Zander Aachen MINOS SD1E User manual

Operating Instructions
Safety Relay MINOS SD1E
MINOS SD1E

2
Safety Relay MINOS SD1E
H. Zander GmbH & Co. KG
Am Gut Wolf 15
52070 Aachen, Germany
[email protected]
www.zander-aachen.de
Version: K11 E61-347-00
Engl. Translation of the original document
Subject to technical modifications,
no responsibility is accepted for the
accuracy of this information.

3
Safety Relay MINOS SD1E EN
Contents
1. Scope..................................................................................................................... 4
2. Target group .......................................................................................................... 4
3. Safety instructions.................................................................................................. 4
4. Appropriate use...................................................................................................... 5
5. Disclaimer and warranty......................................................................................... 6
6. Features................................................................................................................. 7
7. Function ................................................................................................................. 7
8. Application examples ............................................................................................. 9
9. Mounting .............................................................................................................. 12
10. Electrical connection ........................................................................................... 12
11. Commissioning ................................................................................................... 13
12. Checks and maintenance.................................................................................... 14
13. Proof-Test ........................................................................................................... 15
14. Terminal assignment and LED displays............................................................. 16
15. Wiring / Applications............................................................................................ 17
16. Time diagrams ................................................................................................... 24
17. Monitoring table .................................................................................................. 26
18. Dimensions ......................................................................................................... 28
19. Safety parameters............................................................................................... 28
20. Technical data..................................................................................................... 30
21. Derating .............................................................................................................. 33
22. Variants / Ordering-No. ....................................................................................... 34
23. Service................................................................................................................ 35
24. Declaration of conformity .................................................................................... 36
25. Edition of listed standards................................................................................... 38

4
Safety Relay MINOS SD1E
• who are familiar with proper handling of the
safety components
• who are familiar with the applicable EMC
and ESD regulations
• who are familiar with the local regulations
concerning work safety and accident
prevention
• who have read and understood these
operating instructions.
The user shall be responsible for integrating
the device into a safe overall system. For this
purpose, the overall system has to be vali-
dated, e.g. according to EN ISO 13849-2.
Opening the device, any kind of manipulation
to it and bypassing the safety devices are not
permitted.
The device version (see nameplate "Ver.")
should be stored and checked before every
commissioning. If there is a version change,
the use of the device in the overall application
should be revalidated.
1. Scope
This document is valid for the following safety
modules:
MINOS SD1E (Order-No.: 472841)
2. Target group
Specialist electricians and assembly, setup
and service specialists who possess special
knowledge in working with safety compo-
nents.
3. Safety instructions
Safety components are intended to
protect people. Not following the
safety instructions, improper instal-
lation or manipulation may result in
fatal injuries to persons and damage to
property. Safety devices must not be by-
passed, removed or manipulated in any way.
Please follow all the safety instructions and
warnings mentioned in this document.
Installation, commissioning, maintenance,
and decommissioning should be done only by
authorised and qualified technicians:

5
Safety Relay MINOS SD1E EN
4. Appropriate use
MINOS SD1E is a safety emergency stop
relay for monitoring e.g. emergency stop
buttons, safety doors and light curtains. The
modules are also certified for operation in
furnaces and vessels according to
EN 50156-1 / EN 746-2.
The approved operating parameters for use
must be complied (see chapter 20 "Technical
data").
A risk assessment should be carried out on
the machine before using the device. For
example, according to:
EN ISO 13849-1, Safety-related parts of
control systems, Appendix A
EN ISO 12100, Safety of machinery - General
principals for design - Risk assessment and
risk reduction
IEC 62061, Safety of machinery - Functional
safety of safety-related electrical, electronic
and programmable electronic control sys-
tems.
Additional requirements may have to be
considered depending on the type of machine
or plant.
Appropriate use also includes compliance
with:
EN ISO 13849-1, Safety-related parts of
controllers,
EN 60204-1, Electrical equipment in
machines.
For further information please
refer to the above mentioned
documents.
ATTENTION!
• The user is responsible for integrating the
device into a safe overall system. For this
purpose, the overall system has to be
validated, e.g. according to
EN ISO 13849-2
• If a operating instruction is enclosed with
the product, then the specifications given in
the operating instruction are applicable

6
Safety Relay MINOS SD1E
5. Disclaimer and warranty
If the above mentioned conditions for appro-
priate use are not complied with or if the
safety instructions are not followed or if any
maintenance operations are not carried out as
required, this shall lead to an exclusion of
liability and loss of warranty.
ATTENTION!
We would like to point out that it is the full
responsibility of the operator to ensure a plant
availability.
Using the SD1E, a safety emergency stop
relay according to
• EN ISO 13849-1
• IEC 62061
• IEC 61508
• EN 50156-1
• EN 746-2
• IEC 61511-1
is used, which will be brought into the safe
state when the safety function is requested.
This means that the connected load is
switched off as soon as a request from con-
nected sensor elements or diagnostic meas-
ures detects a dangerous state, e.g. caused
by a component fault.
Since process-related applications in particu-
lar have high demands on availability, limited
availability can also have significant conse-
quences.
It is therefore recommended to stock a sec-
ond unit to avoid long downtimes in such a
case.
These are recommendations of the manufac-
turer, the evaluation of the importance of the
plant availability is the sole responsibility of
the operator.

7
Safety Relay MINOS SD1E EN
6. Features
• Use up to PL e, Cat. 4, SILCL 3
• Certified for operation in
furnaces and vessels according to
EN 50156-1 / EN 746-2.
• Stop Category 0 according to EN 60204-1
• 1 two-channel safe input
• 1 safe relay contact
• 1 auxiliary output (PNP)
• Automatic or monitored manual start
selectable at the device
• 6.8 mm width
• Extensive monitoring via front LED‘s
7. Function
Config-Switches S1 and S2:
At the back of the device are two slide-
switches (S1 and S2) to configure the SD1E.
The following functions can be configured:
With the Config-Switch S1, the function of the
safety circuit at I1 / I2 can be configured.
According to your application a cross circuit
monitoring can be enabled or disabled (see
Fig. 1)
With the Config-Switch S2, the function of the
start input at S21 can be configured. An
automatic start or an monitored, manual start
can be set.
For this, turn the SD1E until the printed
configurationtable (see Fig. 1) is facing up
and the opening at the back of the device is
visible. Two slide switches can be seen,
which you can slide to the left or right side
depending on the desired configuration (see
Fig. 1).

8
Safety Relay MINOS SD1E
For example:
For a two channel application with cross
circuit monitoring and automatic start the
Config-Switches must be set as follows:
Config-Switch S1: Left (Enabled)
Config-Switch S2: Right (Automatic)
Safety circuit I1 / I2:
The safety circuit is designed to be used as
single or dual channel via I1 and I2 depending
on the wiring and the position of the Config-
Switch S1 (see chapter 12 “Commissioning”).
Start input S21:
A monitored, manual start or an automatic
start is provided via the terminal S21. The
start function can be set via the Config-Switch
S2 on the back of the device. (see chapter 12;
“Commissioning”).
Safe relay contact 13-14:
Considering the start behaviour, the safe
relay contact switches on at the time the
safety circuit closes. Opening the safety
circuit results in an immediate shutdown (safe
condition).
Auxiliary output C1:
The PNP-semiconductor output switches
invertedly to the safe relay contact and may
not be used as safe output.
Behaviour in case of a fault:
It is ensured that one single fault does not
lead to loss of the safety function and that
every fault is detected latest when the system
Fig. 2 Block diagram SD1E
Fig. 1 Configurationtable SD1E

9
Safety Relay MINOS SD1E EN
Note: Config-Switches are set as follows:
S1: Enabled / S2: Manual
(see chapter 7. “Function”)
8. Application examples
Application example 1:
SD1E for two-channel emergency-stop
monitoring with short circuit monitoring and
monitored manual start up to PL e / SIL 3.
Fig. 3 Two-channel emergenc -stop monitoring
with cross circuit monitoring
Application example 2:
SD1E for single-channel emergency stop
monitoring with automatic start up to
PL c / SIL 1.
Fig. 4 Single-channel emergenc stop
monitoring with auto-start
Note: Config-Switches are set as follows:
S1: Disabled / S2: Automatic
(see chapter 7. “Function”)

10
Safety Relay MINOS SD1E
Application example 4:
SD1E for dual channel safety door monitoring
with manual start up to PL e / SIL 3.
Fig. 6 Dual channel safet door monitoring
Note: Config-Switches are set as follows:
S1: Enabled / S2: Manual
(see chapter 7. “Function”)
Note: Config-Switches are set as follows:
S1: Enabled / S2: Automatic
(see chapter 7. “Function”)
Application example 3:
SD1E for two-channel monitoring of a non-
contact safety switch with short circuit moni-
toring and automatic start up to PL e / SIL 3.
Fig. 5 Dual channel safet door monitoring
with non-contact safet switch

11
Safety Relay MINOS SD1E EN
Note: Config-Switches are set as follows:
S1: Disabled / S2: Automatic
(see chapter 7. “Function”)
Application example 5:
SD1E for two-channel monitoring of an
OSSD-Output, e.g. light curtain/grid and
automatic start up to PL e / SIL 3 (cross
circuit monitoring by OSSD-Output)
Fig. 7 Monitoring of an OSSD-Output, e.g. light
curtain / light grid with auto-start
Legend for all application examples:
E-Stop: Emergency stop button
Start: Start button
KA/KB: Positively driven contactors;
Monitoring via feedback circuit
PL and SIL: According to EN ISO 13849-1
and IEC 62061 / IEC 61508.
Specified safety level, considering a fault
exclusion in the wiring between SD1E and the
connected contactors KAand KB. See details
in chapter 15 "Wiring / Applications - Safe
relay contact”

12
Safety Relay MINOS SD1E
9. Mounting
The device has to be installed in a cabinet
having minimum protection class of IP54:
• Mount on a 35 mm mounting rail as per
EN 60715
• Ensure adequate heat dissipation in the
cabinet
• The mounting distance to the adjacent
devices depends on the load at the safe
contact. See chapter 20 "Technical data -
Safe relay contact“ and chapter 21
“Derating“
Fig. 8 Mounting / Demounting
10. Electrical connection
• Wiring and Config-Setting via the Config-
Switches should only be carried out while
the voltage supply is switched off
• Do not connect any external voltages to the
output C1
• The output C1 is short-circuit-proofed.
Overloading is not allowed and results in
damage to the device. (see chapter 20
"Technical data")
• All inductive loads at C1 and 13-14 should
have adequate protection circuit such as a
free-wheeling diode
• Auxiliary output C1 may not be used as
safety output
• All electrical connections must either be
isolated from the main supply by safety
transformers (SELV/PELV) according to
IEC 61558-2-6 with limited output voltage
in the event of a fault, or by other
equivalent isolation measures
• All lines to the device must be supplied by
the same, short circuit proofed power
supply. Seperate power supplys for A1/A2
and all input circuits are not permitted.

13
Safety Relay MINOS SD1E EN
11. Commissioning
1. Set the Config-Switches
Set the Config-Switches at the back of the
device according to your application (see
chapter 7 “Function”).
2. Wiring the safety circuit
Wire the safety circuit according to your
application, as well as the required safety
levels determined (see chapter 15 “Wiring /
Applications - Safety circuit“).
3. Wiring the start circuit / feedback circuit
Wire the start circuit and the feedback circuit
according to your application (see chapter 15
“Wiring / Applications - Start circuit”).
4. Wiring the power supply
Connect the power supply to the terminals A1
and A2 (see chapter 15 “Wiring / Applications
- Power supply “).
5. Starting the device
Switch on the power supply. The LED UB
starts lighting immediately.
If the "Automatic start" behaviour is set, the
safe relay contact will close immediately with
a closed safety circuit and closed feedback
loop.
If "monitored manual start" is set , press and
release the start button after closing the
safety circuit and the feedback loop to close
the safe relay contact.
The LED’s I1, I2 and K1/2 start glowing.
6. Triggering the safety function
Open the safety circuit. The safe relay contact
opens immediately. The LEDs I1, I2 and K1/2
are off.
7. Switching on again
Restart the device.
ATTENTION!I
If automatic start is configured, the
safe contact 13-14 immediately
closes when the safety circuit is closing.
The monitored manual start of the device
should not be used to start the machine in
accordance with EN ISO 13849-1.

14
Safety Relay MINOS SD1E
12. Checks and maintenance
The following checks are regularly required to
ensure proper and continuous functioning:
• Check the switching function
• Check for signs of manipulation and safety
function bypassing
• Check if the device is mounted and con-
nected securely
• Check for soiling
Check if the safe function of the whole safety
system is working properly, in particular:
• Every time after initial commissioning
• Every time after replacing a component
• After a long downtime
• After every fault
Regardless of this, the safe functioning of the
safety device should be checked at suitable
intervals, e.g. as part of the maintenance
schedule of the plant. No maintenance is
required for the device itself.
ATTENTION:
Proper operation is no longer
guaranteed if the device is dam-
aged, e.g. after a fault. Replace the device in
such cases. Only the manufacturer may
repair the device and open the housing.

15
Safety Relay MINOS SD1E EN
13. Proof-Test
To check the correct function of the device
within the framework of a proof test, the
following steps must be carried out:
• Demand the safety function by opening the
safety circuit. Check that the relay contact
(13-14) opened by activation of the safety
function.
• Close the safety circuit and start the device
again. Check that the relay contact
(13-14) closed again.
If the device doesn‘t switch on again, the
proof-test failed.
ATTENTION:
If the proof-test fails, the device
must be replaced. Otherwise there is a risk of
loss of functional safety.

16
Safety Relay MINOS SD1E
14. Terminal assignment and LED display
Fig. 9 Front view SD1E
A1: Power suppl + DC 24 V
A2: Power Suppl 0 V
S21: Control line start
I1: Control line safet circuit 1
I2: Control line safet circuit 2
13: Safe Rela Contact
14: Safe Rela Contact
C1: Auxilliar Output
SD1E: Variant label
Label - Upper terminal block
Label - Lower terminal block
Monitoring LEDs: UB, I1, I2, K1/2 (see monitoring table)

17
Safety Relay MINOS SD1E EN
15. Wiring / Applications
Depending on application or result of the risk
assessment, e.g. according to EN ISO 13849-
1, the device should be wired according to
Fig. 10 to 22.
Safety circuit
Dual-channel emergency stop or safety door
monitoring with short circuit monitoring.
Up to PL e / SIL 3
Position Config-Switch S1: Enabled (Left)
Fig. 10 Potential-free NC contacts dual channel
Fig. 11 PNP solid-state outputs dual channel

18
Safety Relay MINOS SD1E
Safety circuit
Single-channel emergency stop or safety door
monitoring with earth fault monitoring.
Up to PL c / SIL 1
Position Config-Switch S1: Disabled (Right)
Fig. 12 Potential-free NC contact single channel
Fig. 13 PNP solid-state output single channel
Safety circuit
Dual-channel monitoring of safe OSSD
outputs with integrated cross circuit monitor-
ing.
Up to PL e / SIL 3
Position Config-Switch S1: Disabled (Right)
Fig. 14 OSSD outputs dual channel

19
Safety Relay MINOS SD1E EN
Safety circuit
Single-channel monitoring of safe OSSD
output.
Up to PL e / SILCL 3
Position Config-Switch S1: Disabled (Right)
Fig. 15 OSSD outputs single channel
Start circuit
Monitored manual start without feedback
circuit.
Note: Evaluation of the falling edge of the
start signal (contact opens).
Position Config-Switch S2: Manual (Left)
Fig. 16 Manual start without feedback circuit
Note:
OSSD-Output meet the requirements for
Safety-Level and fault exclusion of a short
circuit in the safety circuit according to
EN ISO 13849-2.

20
Safety Relay MINOS SD1E
Fig. 17 Manual start with feedback circuit
KA, KB:
Positivel driven NC contacts of the connected
contactors or expansion modules.
Start circuit
Monitored manual start with feedback circuit.
Note: Evaluation of the falling edge of the
start signal (contact opens).
Position Config-Switch S2: Manual (Left)
Start circuit
Automatic start.
Note: Difference time monitoring at safety
circuit in case of automatic start:
I2 before I1: Difference time is arbitrary
I1 before I2: Difference time max. 300 ms
Position Config-Switch S2: Automatic (Right)
Fig. 18 Automatic start without feedback circuit