WEG CPW22 User manual

Emergency Stop Control
Control de Parada de Emergencia
Controle de Parada de Emergência
CPW22
User's Manual
Manual del Usuario
Manual do Usuário
Motors I Automation I Energy I Transmission & Distribution I Coatings

User's Manual
Series: CPW22
Language: English
Document: 10007941524 / 00
Publishing Date: 10/2020

Summary of Reviews
The information below describes the reviews made in this manual.
Version Review Description
-R00 First edition

Summary
1 SAFETY INSTRUCTIONS .......................................................................... 4
1.1 APPLICABLE STANDARDS ...............................................................................................................4
2 GENERAL INFORMATION......................................................................... 5
2.1 FEATURES ...........................................................................................................................................5
2.2 FUNCTIONS .......................................................................................................................................6
2.3 APPLICATIONS ...................................................................................................................................7
2.4 TERMS AND DEFINITIONS................................................................................................................9
3 INSTALLATION AND CONNECTION ...................................................... 11
3.1 CONNECTIONS ................................................................................................................................ 11
3.2 MOUNTING .......................................................................................................................................12
4 TECHNICAL SPECIFICATIONS............................................................... 13
5 DIMENSIONS .......................................................................................... 14
6 MAINTENANCE........................................................................................ 15
7 DECLARATION OF CONFORMITY......................................................... 16
7.1 APPROVALS.......................................................................................................................................16

Safety Instructions
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1 SAFETY INSTRUCTIONS
The alert symbols shown below indicates potential hazard, risk or recommendation. If not follow the alerts may
cause dangerous situations to user or process.
DANGER!
Failure to comply with safety regulations can result in death, serious injury and / or serious damage.
Installation and commissioning of the device must be performed only by qualified and authorized
personnel.
The electrical connection of the device can only be made with the device isolated.
ATTENTION!
The general concept of the control system in which the device is incorporated must be validated by
the user.
The electrical connection of the device must comply with the instructions contained in this user
manual; otherwise, there is a risk that the safety function will be lost.
It is not allowed open the device, adulterate it or ignore security devices.
NOTE!
Observe regulations of the country when transporting, installing and disposing of the device.
All relevant safety rules and standards must be observed.
1.1 APPLICABLE STANDARDS
CPW22 complies with the following european directives and international standards:
Table 1.1: Applicable standards
European Directives
2006 / 42 / EC Machinery directive
2011 / 65 / EU + 2015 / 863 RoHS directive
International Standards
EN ISO 13849-1: 2015 Safety of machinery – safety-related parts of control systems
IEC 62061: 2005
+ AC:2010 + A1: 2013 + A2: 2015
Safety of machinery – functional safety of safety-related electrical, electronic and programmable
electronic control systems
IEC 60947-5-1: 2003 + A1: 2009
Low-voltage switchgear and control gear
Control circuit devices and switching elements
Electromechanical control circuit devices
IEC 61508 Parts 1-7: 2010 Functional safety of electrical / electronic / programmable electronic safety-related systems
EN IEC 63000: 2018 Technical documentation for the assessment of electrical and electronic products with respect
to the restriction of hazardous substances

General Information
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2 GENERAL INFORMATION
For machines and systems that can produce a risk for people when in operation, the EU Machinery Directive defines
minimum requirements that are intended to reduce to a minimum the specific hazards and the related risks of accident.
If all sources of danger cannot be eliminated by design measures, appropriate protective measures must be taken,
to prevent people entering the danger area.
The emergency stop safety relay CPW22 is designed for safety-related system and comply the requirements of
IEC 62061 and can be used up to safety category 4 – PL e according to EN ISO 13849-1.
The CPW22 are designed to execute safety-related functions as part of a process or machine. It is the responsibility of the
manufacturer of process or machine to ensure the correct functionality and safety functions of the entire process or machine.
The CPW22 is a safety relay suitable to following safe guarding applications:
Mechanical safety switches with and without guard locking.
Non-contact safety switches.
Emergency stop switchgear.
Electro-sensitive protective equipment, etc.
2.1 FEATURES
The CPW22 has the following main features:
Standard case - 22.5 mm [0.885] in.
3 relay outputs, safety and redundant.
1 auxiliary relay output.
Single and dual-channel operation possible.
Manual or automatic start.
Cyclic monitoring of the output contacts.
Comply up to category 4, PL e, SIL 3, SIL CL3.
Connection of:
Emergency stop button.
Safety switch.
Non-contact safety switch.
OSSD-outputs devices.
Light curtains.
Initialization available in 2 behaviors:
Monitored manual start.
Automatic start.
Relay status indication by front view.

General Information
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NOTE!
Depending on the application and configuration some features can be not reached.
2.2 FUNCTIONS
The CPW22 is powered (A1 / A2) with extra-low voltage (SELV / PELV). The internal logical system closes the safety
contacts when the monitored safety inputs is closed and start button (S21) is pressed.
When the monitored safety inputs is opened (S12 / S13 / S14), the output contacts (13-14 / 23-24 / 33-34), forced
guided, are opened and safely shutdown the machine. It is ensured that a single fault does not lead to the loss
of the safety function and that every fault is detected by self-monitoring in a cyclical manner, ensuring detection
after re-energization.
POWER
START
LOGIC
S21 S10 S11 S12 S13 S14
K1
K2
A1 A2 14 24 34 42
13 23 33 41
+ -
+
-
Figure 2.1: Block diagram
SINGLE-CHANNEL SAFETY CIRCUIT
A single positively driven contact in the safety component is connected to the relay. This type of connection is
suitable for categories 1 or 2 according EN ISO 13849-1.
DUAL-CHANNEL SAFETY CIRCUIT
Two contacts of which at least one is a positively driven contact are connected to the relay. This type of connection
is suitable for categories 3 or 4 according EN ISO 13849-1.
RELAY START CONTROL
After the relay has switched off, the relay must be re-started, with manual or automatic start:
Manual start: The relay is started by actuating a button. Before the safety inputs must be re-established.
Automatic start: The relay switches on automatically as soon as the safety inputs changes back to the safe
state.
ATTENTION!
The renewed starting of the machine can only occurs automatically if it is ensured that there can be
no dangerous state.

General Information
CPW22 | 7
English
2.3 APPLICATIONS
Depending on the application or the result of the risk assessment according standard ISO 13849-1 and the safety
level achieve according IEC 61508, the CPW22 must be wired according examples shown below:
Suitable Electro-Sensitive Protective Equipment Safety Level
Light curtains
OSSD-outputs
devices
E
OSSD 2 OSSD 1
S14 S12 S13
A1
S10
A2
24 V
S11 S21 13
14
K1 K2 X1
N
23
24
33
34
41
42
K1 *
L
K2 *
R
Light
curtain
Manual start
Automatic start
~ ~
+ -
EN ISO 13849-1
PL e
CAT 4
IEC 61508 1-7
SIL 3
IEC 62061
SIL CL3
Dual-channel input device, OSSD type, with manual start (for automatic start: jumper S12 / S21).
ATTENTION!
The same ground reference connection must be used for all system components. To applications with
mechanical or electromechanical safety switches with or without contact does not recommended use
dual-channel inputs with two PNP inputs.
Suitable
Mechanical Safety Switches with/without Guard Locking
Non-Contact Safety Switches
Emergency Stop Switchgear
Safety Level
Emergency
buttons
Safety switches
Grid sensors
S10
~ ~
24 V+ -
S11
S14 S21 13
A1 A2 14
K1 K2 X1
24 34 42
23 33 41S13 S12
K1 *
L
N
K2 *
Emergency stop
Manual start
Automatic start
EN ISO 13849-1
PL e
CAT 4
IEC 61508 1-7
SIL 3
IEC 62061
SIL CL3
Dual-channel input device, type mechanical or electromechanical contact, with manual start (for automatic start: jumper S12 / S21).
ATTENTION!
To applications with mechanical or electromechanical safety switches with or without contact is highly
recommended use dual-channel inputs with one channel PNP and other NPN.

General Information
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Suitable
Mechanical Safety Switches with/without Guard Locking
Non-Contact Safety Switches
Emergency Stop Switchgear
Safety Level
Emergency
buttons
Safety switches
Grid sensors
Emergency stop
Manual start
Automatic start
S14
~ ~
24 V+ -
A1 A2 14 34 42
K1 K2
24
S12 S13 S10 S11 S21 13 23 33 41
K1 *
L
N
X1
K2 *
EN ISO 13849-1
PL d
CAT 3
IEC 61508 1-7
SIL 2
IEC 62061
SIL CL2
Dual-channel input device, type mechanical or electromechanical contact, with manual start (for automatic start: jumper S12 / S21).
ATTENTION!
To applications with mechanical or electromechanical safety switches with or without contact does not
recommended use dual-channel inputs with two PNP inputs.
Suitable
Mechanical Safety Switches with/without Guard Locking
Non-Contact Safety Switches
Emergency Stop Switchgear
Safety Level
Emergency
buttons
Safety switches
Grid sensors
Emergency stop
Manual start
Automatic start L
N
K1 *
K2 *
~ ~
24 V+ -
S14 S12 S13 S10
A1 A2
S11 S21 13
14
K1 K2 X1
23
24
33
34
41
42
EN ISO 13849-1
PL c CAT 1
IEC 61508 1-7
SIL 1
IEC 62061
SIL CL1
Single-channel input device, type mechanical or electromechanical contact, with manual start (for automatic start: jumper S12 / S21).
*Optional feedback loop to monitor contactors or the expansion modules.

General Information
CPW22 | 9
English
Configuration Manual Automatic
Start
S1 S0 S3
S1 S0 S3
Feedback
S1 S0 S3
K1
K2
S1 S0 S3
K1 K2
ATTENTION!
If set as automatic start, the safety contacts switch immediately after device powered.
If set as manual start, not must be possible to reach the restart command button from inside the
danger area.
NOTE!
Additional data can be requested from the manufacturer for applications that deviate from these
conditions.
DIAGNOSTIC
To assure the system diagnostic is reached its necessary perform a manually test, reached when the safety relay
reach the safe state (switch off the inputs). According applications the following test intervals must be ensured.
Diagnostic
Standard CAT PL Test Interval
EN ISO 13849-1 4 e Once month
3 d Once year
2.4 TERMS AND DEFINITIONS
CPW22
Emergency Stop Safety Relay from WEG Company.
CAT
Category: Classification of the safety-related parts of a control system in respect of their resistance to faults and
their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts,
fault detection and/or by their reliability.
[EN ISO 13849-1:2015]
PL
Performance Level: Discrete level used to specify the ability of safety-related parts of control systems to perform
a safety function under foreseeable conditions.
[EN ISO 13849-1:2015]

General Information
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SIL
Safety Integrity Level: Discrete level for specifying the safety integrity requirements of the safety functions, where
safety integrity level 4 has the highest level of safety integrity and safety integrity level 1 has the lowest.
[IEC 61508:2010]
PFD
Probability of Dangerous Failure Demand: Safety unavailability of safety-related system to perform the specified
safety function when a demand occurs from the control system.
[IEC 61508:2010]
SFF
Safe Failure Fraction: Property of a safety related element that is defined by the ratio of the average failure rates
of safe plus dangerous detected failures and safe plus dangerous failures.
[IEC 61508:2010]
SIL CL
SIL Claim Limit: Maximum SIL that can be claimed for a safety related electrical control system in relation to
architectural constraints and systematic safety integrity.
[IEC 62061:2005]
PFHd
Probability of dangerous Failure per Hour: Average probability of dangerous failure within 1 h.
[IEC 62061:2005]
MTTFd
Mean Time To dangerous Failure: Expectation of the mean time to failure. Normally expressed as an average of
expectation of the time to failure.
[EN ISO 13849-1:2015 and IEC 62061:2005]
OSSD
Output Signal Switching Device: Output switching element, verified by inspections or tests, independently and
continuously, able to detect the following foreseeable faults when in ON-state:
Short circuit of the output to supply voltage.
Short circuit of the output to ground.
Short circuit between outputs.
Overload.
[IEC 61496-1:2012]
SELV / PELV
Safety Extra-Low Voltage / Protective Extra-Low Voltage: Eletric system in wich the voltage cannot exceed the value
of extra-low voltage, protecting against eletric shock under normal operation and under single fault conditions,
including earth faults in order electric circuits.
[IEC 61140:2016]

Installation and Connection
CPW22 | 11
English
3 INSTALLATION AND CONNECTION
3.1 CONNECTIONS
Table 3.1: Connection descriptions
Description Type Pin Function Front View
Power supply
IN A1 AC / DC Positive [+]
41
42
A1
S10
13
14
S11
S12
S14
S13
S21
A2
RELAY 1
RELAY 2
23
24
33
34
IN A2 AC / DC Negative [-]
Controlled voltage
OUT S10 Negative reference [-]
OUT S11 Positive reference [+]
Digital inputs
IN S12 Channel 1 PNP Input
IN S13
S14
Channel 2 NPN Input
Channel 2 PNP Input
IN S21 PNP Start Control
Relay outputs
OUT
13-14
23-24
33-34
Output Current paths
3 NO contacts
OUT 41- 42 Auxiliary Output
1 NC contact
CONNECTION INSTRUCTIONS
The electrical connection of the safety relay for other devices is carried out by fixed terminals with screws. To
ensure the electrical connections integrity the following connection instructions must be considered:
Table 3.2: Electrical connection instructions
Parameter Value
Cable section 24 to 12 AWG
0.5 to 2.5 mm²
Cable resistance ≤ 40 Ω
Cable length of control line ≤ 100 m
Connection type Screw terminals
Tool Screwdriver slot Nº3
Torque ≤ 0.4 N.m.
ATTENTION!
Ensure that safety relay is turned off before perform the electrical connections.
Do not use the safety relay like supply to external devices.

Installation and Connection
12 | CPW22
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3.2 MOUNTING
The CPW22 is intended for installation in control cabinets with a minimum degree of protection of IP54, mounted
on a 35 mm DIN rail according to DIN EN 60715 TH35.
Fixing on 35 mm DIN rail
1º Put on DIN rail.
2º Press spring action.
3º Pull down, lock.
1º
2º
3º
Installed
Removal
1º Press spring action.
2º Pull down and front.
3º Pull up to release.
1º
3º
2º
Figure 3.1: Mounting

Technical Specifications
CPW22 | 13
English
4 TECHNICAL SPECIFICATIONS
Table 4.1: CPW22 technical specifications
Electrical
Operating voltage – SELV / PELV + 24 V DC / AC ± 15 %
Reverse polarity protection Yes
Frequency rated 50 / 60 Hz
Power consumption ≤ 3 VA
Response time ≤ 10 ms
Controlled voltage at S11 CA 26 to 36 V DC
DC 20 to 30 V DC
Switching current, at 24 V DC S12 40 mA
S13 / S14 40 mA
Logic of inputs S12 PNP
S13 / S14 NPN / PNP
Working temperature -10 to +55 °C [+ 14 to + 131 ºF]
Storage temperature -40 to +70 °C [- 40 to + 158 ºF]
Output switching Force guided relays
Safety contacts 3 NO contacts (redundant)
Auxiliary contact 1 NC contact
Switching capability DC13 24 V DC @ 3 A
AC15 250 V AC @ 3 A
Feedback Yes
Led indicators 2, relay status K1 and K2
Mechanical
Housing material Polycarbonate PC
Dimensions 114.5 x 99 x 22.5 mm [4.50 x 3.89 x 0.88 in]
Weight ± 0.180 Kg
Connection type Screw terminals
Connection terminals EUA 24 to 12 AWG
SI 0.5 to 2.5 mm²
Ambient temperature -10 to +55 °C [+ 14 to + 131 ºF]
Degree of protection IP 20
Degree of contamination 2
Mounting DIN rail 35 mm
Lifecycle Electrical 2 E6
Mechanical 1 E7
Time life 20 years
Safety
EN ISO 13849-1 CAT 4
PL E
IEC 61508 1-7
SIL 3
PFD 6 E-5 AVG
SFF 98 %
IEC 62061
SIL CL 3
PFHd 1 E-9 1/h
MTTFd > 100 years

Dimensions
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5 DIMENSIONS
108 [4.252]
114,5 [4.507]
22,5 [0.885]
99 [3.897]
Figure 5.1: Dimensions in millimeters [inches]

Maintenance
CPW22 | 15
English
6 MAINTENANCE
If the safety relay does not operates according necessary applications, check the possible faults listed below
before send device to maintenance.
DEVICE DOES NOT SWITCH ON
Check the wiring connections and comparing with wiring diagram applications.
Check the operating voltage at A1 / A2.
Check the safety switch used for correct function and adjustment.
Check whether the emergency stop circuit is closed.
Check whether the start button (with manual start) is closed.
Check if the feedback loop is closed.
DEVICE CAN NOT BE SWITCHED ON AGAIN AFTER AN EMERGENCY STOP
Check whether the emergency stop circuit was closed again.
Check if the start button or the emergency stop circuit (with manual start) opened before closing again.
Check if the feedback loop opened before closing again.
If these steps do not remedy the fault either, return the device to the manufacture for examination.
ATTENTION!
Opening the device is impermissible and will void the warranty.

Declaration of Conformity and Approvals
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English
7 DECLARATION OF CONFORMITY
7.1 APPROVALS
Functional
Safety
Type
Approved
www.tuv.com
ID 0600000000

Manual del Usuario
Serie: CPW22
Idioma: Español
Documento: 10007941524 / 00
Fecha de Publicación: 10/2020

Sumario de Revisiones
La información abajo describe las revisiones ocurridas en este manual.
Versión Revisión Descripción
-R00 Primera edición

Sumario
1 INSTRUCCIONES DE SEGURIDAD........................................................ 20
1.1 NORMAS APLICABLES ...................................................................................................................20
2 INFORMACIONES GENERALES............................................................. 21
2.1 CARACTERÍSTICAS..........................................................................................................................21
2.2 FUNCIONES ....................................................................................................................................22
2.3 APLICACIONES.................................................................................................................................23
2.4 TÉRMINOS Y DEFINICIONES..........................................................................................................25
3 INSTALACION Y CONEXIÓN .................................................................. 27
3.1 CONEXIONES ..................................................................................................................................27
3.2 MONTAJE ..........................................................................................................................................28
4 ESPECIFICACIONES TÉCNICAS ............................................................29
5 DIMENSIONES ........................................................................................30
6 MANTENIMIENTO.................................................................................... 31
7 DECLARACIÓN DE CONFORMIDAD ..................................................... 32
7.1 APROBACIONES ...............................................................................................................................32