The HR6S-AF Safety Module is a device designed for the interruption of safety-related electrical circuits in machinery and processes. It offers a range of application functions to monitor signals from various sensors and devices, ensuring operational safety.
Function Description
The HR6S-AF module provides six distinct application functions, configurable via a selector. It features two safety-related inputs, three safety-related relay outputs, and one non-safety-related status/diagnostics output. Additionally, it includes a non-safety-related start input with eight selectable start functions. For expanded capabilities, an extension module (HR6S-EP) can be connected to increase the number of safety-related outputs by six.
The device supports various input types from sensors, including:
- NO, NC, C/O contacts: Suitable for Emergency Stop push-buttons, guard door switches, and coded magnetic switches.
- PNP transistors: Used with magnetic switches and proximity switches.
- OSSD (Output Signal Switching Device) outputs: Compatible with electro-sensitive protective equipment like type 4 light curtains and RFID sensors.
Key operational principles include:
- Dynamization: This feature is used for cross-circuit detection between safety-related inputs or between a safety-related input and the Start input, or to an external power supply unit or ground. It employs periodically generated test pulses at the control outputs of the safety-related inputs (S#1) and the start input (Y1).
- Synchronization: The device can monitor synchronized behavior of input channels, ensuring that safety-related inputs are activated within specified synchronization times. If inputs are not activated within this timeframe, safety-related outputs will not activate.
- Signal Interlock Monitoring: This function detects conditions where a sensor/device fails to provide the expected input signal, such as due to contact welding. The device expects "simultaneous" deactivation of two safety-related inputs within a 200 ms monitoring time. Failure to meet this condition triggers a signal interlock alert, preventing the device from transitioning to an energized state. To clear this condition, affected inputs must be deactivated for at least one second.
The HR6S-AF operates through several states: Power off, Off/Configuration, Initialization, Run: Outputs Deenergized, Run: Outputs Energized, and Error. Configuration is only possible in the Off/Configuration state. The device performs self-tests during Initialization. The "Run: Outputs Deenergized" state signifies regular operation with the safety function active, while "Run: Outputs Energized" means the safety function is not active (outputs are energized). An "Error" state is entered upon detection of a fault. The defined safe state for the device is when safety-related outputs are de-energized (open for Normally Open contacts).
Important Technical Specifications
General:
- Device Types: Available with Push-in terminals (HR6S-AF1C) or screw terminals (HR6S-AF1P).
- Dimensions: 22.5 mm (0.89 in) width, 119 mm (4.7 in) height with terminals, 117 mm (4.61 in) depth.
- Weight: 0.2 kg (0.44 lbs).
- Degree of Protection: IP40 for housing, IP20 for terminals.
Supply:
- Supply Voltage: 24 VAC (-15% to 10%) or 24 VDC (-20% to 20%).
- Nominal Input Power: 5 VA (24 VAC), 2 W (24 VDC).
- Frequency Range AC: 50...60 Hz.
- Insulation Voltage: 300 V.
- Impulse Withstand Voltage: 4 kV.
Safety-Related Inputs:
- Number of Inputs: 2 (positive supplied, each with 1 control output DC+ and 1 input CH+).
- Output Voltage at DC+: >15 VDC.
- Input Voltage at CH+: 0...24 VDC (+20%).
- Switching Voltage for Activation: >15 VDC.
- Switching Voltage for Deactivation: <5 VDC.
- Input Current: 5 mA.
- Maximum Wire Resistance: 500 Ω.
- Maximum Wire Length: 30 m (98.43 ft) if supply via control outputs is not used.
Safety-Related Outputs:
- Number of Relay Contacts: 3 (Normally Open, instantaneous).
- Maximum Short Circuit Current IK: 1 kA.
- Maximum Continuous Current: 6 A.
- Maximum Total Thermal Current ΣIth: 12 A.
- Minimum Current: 10 mA.
- Minimum Voltage: 5 V.
- Utilization Category (IEC 60947-4-1 and IEC 60947-5-1): AC-1: 250 V, AC-15: 250 V, DC-1: 24 V, DC-13: 24 V.
- Maximum Current (Normally Open Relay Contacts): AC-1: 5 A, AC-15: 3 A, DC-1: 5 A, DC-13: 3 A.
- External Fusing: 10 A, category gG, for Normally Open.
Additional Non-Safety-Related Output (Z1):
- Number of Semiconductor Pulsed Outputs: 1.
- Output Voltage: 24 VDC.
- Maximum Current: 20 mA.
- Maximum Wire Length: 30 m (98.43 ft).
Timing Data:
- Maximum Response Time (Safety-Related Input): 20 ms.
- Maximum Response Time (After Power Outage AC): 200 ms.
- Maximum Response Time (After Power Outage DC): 120 ms.
- Recovery Time (After Request at Safety-Related Input): 200 ms.
- Switch-On Delay (Power On & Automatic Start): 2500 ms.
- Delay (Activation of Safety-Related Input or Valid Start Condition): 100 ms.
- Monitored Start Waiting Time: 2500 ms.
- Minimum Duration of Start Pulse (Monitored Start): 80 ms.
- Test Pulse Duration (Dynamization): 2 ms.
- Test Pulse Interval (Dynamization): 500 ms.
- Maximum Delay of Test Pulse (Dynamization): 40 ms.
- Test Pulse Phase Shift (Dynamization): At least 70 ms.
- Debounce Time (Standard): 2.5 ms.
- Debounce Time (with OSSD): 4 ms.
- Signal Interlock Monitoring Time: 200 ms.
Functional Safety Data:
- Defined Safe State: Safety-related outputs are de-energized (Normally Open: open).
- Maximum Performance Level (PL): PL e, Category 4 (Actual PL and category depend on wiring and configuration).
- Maximum Safety Integrity Level (SIL): SIL 3 (Actual SIL depends on wiring and configuration).
- Safety Integrity Level Claim Limit (SILCL): SILCL 3 (Actual SILCL depends on wiring and configuration).
- Hardware Fault Tolerance (HFT): 1.
- Stop Category for Emergency Stops: 0.
- Lifetime: 20 years at 55 °C (131 °F) ambient temperature.
- Safe Failure Fraction (SFF): >99%.
- Probability of Dangerous Failure per hour (PFHD): 1.13 x 10⁻⁹.
- Mean Time To Dangerous Failure (MTTFᴅ): >30 years.
- Average Diagnostic Coverage (DCavg): ≥99%.
Usage Features
Configuration:
The device is configured using an application function selector and a start function selector located on the front panel, protected by a sealable transparent cover. Modifications to these selectors only take effect after a power-up cycle. It is crucial to remove power before adjusting selector positions to avoid configuration errors. The device can detect certain technically incorrect configurations, but not unwanted ones (e.g., automatic start configured when a monitored start is required by risk assessment).
Start Functions:
The HR6S-AF offers various start functions, including:
- Automatic Start: The start input is permanently active (e.g., by bridging or external power supply). Outputs activate within 100 ms after safety-related inputs are activated.
- Manual Start: Requires activation of the start input (e.g., via a push-button or logic controller) after both the start input and safety-related inputs are activated.
- Monitored Start with Falling Edge: Requires the start input to be activated for at least 80 ms. Outputs activate on the falling edge of the start input, provided safety-related inputs are already active.
- Startup Test: Performed after power-up, typically for guard monitoring applications. Safety-related inputs must be deactivated and then activated (e.g., by opening and closing a guard) before safety-related outputs can activate.
These start functions can be configured with or without a startup test and with or without dynamization, depending on the application and the type of sensor/device connected to the start input.
Diagnostics:
The device provides diagnostic information through LEDs on the front panel and a pulsed status output (Z1).
- LED Indicators: LEDs for POWER, ERROR, STATE, START, and S## (for safety-related inputs) provide visual feedback on the device's status, power supply, output state, start condition, and input states.
- LED ERROR - Alerts: Flashing ERROR LED in conjunction with S## LEDs indicates alerts such as "Synchronization time exceeded" or "Signal interlock condition." These alerts transition the device to a safe state, requiring the cause to be removed for normal operation to resume.
- LED ERROR - Detected Errors: Solid ERROR LED with other LEDs indicates detected errors (e.g., general error, configuration error, power supply error, cross circuit detection). These errors also transition the device to a safe state and require a power cycle after the cause is resolved.
- Status Output Z1: Provides diagnostic information as a 10-bit pulsed pattern (each bit 200 ms). The first four bits (0010) signal the start of a sequence, followed by six bits containing the specific diagnostic code. This output can be connected to a logic controller for detailed error analysis.
Maintenance Features
Service and Repairs:
The HR6S-AF is designed without user-serviceable parts. Users should not attempt to open, service, or repair the device.
Maintenance Plan:
A comprehensive maintenance plan is essential for ensuring the continued safety and reliability of the device:
- Regular Function Triggering: Ensure that safety-related functions are triggered at minimum intervals as required by applicable regulations and process definitions.
- Wiring Inspection: Inspect all wiring at regular intervals for any signs of damage or degradation.
- Threaded Connection Tightening: Periodically tighten all threaded connections to prevent loosening over time.
- Lifetime Verification: Verify that the device is not used beyond its specified lifetime of 20 years. The end of the lifetime can be calculated by adding 20 years to the date of manufacture (indicated on the nameplate). For example, a device manufactured in week 10 of 2019 should not be used after week 10 of 2039. This information must be included in the customer's maintenance plan by the machine designer or system integrator.
Transportation, Storage, and Disposal:
- Environmental Conditions: Adhere to specified environmental conditions for transportation and storage to prevent damage.
- Disposal: Dispose of the product in accordance with all applicable regulations.
Accessories:
Available accessories include:
- Coding bits (HR9Z-EC): Used to ensure correct insertion of terminal blocks if they are removed.
- Sealing strips (HR9Z-ES): Uniquely numbered strips used to seal the transparent front cover, preventing unauthorized access to configuration selectors.
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