Pepperl+Fuchs FYQLA1-140R-3 User manual

FACTORY AUTOMATION
INSTRUCTION MANUAL
Door Interrupt System
With FYQLA1-140R-3
Logic Amplier
Original Instructions

Contents
Introduction...................................................................................................... 3
Declaration of conformity.................................................................................. 4
Information regarding EC conformity ................................................................. 4
Document purpose ............................................................................................ 4
Scope........................................................................................................... 4
Delivery........................................................................................................ 4
Denitions ................................................................................................... 5
Symbols used............................................................................................... 5
General statements................................................................................. 5
Qualied personnel...................................................................................... 5
Intended use ............................................................................................... 6
Safety system test........................................................................................ 6
Product description........................................................................................... 7
Features ....................................................................................................... 7
Functions........................................................................................................... 7
Power-up sequence ....................................................................................... 7
Daily inspection ....................................................................................... 8
Safety inputs............................................................................................... 10
Reset faulted state....................................................................................... 10
Hardware ......................................................................................................... 10
Inputs ......................................................................................................... 10
Indicators.................................................................................................... 11
Indicator status table................................................................................... 11
Guided relays .............................................................................................. 12
Input devices ................................................................................................... 12
Magnetic switches...................................................................................... 12
Nominal oset distances ............................................................................. 13
Device dimensions ...................................................................................... 13
Installation ...................................................................................................... 14
Installation requirements............................................................................ 14
Clearance around the device ....................................................................... 14
General safety notes ...................................................................................... 14
Installation and testing................................................................................ 14
Electrical installation ....................................................................................... 15
Powering the device.................................................................................... 15
Wiring requirements ................................................................................... 15
Wiring diagram ........................................................................................... 16
Electrical connection .................................................................................. 17
Commissioning and startup.............................................................................. 18
Validation of the application....................................................................... 18
Diagnostics...................................................................................................... 19
Faults .................................................................................................... 19
Technical support ................................................................................... 19
Troubleshooting ................................................................................. 19
Fault diagnosis ................................................................................... 20
Approvals............................................................................................... 20
Product specications...................................................................................... 20
Dimensions...................................................................................................... 23

3
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Introduction
Congratulations!
You have chosen a device manufactured by Pepperl+Fuchs. Pepperl+Fuchs
develops, produces and distributes electronic sensors and interface modules for
the market of automation technology on a worldwide scale.
Before you install this device and put it into operation, please read the instructions
thoroughly. The instructions and notes contained in this operating manual will
guide you step-by-step through the installation and commissioning procedures to
ensure trouble-free use of this product. By doing so, you:
• Can utilize the entire range of device functions
• Reduce costs from downtime
• Increase the eectiveness and operating eciency of your machine
Store this instruction manual somewhere safe in order to have it available for future
reference. Directly after opening the packaging, please ensure that the device is
intact and that the package is complete.
Copyright
Copyright © 2017 by Pepperl+Fuchs, Inc.
All rights reserved
The company Pepperl+Fuchs, Inc. claims copyright on this documentation. To
modify, extend, hand over to a third party, or copy this documentation without
written approval by the company, Pepperl+Fuchs, Inc. is expressly prohibited. Nor
is any liability assumed for damages resulting from the use of the information
contained herein. Further, this publication and features described herein are
subject to change without notice.
The publisher reserves the right to alter the information and data contained in
this manual without prior notice. Unless otherwise indicated, the company names
as well as other names and data used in the examples are purely ctitious. The
publisher may have registered patents or pending patent applications for subject
matter covered in the manual. This manual does not give you license to these
patents.

4
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Contact
If you have any questions about the device, its functions, or accessories, please
contact your local Pepperl+Fuchs representative.
Declaration of conformity
The FYQLA1-140R-3 was developed and manufactured compliant with the
applicable standards and guidelines.
A corresponding declaration of conformity may be requested from the manufacturer.
Information regarding EC conformity
Pepperl+Fuchs declares that the product described in this manual conforms with
EC Directives by providing the following information:
Manufacturer Pepperl+Fuchs GmbH, Lilienthalstraße 200, 68307
Mannheim, Germany, www.pepperl-fuchs.com
Declaration of conformity www.pepperl-fuchs.com
Directives observed
2006/42/EC (Machinery Directive)
2014/30/EU (EMC Directive)
2014/35/EU (Low Voltage Directive)
Standards observed EN ISO 13849-1:2015, EN 60664-1:2008,
EN 61326-1:2012, EN 61326-3-2:2008
Documentation ocer Pepperl+Fuchs GmbH, Lilienthalstraße 200, D-68307
Mannheim, Germany
Document purpose
Scope
The purpose of this document is to give the user the required information to
properly apply and install the door interrupt system. The product model covered
under this document includes the FYQLA1-140R-3.
Delivery
Included in the delivery:
• 1 - FYQLA1-140R-3 logic amplier
• 10 - 22 k resistors
• 1 - Instruction manual
Must be used with approved devices that are sold separately.
See page 12.
Note
Note

5
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Denitions
• Input Device – Externally mounted dual-channel switching device
• Input – Dual channel, redundant monitoring port
• Qualied Personnel – Persons trained in the use of the product, machinery,
and system
Symbols used
This symbol warns of a danger.
Failure to observe this warning may result in personal injury or
death, property damage or destruction.
This symbol warns of a possible fault.
Failure to observe the instructions given in this warning may
result in the device and any facilities or systems connected to
it developing a fault or even failing completely.
This symbol draws your attention to important information.
General statements
Qualied personnel
The door interrupt system is a safety product. However, just adding the door
interrupt system to a machine or process will not meet safety standards.
Functional Safety Management (FSM), considering a full lifecycle approach,
must be used to guarantee functional safety. Competence is essential in the
delivery of functional safety. The application must be planned by qualied
personnel that know how to apply the necessary standards and regulations.
The door interrupt system must be installed by qualied personnel who are
properly trained in the installation and usage of the FYQLA1-140R-3 product.
These persons must have access to all instructions and knowledge of all
required safety requirements regarding the application of such devices and
machinery equipment.
Requirements:
• Manual must be read by persons using this equipment
• Device users must be trained and qualied in the use of safety-rated
devices
• Users must learn and follow all the safety rules and operating principles in
this manual
• Users must follow all warnings, cautions, and other safety messages in this
manual
• Only original spare parts from Pepperl+Fuchs may be used for repairs
• The unit contains no user serviceable parts
Warning
Attention
Note

6
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Intended use
The door interrupt system monitors up to six input devices. The external devices
are individually wired to the system and the signals are evaluated to determine if
one of the input devices is in the open state.
The FYQLA1-140R-3 must be used in accordance with its intended
purpose. The system must be installed according to regulations for
safeguarding from hazardous locations or areas being entered, or as
a safety relay for safety components appropriate for the described
conditions. When used dierently, the intended function of the system
is not guaranteed. Appropriate measures should be taken such that
any forseeable misuse is prevented
Safety system test
Only a qualied trained person should perform this test. Any
problems detected as a result of this test must be repaired by
qualied personnel before operating the equipment! DO NOT operate
the equipment if problems are detected or serious injury could result!
The purpose of this test is to verify the function of each switch and
control component in the safety system. The person performing the
test should be familiar with the dierent guards and controls on the
equipment. This test should be performed daily. If the machine is not
in continuous operation, test before each use. See the Daily inspection
ow diagram, pages 8-9.
Regular maintenance testing
It is recommended to test the door interrupt system regularly to verify proper
operation on a daily schedule. These should be performed and documented by
qualied personnel. See test sequence, Daily inspection, pages 8-9.
This safety device and associated equipment should be tested
regularly by qualied personnel familiar with the principles and
procedures in this manual. If the testing indicates a problem with this
device or system, the equipment is not safe to operate. Call qualied
personnel immediately to locate and repair the fault.
This safety device and associated equipment should be tested when
any change or modication is done to the device and/or setup by
qualied personnel familiar with the principles and procedures in
this manual. If the testing indicates a problem with this device or
system, the equipment is not safe to operate. Call qualied personnel
immediately to locate and repair the fault.
Warning
Warning
Warning
Note

7
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Product description
Features
The FYQLA1-140R-3 is a category 3 PL d( ISO 13849-1:2015) logic amplier.
The basic features of the FYQLA1-140R-3 include inputs for up to six individual
two-channel switches for monitoring door access or guarded/monitored functions.
Both channels are monitored and cross checked for proper operational switch
states. The safety function monitors all switches, and they must have closed state
conditions on both channels to allow the safety relay output to be energized.
• Monitored inputs (6)
• N.O. output relay contact
• Internal relay monitoring
• Screw terminals
• LED input indicators
• LED fault indicator
• LED relay status indicators
• LED relay power indicator
Together with the 50FY41 series sensors and 52FY31 series actuators, the
FYQLA1-140R-3 can be used to protect one or more points of hazardous areas.
Functions
Power-up sequence
After power is applied to the system, an internal system check is performed
verifying the functional logic and connected switch conditions. If any errors are
detected at power-up, the safety output relays will remain in the de-energized
state. Time to complete this internal verication is approximately two to three
seconds.
Power-up state (output relay energized):
• All internal function checks were veried and all input switch states are in the
closed position
Power-up state safety function (output relay de-energized):
• All internal function checks were veried, but one or more input switch states
are in the open position
• One or more internal function checks fail

8
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Are any red input
LEDs on?
Verify all doors are closed
Are the 2 green relay
LEDs lit?
Are any red input
LEDs on?
Are only the 2 red
input LEDs for the open
door lit?
Are the 2 red relay
LEDs lit?
Wait 3 -5 seconds
Is the red fault LED
lit or blinking?
Close open guard/door
Have all inputs
been tested?
Document results in
inspection records
No
No
No No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Open or remove first
guard/door equipped with
the 50FY41 switch
Done / Passed
Shut down machine &
contact repair technician
Yes
Ensure that all door guard
switches are closed
Wait 3 -5 seconds
Reapply power
Power off
No
Open or remove next
guard/door equipped with
the 50FY41 switch
Description
SR1 Grn LED
SR2 Grn LED
SR1 Red LED
SR2 Red LED
Input 1a LED
Input 1b LED
Input 2a LED
Input 2b LED
Input 3a LED
Input 3b LED
Input 4a LED
Input 4b LED
Input 5a LED
Input 5b LED
Input 6a LED
Input 6b LED
Fault LEDs
All guards closed
O at all times other than
momentarily at power up
Only input 1 open Only input 2 open Only input 3 open Only input 4 open Only input 5 open Only input 6 open
Daily inspection p p
Input status LEDs
pGreen LED
Red LED
Red fault LED
SR1, SR2 LEDs Red relay status Green relay status
1A, 1B 2A, 2B
3A, 3B 4A, 4B
5A, 5B 6A, 6B

9
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Are any red input
LEDs on?
Verify all doors are closed
Are the 2 green relay
LEDs lit?
Are any red input
LEDs on?
Are only the 2 red
input LEDs for the open
door lit?
Are the 2 red relay
LEDs lit?
Wait 3 -5 seconds
Is the red fault LED
lit or blinking?
Close open guard/door
Have all inputs
been tested?
Document results in
inspection records
No
No
No No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Open or remove first
guard/door equipped with
the 50FY41 switch
Done / Passed
Shut down machine &
contact repair technician
Yes
Ensure that all door guard
switches are closed
Wait 3 -5 seconds
Reapply power
Power off
No
Open or remove next
guard/door equipped with
the 50FY41 switch

10
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
System inputs
The six device inputs allow the user to monitor up to six functional switch devices.
Each device must have two channels of output, one sourcing output and one
sinking output. These outputs must operate in tandem for a valid switch function
to be recognized by the FYQLA1-140R-3. If the output channels of the switches are
not functioning in a synchronized manner the amplier will not accept the switch
closure as a valid. The allowable timing between closure of switch channel A and
channel B is approximately one second. If any given pair of switch channels does
not transition to the proper state in the minimum time, then the monitor will issue a
fault on that switch channel and prevent the output from closing.
Reset faulted state
If an invalid door switch sequence is detected by the Channel A and Channel B
synchronization, the output safety relays will open and red fault LED will blink.
Reset is accomplished by a power down/power up sequence.
Output relays to de-energize equipment
When an invalid input condition is recognized by the door interrupt
system, the output safety relay will be de-energized. This will cause the
relay contact pair to open. Be sure to verify the contact power ratings
when applying these relay outputs to energize/de-energize associated
equipment.
Hardware
Inputs
• Six switch inputs compatible with dual channel devices
▸ Pepperl+Fuchs’ 50FY41 series magnetic sensors
Attention
Actuator Switch
Channel A
Channel B
Monitor input
Channel A
Channel B
Minimum time
between transitions

11
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Indicators
The FYQLA1-140R-3 has indicators on front of the device for the following
functions:
• State of the connected input switches
▸ Two indicators per switch input (channel A & channel B)
▸ Indicator is illuminated (on) when the switch state is open
• Relay output status
▸ Two indicators available, one per relay state:
Red indicator illuminated when de-energized
Green indicator illuminated when energized
• Fault Indicator
▸ Fault indicator ashes under the following conditions:
Input switch sequence error (channel A and channel B timing)
▸ Output relay contact monitor fault
Indicator status table
Condition
Switch Status Relay 1 Status Relay 2 Status Red
Fault
LEDs
SR1
Contact
Status
Red
Channel
1 LED
Red
Channel
2 LED
Red
Open
LED
Green
Closed
LED
Red
Open
LED
Green
Closed
LED
Normal
Operation
Door
Sensor
Open
Door
Sensor
Closed
p p
Faults
Door
Sensor
Fault1
Relay 1
Welded
Contact
Fault2
p
Relay 2
Welded
Contact
Fault2
p
Internal
Relay
Fault2
Power O
1) Indicator status changes to fault 1-2 seconds after input sequence fault is detected
2) Fault may require the next operational cycle to start before fault is indicated
Red
BLINKING
OFF
OPEN
CLOSED
pGreen LED ON
Red LED ON

12
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Guided relays
The door interrupt system incorporates two force-guided safety relays that are
monitored for proper operation and generate a redundant output for application
use.
Input devices
Magnetic switches
The 50FY41 series hall eect door switches are a noncontact, magnetic actuation
system consisting of a sensor and a magnetically keyed actuator. The sensor
contains two hall-eect integrated circuits that are connected independently.
When exposed to this magnetic actuator and properly aligned, the sensor
responds with an output.
Approved devices
• 50FY41 series Hall eect door interrupt sensor
• 52FY31 series Keyed hall eect magnetic-actuator
NOTE: These are the only approved devices that should be used.
50FY41 sensor alignment
Ensure the alignment of the sensor and magnetic actuator are correct
for proper operation. A 10 mm (0.39 in) separation distance between
sensor and actuator will cause an OFF condition, independent of axial
oset distance.
Cable length
Sensor cable length must not exceed 25 m (80 ft).
Attention
Attention
Attention

13
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Distance
Offset
Magnet actuator
Hall effect sensor
Sensing distance mm (in)
Oset Max. Actuator
Distance
O Distance
0 (zero) 2.5 (0.1) 10 (0.4)
3.8 (0.15) 1.3 (0.05) 10 (0.4)
7.5 (0.3) 0 (zero) 10 (0.4)
25.4 12.7
2 x ø5
39
25.4
39
Cable Length
50FY41 hall eect sensor
52FY31 magnet actuator
25.4 12.7
2 x ø5
39
25.4
39
Device dimensions
(for reference only—dimensions in mm)
Nominal oset distances

14
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Installation
Installation requirements
Panel mounted inside an enclosure using the four mounting feet in the stainless
steel housing. The FYQLA1-140R-3 is intended to be installed in a clean and dry
environment. A control cabinet must be used to guarantee that the unit is exposed to
no worse than an IP20 environment. The unit is designed to meet the requirements for
industrial environments. Suitability for other environments cannot be ensured.
Clearance around device
Adequate clearance should be provided around the device to allow for proper
cooling and ventilation of the control unit.
General safety notes
Installation and testing
After installation, the FYQLA1-140R-3 and all connected devices must be tested to
ensure proper wiring and operation. All wiring should be veried before applying
power to the unit. Once power is applied, each door switch should be opened to
verify proper operation of the system.
Periodic inspection and testing of the door interrupt system is
recommended. The device must be cycled and safety operation veried
once per day, or between equipment usage cycles. During this time,
proper operation of the safety switches and the correct response
of output safety relays must be veried. Inspection records of the
performed inspections must be maintained.
Note

15
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Electrical installation
Switch the main machine power OFF prior to installation!
The machine could inadvertently start during installation.
The door interrupt system fullls the EMC requirements in accordance
with EN/IEC 61326-3-2:2008 for safety related systems.
Powering the device
The FYQLA1-140R-3 is to be powered only with 120 VAC with
a supply tolerence of no greater than 15% and a frequency of
45-65 Hz.
All connected downstream devices and wiring/installation must
correspond to the required category according to
ISO 13849-1:2015.
Wiring requirements
• GREEN terminal block: Input supply power/Relay contact output
• BLACK terminals: CH1 ... CH 6, 50FY41 switch inputs
Improper installation
This product is designed to conform to the technical requirements of
ISO 13849-1:2015. To ensure compliance with these requirements,
50FY41 series sensors and 52FY31 series actuators MUST be used
with the FYQLA1-140R-3.
Consult with the local safety agency and its requirements when
designing a machine control system, interface, and all control
elements that aect safety. Strictly adhere to all installation
instructions. Failure to comply with these instructions could result in
death or serious injury.
Warning
Warning
Warning

16
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Wiring diagram
FYQLA1-140R-3

17
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Electrical connection
Monitor terminals 50FY41 Unused inputs
R (positive) RED - positive
Use two, 22 K
resistors
(included)
W (normally open, sourcing) WHITE - output
B (negative) BLACK - ground
O (normally open, sinking) ORANGE - output
If less than six sensors are connected to the safety monitor, install two, 22 K
resistors (one between R-W and one between B-O) into the unused inputs.
Do not connect or remove wires with power applied.
Warning
x1
x2
x3
x4
50FY41
Red
Orange
White
Black
R
W
B
O
R W B O

18
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Commissioning and startup
Do not commission without a check by qualied safety personnel!
The door interrupt system must be installed by qualied personnel
who are properly trained in the installation, application, and usage of
the FYQLA1-140R-3 product.
You must ensure that no one is located in the hazardous area before
commissioning!
Check the hazardous area and secure it so that people cannot enter.
For example, set up warning signs, attach blocking ropes or similar.
Observe the relevant laws and local regulations.
Validation of the application
You may commission the system only if all pretests were successful. Validation may
be performed only by qualied personnel. The general acceptance comprises the
following tests:
• Check whether the components used correspond to the required Performance
Level in accordance with EN ISO 13849-1:2015.
• Check that the devices connected to the door interrupt system are in
accordance with this user manual.
• Clearly mark all connection cables and plugs.
• Perform a complete verication of the safety functions of the system in each
operating mode and error simulation. Observe the response times of the
system in response to tested functions.
Warning
Warning

19
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Diagnostics
Faults
The door interrupt system has multiple LEDs mounted on the top of the device to
provide diagnostic and troubleshooting assistance. LEDs are provided for each
switch input pair, indicating the status of the individual channel. Also provided are
output LEDs indicating the status of each of the safety relays. In addition, a fault
LED provides indication of when an input switch error has occurred, resulting in a
fault condition and opening of the safety relay. Fault conditions can be cleared only
upon power down-power up, of the door interrupt system.
Technical support
Troubleshooting
Problem Probable cause Remedy
No LEDs illuminated
No supply power Verify incoming power is present
Blown internal fuse Verify input power is within spec,
and then replace fuse
Fault LED is ashing
and single LED is lit
for a sensor input
while actuated or
de-actuated
Misaligned sensor and
actuator
Check alignment and realign as
needed
Input screw terminal loose Fully install screw terminal
Defective sensor See Fault diagnosis (next page)
to help determine problems
Internal failure in door switch
monitor
All inputs activated
(all input LEDs are o)
and the relays do not
activate
Defective unit Replace unit

20
Door Interrupt System with FYQLA1-140R-3 Logic Amplier
Fault diagnosis
If fault LED ashes and no sensor alignment problem can be found:
• Turn o power
• Unwire sensors from input terminals
• Power up unit
•
If fault LED begins to ash repeatedly after 2-3 seconds, the system needs to be
replaced. If the fault LEDs do not begin to ash:
• Remove power, then wire one sensor (R,W,B,O) connection at a time. Apply
power, waiting 2-3 seconds. Repeat sequence with all sensors until fault
LED begins to ash. This will be the sensor/actuator that is generating
the fault condition. Reevaluate alignment and terminal connections. If no
problem is found, replace the sensor and/or actuator in question
Approvals
UL508
Input specications
FYQLA1-140R-3 120 VAC ± 15% <0.25A @ 45 to 65 Hz
Input devices (6) dedicated noncontact hall eect door
sensors (50FY41 series)
Switch voltage input 12 VDC (2 channel, sink/source)
Typical response time 20 ms (switch open to contact open)
Power up time 3 s
Output specications
Contact material AgCuNi + 0.2 um Au
Continuous current 5 mA to 5 A (N.O. contact)
Relay type 1 relay output, force guided connection,
normally open contacts
Inrush current (max) 30 A for 20 ms
Maximum switching
characteristics
(Determined acc. to
EN60947-4-1/EN60947-5-1)
External fusing should be added
to protect the application and unit
from unforseen circumstances
AC-1: 250 V/5 A (100,000 cycles)
AC-15: 230 V/3 A (150,000 cycles)
DC-1: 24 V/5 A (100,000 cycles)
DC-13: 24 V/1 A /0.1 Hz (100,000 cycles)
Product specications