1 Preliminary note The instructions are part of the unit� They are intended for authorised persons according to the EMC and Low Voltage Directive and safety regulations� The instructions contain information about the correct handling of the product� Read the instructions before use to familiarise yourself with operating conditions, installation and operation�...
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• In case of malfunction of the unit please contact the manufacturer� Tampering with the unit is not allowed� • Disconnect the unit externally before handling it� Also disconnect any independently supplied relay load circuits� • After setup the system has to be subjected to a complete function check� • Only use the unit under the specified operating conditions (→ 10 Technical data)�...
3 Items supplied • 1 G1501S safety relay including 5 Combicon connectors with screw terminals • 1 copy of the operating instructions safety relay, reference 704064� If one of the above-mentioned components is missing or damaged, please contact one of the ifm branch offices�...
By taking administrative measures in the application it must be ensured that • the safety relays type G1501S in operation are subjected to a self-test (switching off) within a period of maximum 12 months (intermittent operation) • the safety-related relay contacts are protected using a suitable fuse of 3�6 A as...
5 Structure and operating principle 5.1 Indicators and connections Supply voltage (L-, L+), function terminals (Y1, Y2) Y4, Y5, Y6, Y7: Operating mode selection, auxiliary output S33, S34, S43, S44: Connection for safety inputs / outputs LED yellow: Triggering of the relay output channel 1 LED yellow: Triggering of the relay output channel 2 LED yellow: Input signal channel 1 or TE (for clocked sensor) LED yellow: Input signal channel 2 or A (for clocked sensor)
6 Installation ► Mount the unit on a DIN rail in a housing protected against dust and humidity (min� IP54 - degree of soiling 2)� 7 Electrical connection ► Use 60/75°C copper conductors only� 7.1 Supply voltage The external supply unit must have a safe separation� In case of a fault the voltage can exceed the value of 60 V DC for a maximum of 200 ms, but must not exceed the value of 120 V DC�...
7.2 Feedback contacts / monitored or automatic start Automatic start Automatic activation without monitoring� L- Y1 Y2 L+ Monitoring of the feedback contacts (normally closed) for automatic start The circuit is enabled when the feedback contacts are closed� Consider the current flowing through the feedback contacts (→ 10 Technical data).
7.3 Output circuit Connect the load Connect the load to be controlled to the outputs C1 (13-14) or C2 (23-24)� 3,6 A Adhere to the maximum and minimum load conditions (→ 10 Technical data). 3,6 A Output Y7 provides a non-safety related signal for A2 Y4 Y5 Y6 Y7 communication to a plc�...
8 Connection - Function - Fault diagnosis The safety relay can be connected or used in different ways: 1� Safety relay for fail-safe sensors/switches with 2 PNP outputs (e�g� GM701S)� 2� Safety relay for clocked fail-safe sensors (e�g� GM504S) 3� Two-hand control to EN 574, type IIIC, with electronic sensors/switches 4�...
• Light curtain (ESPE to EN 61496-1) • Laser scanner 8.1.1 Connection Fail-safe sensor/switch with a current consumption of ≤ 50 mA: G1501S 1: Fail-safe sensor/switch Fail-safe sensor/switch with a current consumption of > 50 mA: G1501S 24 V DC...
8.1.2 Function Input circuit Output status LED display Stop flashing: ► Activate inputs in correct time sequence (→ fig. above)
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Input circuit Output status LED display 24 V 24 V K1 E1 Power OSSD1 OSSD2 K2 E2 Fault OSSD1 OSSD2 24 V 24 V K1 E1 Power OSSD1 OSSD2 K2 E2 Fault OSSD1 OSSD2...
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Input circuit Output status LED display...
8.1.3 Fault diagnosis In case of a fault switch the safety relay off and on again! LED display Cause of the fault Troubleshooting • No voltage supply ► Check wiring • Overvoltage ► Check power supply • Connection A1/A3 or A1/A2 reversed • Wire break ►...
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LED display Cause of the fault Troubleshooting • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Undervoltage ► Check wiring ► Check power supply • Short circuits ► Check wiring • Input S43 active more than 0�5 s ►...
Example of fail-safe sensors/switches: • Fail-safe inductive sensor GM504S Up to 10 clocked fail-safe sensors can be connected to one safety relay� 8.2.1 Connection Connection of one fail-safe sensor/switch: G1501S 1: Fail-safe sensor/switch Connection of 2 fail-safe sensors/switches: G1501S 1: Fail-safe sensor/switch 1...
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The use of the safety splitter box E11569 is recommended: G1501S 1: Fail-safe sensor/switch 1 3: E11569 wh = white 2: Fail-safe sensor/switch 2 4: e�g� E10884 bk = black 5: e�g� E10662 bn = brown bu = blue Connection of 3 to 10 fail-safe sensors/switches:...
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The use of the safety splitter box E11569 is recommended: G1501S 24 V DC 1: Fail-safe sensor/switch 1 4: E11569 wh = white 2: Fail-safe sensor/switch 2 5: e�g� E10884 bk = black 3: Fail-safe sensor/switch 3 6: e�g� E10662...
8.2.3 Fault diagnosis In case of a fault switch the safety relay off and on again! LED display Cause of the fault Troubleshooting • No voltage supply ► Check wiring • Overvoltage ► Check power supply • Connection A1/A2 reversed • Wire break ► Check wiring • Feedback contacts open ►...
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LED display Cause of the fault Troubleshooting • Short circuit S34/L+ ► Check wiring • Short circuit S43/L+ or S34/ ► Check wiring • Missing clock ► Check wiring • Wiring fault • Connection A2/A3 reversed • Short circuit S43/L- • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Overvoltage ►...
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LED display Cause of the fault Troubleshooting • Short circuits ► Check wiring...
This wiring meets the requirements type IIIB to EN 574� Use up to type IIIC is possible using corresponding sensors/switches with two independent switching elements, internal plausibility check and protected or screened wires� 8.3.1 Connection Connection of two 2-wire DC: G1501S 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2...
8.3.2 Function Input circuit Output status LED display 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2...
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Input circuit Output status LED display 24 V K1 E1 Power K2 E2 Fault 24 V K1 E1 Power K2 E2 Fault 24 V K1 E1 Power > 0,5 s K2 E2 Fault > 0,5 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2...
8.3.3 Fault diagnosis In case of a fault switch the safety relay off and on again! LED display Cause of the fault Troubleshooting • No voltage supply ► Check wiring • Overvoltage ► Check power supply • Connection A1/A3 or A1/A2 reversed • Wire break ►...
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LED display Cause of the fault Troubleshooting • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Undervoltage ► Check wiring ► Check power supply • Short circuits ► Check wiring • Inputs S34 and S43 not ►...
This wiring (with only one normally open contact per sensor/switch) meets the requirements of type IIIB to EN 574� Use up to type IIIC is possible using corresponding sensors/switches approved to EN 60947-5-1 annex K and protected or screened wires� G1501S 1: Mechanical fail-safe switch 1 2: Mechanical fail-safe switch 2...
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Connection of mechanical switches according to type IIIC to EN 574 G1501S 1: Mechanical switch 1 (no positively 2: Mechanical switch 2 (no positively driven driven contacts) contacts) Connection of a 2-channel fail-safe sensor/switch e�g� "electro-sensitive protective equipment" (ESPE) to EN 61496-1...
8.4.3 Fault diagnosis In case of a fault switch the safety relay off and on again! LED display Cause of the fault Troubleshooting • No voltage supply ► Check wiring • Overvoltage ► Check power supply • Connection A1/A3 or A1/A2 reversed • Wire break ►...
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LED display Cause of the fault Troubleshooting • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Undervoltage ► Check wiring ► Check power supply • Short circuits ► Check wiring • Inputs S34 and S43 not ► Check wiring activated within 0�5 s ►...
The 2-channel fail-safe sensors/switches are for example "electro-sensitive protective equipment" (ESPE) to EN 61496-1� The contacts of the sensors/switches must allow a minimum current of 6 mA� 8.5.1 Connection G1501S 1: Mechanical switch 1 2: Mechanical switch 2...
8.5.2 Function Input circuit Output status LED display 1: Fail-safe sensor/switch 1 2: Fail-safe sensor/switch 2 3: Order and time difference insignificant (indefinite simultaneity) : N�O� contact activated...
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Input circuit Output status LED display 24 V K1 E1 Power K2 E2 Fault 24 V K1 E1 Power K2 E2 Fault 1: Fail-safe sensor/switch 1 2: Fail-safe sensor/switch 2 : N�O� contact activated...
8.5.3 Fault diagnosis In case of a fault switch the safety relay off and on again! LED display Cause of the fault Troubleshooting • No voltage supply ► Check wiring • Overvoltage ► Check power supply • Short circuit ► Check wiring • Wire break • Short circuit ►...
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LED display Cause of the fault Troubleshooting • Wiring fault ► Check wiring • Missing link Y4/Y5 • Short circuit • Connection A2/A3 reversed ► Check wiring • Missing link Y4/Y5 ► Check wiring • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Overvoltage ► Check wiring • Undervoltage ►...
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LED display Cause of the fault Troubleshooting • Short circuits ► Check wiring...
9 Scale drawing 1: Combicon connector with screw terminals (supplied) 10 Technical data G1501S Safety relay with relay outputs Terminal block Phoenix Contact MSTBO Meets the requirements of: EN ISO 13849-1: 2008 category 4 PL e, SIL 3 (IEC 61508), type IIIC (EN 574)
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Power-on delay time < 6 s Response time [ms] acc� to input circuit → chapter 8�1 8�2 8�3 8�4 8�5 Release Safety requirement Ambient temperature -25���55°C Protection rating IP 20 Housing materials Input characteristics (S34, S43) "1": > 11 V, 6 mA "0": <...
11 Tests/approvals The safety relay G1501S was tested and certified by TÜV-Nord� The safety relay was developed and tested in accordance with the following directives and standards: • 2006/42/EC Machinery Directive • 2004/108/EC EMC Directive • 73/23/EEC or 93/68 Low voltage directive • DIN EN 954-1 (1996) category 4, safety of machinery, safety-related parts of...
12 Terms and abbreviations ESPE Electro-Sensitive Protective Equipment� Cat� Category Category Classification of the safety-related parts of a controller as regards their resistance to failures� Common Cause Failure Common cause failure� Diagnostic Coverage Diagnostic coverage� MTTF Mean Time to Failure Mean time to failure�...
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