for mounting on a DIN rail in the switch cabinet.
Prerequisites for mounting:
• Switch cabinet with appropriate degree of protection (at least IP54).
• Sufficient space on the DIN rail.
• Arrangement of the protective device acc. to EN ISO 13855-1:2010 and IEC 61496-2:2020.
Snap the safety relay onto the DIN rail.
The safety relay can be connected to the safety sensors.
WARNING
Improper mounting may result in serious injury!
The protective function of the safety relay is only ensured if appropriately and professionally
mounted for the respective, intended area of application.
Only allow competent persons to install the safety relay.
Observe the relevant standards, regulations and these instructions.

Electrical connection
Leuze electronic GmbH + Co. KG MSI-SR4B 13
7 Electrical connection
The following must be observed for the current supply of the safety relay:
• Supply voltage 24 V DC ±20 %.
• Safe mains separation acc. to EN/IEC 60742 possible.
• A corresponding power supply unit handles interruptions of the supply voltage up to 10 ms in dura-
tion acc. to IEC 61496-1:2020.
The following conditions apply for the electrical connection:
• The safety relay is to be integrated in the control acc. to ISO 13849-1.
• No safety-relevant signals are switched via the message outputs.
• There are always two switching contacts integrated in the system switch-off circuit.
• Relay switching contacts are fused/protected externally according to their specifications (see
table 13.2).
Connecting the signal lines
For reliable and touch-safe contacts, isolate the connection ends as follows:
• Screw terminals: 7 mm
• Spring-cage terminals: 8 mm
7.1 Terminal assignments
Connected to the safety relay are 16 numbered terminals to which the cables for the various functions are
connected.
DANGER
Risk of death by electric shock!
Depending on external wiring, dangerous voltages may be present at the switching outputs.
During all work at the electrical system or electronics, make certain that each voltage supply
has been interrupted and protected against being restarted.
WARNING
Improper electrical connection may result in serious injury!
Only allow competent persons to perform the electrical connection.
Make certain that supply and signal lines are laid separately from power lines.
Use appropriate spark extinction for contactors in the cabinet.
Observe the installation notices and operating instructions of the products that are to be con-
nected via the safety relay (drive motors, brakes, etc.).
WARNING
Selecting the wrong functions may result in serious accidents!
Always connect safety sensors to an external safety relay and activate the restart interlock.
For access guarding, make certain that the restart interlock cannot be unlocked from within
the danger zone but that the danger zone can be viewed from the acknowledgment button
(Reset).
Select the functions so that the safety relay is used as intended (see chapter 2.1 "Intended
use and foreseeable misuse").

Electrical connection
Leuze electronic GmbH + Co. KG MSI-SR4B 14
Table 7.1: Terminal assignments
7.2 Circuit diagram examples
Figure 7.1: MSI-SR4B with MLC 510 safety light curtain
Terminal MSI-SR4B
13 Relay contact 1 IN
23 Relay contact 2 IN
33 Relay contact 3 IN
41 Signal contact IN
A1 +24V
S35 Restart input
S33 Sensor supply, contacts 24V OUT
S22 Sensor input
S12 Sensor input
A2 0V
S34 Restart automatic output
S31 Sensor input
14 Relay contact 1 OUT
24 Relay contact 2 OUT
34 Relay contact 3 OUT
42 Signal contact IN
MLCx10R
VIN1
VIN1
RNG
OSSD2
MLCx00T
OSSD1
VIN2 FE/Shield FE/Shield VIN2
4
BN
BK
WH
-A1
1 2
3
4
-A2
1 2
3
BN BK
-W1 -W2
5
-W2
GY BU
-W1
5
GY BU
0V
PE
+24V
PE
+24V
0V
n.c.
14 24 42
13 23 41
A1
A2
-K3
1
2
1
2
L+ L+
L- L-
-S1
-K3
-K4
+24V
0V
MSI-SR4B
A1
-A3
A2
S22 S12 S31 S33 S34 S35
2 AOPD-
1 AOPD+
33
34
A1
A2
-K4
2 AOPD+
IV-0
RES-0
RES-I
1
2
*
*

Electrical connection
Leuze electronic GmbH + Co. KG MSI-SR4B 15
* Spark extinction circuit, suitable spark extinction provided
Figure 7.2: MSI-SR4B as the link between ROTOSCAN RS4-4 safety laser scanner and machine con-
trol with contactor monitoring (EDM) and automatic start/restart (start/restart interlock via
laser scanner)
* Spark extinction circuit, suitable spark extinction provided
Figure 7.3: MSI-SR4B as the link between S400 safety hinge switches and machine control with contac-
tor monitoring (EDM) and manual start
n.c.
FP 4 FP 3 FP 2
Alarm
n.c.
Restart
+24V
ROTOSCAN RS4-4
FP 1
n.c. n.c.
OSSD2 OSSD1
X1
X2
reserved n.c. n.c. RS232/422 RxD- RxD+ TxD+ TxD-
8
1
15
9
1
5
6
9
13
6 7 8
-A1
-X2 1
-X1 2
-X1 1
31211109
OG
WH-BK
-W1
8
WH
7
4 53
-W1
65
SH
BK
414 15
2 9
1
2
RD BU
0V
PE
+24V
PE
+24V
0V
0V
1
Shield
Alarm2
14 24 42
13 23 41
1
2
1
2
L+ L+
-K3
-K4
+24V
0V
MSI-SR4B
A1
-A2
A2
S22 S12 S31 S33 S34 S35
2 AOPD-
1 AOPD+
33
34
2 AOPD+
IV-0
RES-0
RES-I
A1
A2
-K3
L- L-
A1
A2
-K4
*
*
1
2
S400-M4M12-B S400-M4M12-B MSI-SR4
0V
-A2-A1 -A3
0V
PE PE
0V
13 23 41A1 S22 S12 S31 S33 S34 S35 33
-K3
-K4
+24V
2 AOPD-
1 AOPD+
2 AOPD+
IV-0
RES-0
RES-I
543 6 7 8 543 6 7 8
A2 14 24 42
A1
A2
-K3
L- L-
34
*
A1
A2
-K4
*
1
2
1
2
L+ L+
+24V +24V
1
2
1
2
1
2-S1

Starting up the device
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8 Starting up the device
Prerequisites:
• Safety sensors, switches and safety relay were mounted and connected in accordance with the
respective instructions.
• Operating personnel were instructed on proper use.
• Dangerous process was switched off and the system has been protected against being restarted
again.
During start-up, test the function of the safety relay (see chapter 9 "Testing").
8.1 Switching on
Requirements for the supply voltage (power supply unit):
• Safe mains separation is ensured (acc. to EN/IEC 60742).
• Changes and interruptions of the supply voltage are handled (acc. to IEC 61496-1:2020).
• The start/restart interlock function is connected and activated.
Switch on the current supply.
Check whether the "ON/OFF" LED on the safety relay lights up.
The safety relay is ready for use.
8.2 Start/restart
The start/restart button can be used to unlock the start/restart interlock. In this way, the responsible person
can restore normal operation of the system following process interruptions (triggering of the protective
function, failure of the voltage supply) (see chapter 8.2.1 "Unlocking start/restart interlock").
8.2.1 Unlocking start/restart interlock
The red and yellow LEDs illuminate as long as the restart is disabled.
Make certain that the active protective field is clear.
If the active protective field is not clear, select a different procedure.
Make certain that there are no people in the danger zone.
Press the start/restart button and release it again (after 0.06 … 2 s).
The safety relay switches back to the "ON" state.
WARNING
Improper use of the safety relay may result in serious injury!
Make certain that the entire device and the integration of the mechanical optoelectronic pro-
tective device was inspected by competent and instructed persons.
Make certain that a dangerous process can only be started while the safety devices are
switched on.
WARNING
Premature unlocking of the start/restart interlock may result in serious injury!
If the start/restart interlock is unlocked, the system can start up automatically.
Before unlocking the start/restart interlock, make certain that no people are in the danger
zone.

Testing
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9 Testing
The safety relays must be exchanged after a maximum of 20 years.
Always exchange the entire safety relay.
For the tests, observe nationally applicable regulations.
Document all tests in a comprehensible manner.
9.1 Before the initial start-up and following modifications
Acc. to IEC/TS 62046 and international regulations (e.g. EU directive 2009/104/EC), tests are to be
performed by competent persons in the following situations:
• Prior to the initial start-up
• Following modifications to the machine
• After longer machine downtime
• After retrofitting or reconfiguring the safety device (safety relay and/or safety sensors)
Test the effectiveness of the shutdown function in all operating modes of the machine acc. to the corre-
sponding checklist (see chapter 9.1.1 "Checklist – initial start-up").
Document all tests in a comprehensible manner and include the configuration of the safety relay along
with the data for the safety and minimum distances in the documentation.
Before they begin work, train the operating personnel on their respective tasks. The training is the
responsibility of the operating company.
Check whether the safety relay was correctly selected acc. to the locally applicable regulations and
directives.
Check whether the safety relay is operated acc. to the specified environmental conditions (see
chapter 13 "Technical data").
Make certain that the safety relay is protected against overcurrent.
Perform a visual inspection for damage and test the electrical function (see chapter 9.2 "To be per-
formed periodically by a competent person").
Minimum requirements for the power supply unit:
• Safe mains separation.
• Power-failure bridging for at least 10 ms.
Not until proper function of the optoelectronic safety device and the safety relay is ascertained may they
be integrated in the control circuit of the system.
9.1.1 Checklist – initial start-up
Interval: once, prior to the initial start-up and following modification
Tester: competent person
WARNING
A running machine may result in serious injury!
Make certain that, during all conversions, maintenance work and inspections, the system is
securely shut down and protected against being restarted.
WARNING
Unpredictable machine behavior during initial start-up may result in serious injury!
Make certain that there are no people in the danger zone.

Testing
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Table 9.1: Checklist – initial start-up
Store this checklist with the machine documents.
9.2 To be performed periodically by a competent person
The reliable interaction of safety sensor, safety relay and machine must be periodically tested in order to
detect changes to the machine or impermissible tampering with the safety sensor. Testing intervals are
determined by nationally applicable regulations (recommendation acc. to IEC/TS 62046: 6 months).
Have all tests performed by competent persons.
Items on the check list Yes No
Were all safety directives and standards relevant to this machine type observed?
Does the declaration of conformity of the machine include a listing of these documents?
Does the safety relay satisfy the safety-related capability (PL, SIL, category) as
required by the risk assessment?
Circuit diagram: Are the safety-related switching outputs (OSSDs) integrated in the
downstream machine control acc. to the required safety category?
Are the switching elements (e.g. contactors) with positive-guided contacts that are con-
trolled by the safety relay monitored by an external device monitoring circuit (EDM)?
Does the electrical wiring match the circuit diagrams?
Have the required protective measures against electrical shock been effectively imple-
mented?
Has the maximum stopping time of the machine been remeasured and recorded in the
machine documents?
Is the required safety distance (protective field to the next point of operation) main-
tained?
Are all points of operation of the machine accessible only through the protective field?
Are all additional protective devices (e.g. safety guards) correctly mounted and pro-
tected against tampering?
Is the command device for triggering the start/restart interlock of the safety relay or the
machine mounted in accordance with specifications?
Are safety relay, connecting cable, plug, protection caps and command devices
undamaged and free of any signs of manipulation?
Has the effectiveness of the protective function been ensured for all operating modes of
the machine by means of a function test?
Is the start/restart button for resetting the safety relay mounted outside of the danger
zone in accordance with specifications in such a way that it cannot be reached from
within the danger zone? Can the entire danger zone be seen from the place at which
the start/restart button is installed?
Does the interruption of any given beam cause the dangerous movement to stop?
When the AOPD is separated from its supply voltage, does the dangerous movement
stop, and, after the supply voltage has been restored, is it necessary to actuate the
start/restart button to reset the machine?
Is the safety relay/Are the safety sensors effective during the entire dangerous move-
ment of the machine?
Are the notices for daily testing of the safety sensor legible to the operating personnel
and are they located in a highly visible location?

Testing
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Observe the nationally applicable regulations and the time periods specified therein.
9.3 To be performed daily by the operating personnel
The function of the safety relay must be checked daily or at change of shifts, and at each change of
machine operating mode as specified in the corresponding checklist (see chapter 9.3.1 "Check list – daily
or at change of shift") so that damages or unauthorized manipulations can be detected.
Stop the dangerous state.
Check the safety relay, sensors, switches and command devices for damage or tampering.
Interrupt the light beam of the protective sensor and actuate the switches and command devices from
a position outside the danger zone and ensure that the machine cannot be started when a light beam
is interrupted.
Start the machine.
Ensure that the dangerous state is stopped as soon as a light beam is interrupted or a switch is actuated.
9.3.1 Check list – daily or at change of shift
Interval: daily or at shift change
Tester: authorized operating personnel or instructed person
Table 9.2: Check list – daily or at change of shift
WARNING
Unpredictable machine behavior during the test may result in serious injury!
Make certain that there are no people in the danger zone.
WARNING
Faults during the daily inspection may result in serious injury!
If you answer one of the items on the check list (see table 9.2) with "no", the machine must no
longer be operated.
Have the entire machine inspected by a competent person (see chapter 9.1 "Before the initial
start-up and following modifications").
Items on the check list Yes No
Are safety relay, protective sensor, connecting cables, plugs and command devices
undamaged and free of any signs of manipulation?
Are all points of operation at the machine accessible only through one or more protec-
tive fields of protective sensors?
Are all additional protective devices mounted correctly (e.g., safety guard)?
Does the start/restart interlock prevent the automatic start-up of the machine after the
protective sensor/safety relay has been switched on or activated?
Interrupt a light beam of the protective sensor with a test object during operation.
Is the dangerous movement shut down immediately?

Maintenance
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10 Maintenance
The safety relay is maintenance-free.