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HR6S-AF HR9Z-B2192 Safety Module Original instructions http://www.idec.com...
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You also agree not to establish any hypertext links to this document or its content. IDEC CORPORATION does not grant any right or license for the personal and noncommercial use of the document or its content, except for a non-exclusive license to consult it on an "as is" basis, at your own risk.
Safety Information Important Information NOTICE Read these instructions carefully, and look at the equipment to become familiar with the device before trying to install, operate, service, or maintain it. The following special messages may appear throughout this documentation or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure.
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PLEASE NOTE Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by IDEC CORPORATION for any consequences arising out of the use of this material. A qualified person is one who has skills and knowledge related to the construction and operation of electrical equipment and its installation, and has received safety training to recognize and avoid the hazards involved.
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Operate the product only with the specified cables and accessories. Use only genuine accessories. Any use other than the use explicitly permitted is prohibited and can result in hazards. HR9Z-B2192 8/2020...
About the Book At a Glance Document Scope This manual describes technical characteristics, installation, commissioning, operation and maintenance of the safety module HR6S-AF. Validity Note (see page 19) . The present document is valid for the products listed in the type code...
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Product Related Information DANGER HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH Disconnect all power from all equipment including connected devices prior to removing any covers or doors, or installing or removing any accessories, hardware, cables, or wires except under the specific conditions specified in the appropriate hardware guide for this equipment.
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WARNING LOSS OF CONTROL The designer of any control scheme must consider the potential failure modes of control paths and, for certain critical control functions, provide a means to achieve a safe state during and after a path failure. Examples of critical control functions are emergency stop and overtravel stop, power outage and restart.
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Terminology Derived from Standards The technical terms, terminology, symbols and the corresponding descriptions in this manual, or that appear in or on the products themselves, are generally derived from the terms or definitions of international standards. In the area of functional safety systems, drives and general automation, this may include, but is not limited to, terms such as safety , safety function , safe state , fault , fault reset , malfunction , failure , error , error message , dangerous , etc.
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In addition, terms used in the present document may tangentially be used as they are derived from other standards such as: Standard Description IEC 60034 series Rotating electrical machines IEC 61800 series Adjustable speed electrical power drive systems IEC 61158 series Digital data communications for measurement and control –...
Chapter 1 Introduction What Is in This Chapter? This chapter contains the following topics: Topic Page Device Overview Front View and Side View Nameplate Type Code HR9Z-B2192 8/2020...
Introduction Device Overview Outline The device is a safety module for interruption of safety-related electrical circuits. The device provides application functions used to monitor signals from different types of sensors/devices. Equipment with the following types of outputs can be connected to the safety-related inputs of the device: NO, NC, C/O, for example, Emergency Stop push-buttons, guard door switches, coded ...
Front View and Side View POWER ERROR STATE START START FUNCTION HR6S-AF 1 Removable terminal blocks, top 2 Removable terminal blocks, bottom 3 LED indicators 4 Start function selector 5 Application function selector 6 Connector for optional output extension module HR6S-EP (lateral)
Introduction Nameplate Nameplate HR6S Safety module The nameplate contains the following data: (see page 19) ) 1 Device type (refer to chapter Type Code 2 Nominal voltage 3 Frequency range VAC supply 4 Input power 5 Maximum current of safety-related outputs with utilization category AC-15 (250 VAC) 6 Maximum current of safety-related outputs with utilization category DC-13 (24 VDC) 7 Maximum total thermal current 8 Maximum Safety Integrity Level (SIL) as per IEC 61508-1:2010...
HR6S: HR6S safety module 5 ... 6 Product version Supply voltage 1 = 24 VAC/VDC Terminal type C = Push-in terminals, removable P = Screw terminals, removable If you have questions concerning the type code, contact your IDEC CORPORATION service representative. HR9Z-B2192 8/2020...
Chapter 2 Technical Data What Is in This Chapter? This chapter contains the following topics: Topic Page Environmental Conditions Mechanical Characteristics Electrical Characteristics Timing Data Data Functional Safety HR9Z-B2192 8/2020...
Technical Data Environmental Conditions Environmental Conditions For Storage The device complies with class 1K5 as per IEC 60721-3-1 (climatic conditions): Characteristic Value Ambient temperature -40 ... 70 °C (-40 ... 158 °F) Rate of change of temperature 1 °C/min (1.8 °F/min) Ambient humidity 10 ...
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Technical Data Environmental Conditions For Operation Characteristic Value Maximum installation altitude above mean sea level 2000 m (6562 ft) Installation required in control cabinet/enclosure with IP54 degree of protection The device complies with class 3K5 and special class 3Z11 as per IEC 60721-3-3 (climatic conditions): Characteristic Value...
Technical Data Electrical Characteristics Supply Characteristic Value Supply voltage AC 24 VAC (-15 ... 10 %) Supply voltage DC 24 VDC (-20 ... 20 %) Nominal input power AC 5 VA (24 VAC) Nominal input power DC 2 W (24 VDC) Frequency range AC 50 ...
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Technical Data Start Input Characteristic Value Output voltage at DC+ >15 VDC Input voltage at CH+ 0 ... 24 VDC (+20 %) Switching voltage activate CH+ >15 VDC Switching voltage deactivate CH+ <5 VDC Input current 5 mA Maximum wire resistance 500 Ω...
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Technical Data Safety-Related Outputs Characteristic Value Number of relay contacts, Normally Open, instantaneous 3 Maximum short circuit current IK 1 kA Maximum continuous current, Normally Open relay contacts Maximum total thermal current ∑I 12 A Minimum current 10 mA Minimum voltage Utilization category as per UL 60947-5-1 B300 and R300 Utilization category as per IEC 60947-4-1 and IEC 60947-...
Technical Data Timing Data Maximum Response Times Characteristic Value Maximum response time to request at 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 Characteristic Value Recovery time after request at safety-related input 200 ms...
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Technical Data Debounce Time of Safety-Related Inputs Characteristic Value Debounce time, standard 2.5 ms Debounce time, with OSSD 4 ms Signal Interlock Monitoring Time Characteristic Value Signal interlock monitoring time 200 ms Synchronization Times The synchronization times for the synchronization of safety-related inputs depend on the application function (see page 58) .
Technical Data Data Functional Safety Data Functional Safety Characteristic Value Defined safe state Safety-related outputs are de-energized Normally Open: open Maximum Performance Level (PL), Category Normally Open: PL e, Category 4 (as per ISO 13849-1:2015) Actual PL and category depend on wiring and configuration.
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Technical Data Electrical durability of the safety-related output relay contacts as per IEC 60947-5-1 AC-15 : 250V AC-1 : 250V DC-1 : 24V DC-13 : 24V 1 Operating cycles 2 Rated current in A (see page 29) for additional technical data that may affect your Refer to chapter Timing Data functional safety calculations.
Chapter 3 Engineering What Is in This Chapter? This chapter contains the following topics: Topic Page Electromagnetic Compatibility (EMC) Basic Principles of Operation Safety-Related Inputs Synchronization of Safety-Related Inputs Dynamization Signal Interlock Monitoring HR9Z-B2192 8/2020...
Engineering Electromagnetic Compatibility (EMC) Conducted and Radiated Electromagnetic Emissions WARNING INSUFFICIENT ELECTROMAGNETIC COMPATIBILITY Verify compliance with all EMC regulations and requirements applicable in the country in which the device is to be operated and with all EMC regulations and requirements applicable at the installation site.
Engineering Basic Principles of Operation Introduction The following sections provide basic information on the principles of operation of the device to assist you in engineering your application function. Operating States The following graphic illustrates the operating states and state transitions of the device: Operating state Description In defined...
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Engineering State Transitions State transition Condition Power on Initialization successful Switch on delay has passed Start condition fulfilled (for example, automatic start or manual start with start button pressed) Safety-related inputs activated For application functions with signal interlock monitoring: no signal interlock ...
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Engineering If the safety-related inputs are not activated (actuator of Emergency Stop pushbutton pushed down), the device remains in the operating state Run: Outputs Deenergized. The motor remains at a standstill. If the safety-related inputs are activated (actuator of Emergency Stop pushbutton pulled out), the device transitions to the operating state Run: Outputs Energized (T3).
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Engineering Timing Diagram for Example with Emergency Stop The following timing diagram provides an overview of the example with Emergency Stop. Legend Item Description The first safety-related input (A) is activated (actuator of Emergency Stop button pulled out). The device remains in the defined safe state. ...
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Engineering Item Description The safety-related input B is deactivated (actuator of Emergency Stop button pushed). The safety-related output is deactivated within the response time (see page 29) . The Emergency Stop is triggered. The device is in the defined safe state. ...
Engineering Safety-Related Inputs Overview WARNING INSUFFICIENT AND/OR INEFFECTIVE SAFETY-RELATED FUNCTIONS Only connect a sensor/device to a safety-related input that meets all requirements as per your risk assessment and that complies with all regulations, standards, and process definitions applicable to your machine/process. Failure to follow these instructions can result in death, serious injury, or equipment damage.
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Engineering Two safety-related inputs with one input channel each with antivalent behavior (magnetic switch with NO at S12 and NC at S22): If the level at terminal S12 is logically 0 and the level at terminal S22 is logically 1, the safety-related input is activated.
Engineering Synchronization of Safety-Related Inputs Overview The device can monitor synchronized behavior of the input channels of the safety-related inputs using various synchronization mechanisms with different synchronization times. If the synchronized input channels of the safety-related inputs are not activated within the synchroni- zation time, the safety-related output or outputs are not activated.
Engineering Dynamization Dynamization of Inputs Dynamization is used for cross circuit detection between two safety-related inputs or between one safety-related input and the Start input or a cross-circuit to an external power supply unit or to ground. Dynamization is implemented by means of periodically generated test pulses at the control outputs of the safety-related inputs S#1 and of the start input Y1.
Engineering Signal Interlock Monitoring Overview Signal interlock is a monitoring function used to detect conditions in which one of the sensors/devices cannot provide the expected input signal for the device, for example, as a result of contact welding. The device expects “simultaneous” deactivation of the two safety-related inputs within the signal interlock monitoring time of 200 ms.
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Engineering The following figure illustrates a condition with signal interlock: Safety-relaed input S## Safety-relaed input S## The first safety-related input is deactivated which starts the signal interlock monitoring time of 200 ms. It is then activated again before the second safety-related input is deactivated. This immediately triggers a signal interlock alert even though the 200 ms have not yet elapsed.
Chapter 4 Installation What Is in This Chapter? This chapter contains the following topics: Topic Page Prerequisites and Requirements Mechanical Installation Electrical Installation HR9Z-B2192 8/2020...
Installation Prerequisites and Requirements Inspecting the Device Damaged products may cause electric shock or unintended equipment operation. DANGER ELECTRIC SHOCK OR UNINTENDED EQUIPMENT OPERATION Do not use damaged products. Keep foreign objects (such as chips, screws or wire clippings) from getting into the product. ...
Installation Mechanical Installation Mounting to DIN Rail The device can be mounted to the following DIN rails as per IEC 60715: 35 x 15 mm (1.38 x 0.59 in) 35 x 7.5 mm (1.38 x 0.29 in) 0.59 0.29 0.04 0.04...
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Installation Screw-Mounting 2 x Φ 4.3 M4 x 12 / 16 11.25 2 x Φ 0.17 M4 (ISO 7093) M4 x 0.47 / 0.63 0.44 Mounting procedure: Step Action Push the additional fastener into the grooves at the device. Prepare the holes on the mounting surface. Screw the device to the mounting surface using the specified screws and a washer M4 as per ISO 7093 for each screw.
Installation Electrical Installation General Information DANGER FIRE, ELECTRIC SHOCK OR ARC FLASH Disconnect all power from all equipment of your machine/process prior to electrical installation of the device. Confirm the absence of power using a properly rated voltage sensing device. ...
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Installation Block Diagram and Terminals The following drawings present the block diagram and the terminals with their designations in the removable terminal blocks. S11 S12 DC+ CH+ DC+ CH+ AC/DC Input Start Input Power Supply DC+ CH+ S21 S22 Terminal Designation Explanation A1, A2 Power supply...
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Installation Terminal Designation Explanation 13, 14, 23, 24, 33, 34 Terminals of the safety-related outputs Pulsed output for diagnostics (see page 79) , not safety-related Connector for output extension module HR6S-EP Safety-Related Inputs WARNING INSUFFICIENT AND/OR INEFFECTIVE SAFETY-RELATED FUNCTIONS Only connect a sensor/device to a safety-related input that meets all requirements as per your risk assessment and that complies with all regulations, standards, and process definitions applicable to your machine/process.
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Installation Start Input WARNING UNINTENDED EQUIPMENT OPERATION Do not use the Start function for safety-related purposes. Use Monitored Start or Startup Test if unintended restart is a hazard according to your risk assessment. Failure to follow these instructions can result in death, serious injury, or equipment damage. The start input consists of one control output DC+ (terminal Y1) and one input channel CH+ (terminal Y2).
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Installation Additional, Non-Safety-Related Output Z1 WARNING INCORRECT USE OF OUTPUT Do not use the additional output Z1 for safety-related purposes. Failure to follow these instructions can result in death, serious injury, or equipment damage. Connect the semiconductor pulsed output Z1 to a suitable input of the logic controller if you want to use the diagnostics pattern the output provides.
Chapter 5 Functions What Is in This Chapter? This chapter contains the following topics: Topic Page Application Functions Start Functions HR9Z-B2192 8/2020...
Functions Application Functions Introduction The following sections provide an overview of the available application functions and a detailed listing of requirements and values of each of the application functions. The chapter Configuration (see page 72) describes the configuration procedure by means of the selectors of the device. Overview of Application Functions Typical applications Type of outputs of sensor/device...
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Functions Application Function 1 Characteristic Value/Description Typical applications Monitoring of Emergency Stop circuits as per ISO 13850 and IEC 60204-1, stop category 0 Monitoring of guards as per ISO 14119/14120 with electrical switches Type of outputs of sensor/device providing the input signal Normally open, normally closed and/or changeover for application function outputs...
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Functions Application Function 2 Characteristic Value/Description Typical applications Monitoring of Emergency Stop circuits as per ISO 13850 and IEC 60204-1, stop category 0 Monitoring of guards as per ISO 14119/14120 with electrical switches Type of outputs of sensor/device providing the input signal Normally open, normally closed and/or changeover for application function outputs...
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Functions Application Function 3 Characteristic Value/Description Typical applications Monitoring of guards as per ISO 14119/14120 with electrical switches Monitoring of guards as per ISO 14119/14120 with coded magnetic switches Monitoring of proximity switches Type of outputs of sensor/device providing the input signal Normally open, normally closed and/or changeover for application function outputs...
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Functions Application Function 4 Characteristic Value/Description Typical applications Monitoring of proximity switches Type of outputs of sensor/device providing the input signal One PNP output for application function S## terminals to be connected S12 and S22 Dynamization Signal interlock monitoring Between terminals S12 and S22 Synchronization of safety-related inputs Wiring of the inputs for sensors/devices with PNP output HR9Z-B2192 8/2020...
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Functions Application Function 5 Characteristic Value/Description Typical applications Monitoring of proximity switches Type of outputs of sensor/device providing the input signal One PNP output for application function S## terminals to be connected S12 and S22 Dynamization Signal interlock monitoring Between terminals S12 and S22 Synchronization: Synchronized terminals Synchronization time...
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Functions Application Function 6 Characteristic Value/Description Typical applications Monitoring of electro-sensitive protective equipment such as type 4 light curtains as per IEC 61496-1 Monitoring of RFID sensors Type of outputs of sensor/device providing the input signal OSSD (Output Signal Switching Device) outputs for application function S## terminals to be connected S12 and S22...
Functions Start Functions Overview WARNING UNINTENDED EQUIPMENT OPERATION Do not use the Start function for safety-related purposes. Use Monitored Start or Startup Test if unintended restart is a hazard according to your risk assessment. Failure to follow these instructions can result in death, serious injury, or equipment damage. The device provides several start functions which are selected by means of the start function selector.
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Functions Automatic Start With automatic start, the start input is permanently active. This can be achieved by bridging the start input or providing an external power supply. When the safety-related input is activated, the safety-related outputs are activated within a maximum of 100 ms (activation delay). The following timing diagram illustrates the automatic start: Activation delay (100 ms): maximum time between activation of safety-related input and activation of safety-related output...
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Functions Manual Start A manual start requires the start input to be activated. The safety-related outputs are activated after both the start input and the safety-related inputs have been activated. The following timing diagram illustrates the manual start: Activation delay (100 ms): maximum time between activation of start input and activation of safety-related output Response time (20 ms): maximum time between deactivation of safety-related input and deactivation of safety-related output...
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Functions Monitored Start with Falling Edge In the case of a monitored start with falling edge, the start input must be activated and remain active for a duration of 80 ms. The safety-related outputs are activated with a falling edge of the start input if the safety-related inputs have been activated in the meantime.
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Functions Startup Test The startup test is performed after the device is powered on. The startup test is typically used for applications involving guard monitoring. The start input is permanently activated by, for example, bridging. After power up, the safety-related inputs must be deactivated and activated before the safety-related outputs are activated.
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Functions Configuring the Start Function The start function is configured by means of the start function selector. Position of start function selector Configured start function Automatic/manual start (depends on sensor/device connected to start input) Without startup test With dynamization ...
Chapter 6 Configuration and Commissioning What Is in This Chapter? This chapter contains the following topics: Topic Page Configuration Commissioning HR9Z-B2192 8/2020...
Configuration and Commissioning Configuration Overview The device detects certain technically incorrect configurations (for example, a configured start function cannot be used with a configured application function). The device cannot detect unwanted configurations (for example, automatic start has been configured, but a monitored start is required for your application as a result of your risk assessment).
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Configuration and Commissioning Configuration Procedure Step Action Verify that the device has been wired according to the safety-related function to be configured. Remove power if the device is not powered off. If an extension module HR6S-EP is connected, remove power from the extension module as well.
Configuration and Commissioning Commissioning Overview WARNING INEFFECTIVE SAFETY-RELATED FUNCTION AND/OR UNINTENDED EQUIPMENT OPERATION Commission the device before it is used for the first time and after each configuration. Commission or recommission the machine/process pursuant to all regulations, standards, and ...
Chapter 7 Diagnostics WARNING INEFFECTIVE SAFETY-RELATED FUNCTION AND/OR UNINTENDED EQUIPMENT OPERATION Only attempt to resolve alerts and errors detected by the device if you are fully familiar with the safety-related applications and the non-safety-related applications as well as the hardware used to operate your machine/process.
Diagnostics Diagnostics via LEDs Overview (see page 17) that provide status information and information The device features various LEDs on alerts and detected errors. Recommission the device (see page 74) if, during troubleshooting, you modify the position of the application function selector, the start function selector. LED POWER State Meaning...
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This LED flashes in conjunction with additional S## LEDs to indicate alerts. In the case of an alert, the device transitions to the defined safe state. Remove the cause of the alert to exit the defined safe state and resume operation. Contact your IDEC CORPORATION service representative if the condition persists.
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You must remove the cause of the detected error and perform a power cycle of the device to exit the defined safe state and resume operation. Contact your IDEC CORPORATION service representative if the condition persists.
Diagnostics Diagnostics via Status Output Z1 Overview WARNING INCORRECT USE OF OUTPUT Do not use the additional output Z1 for safety-related purposes. Failure to follow these instructions can result in death, serious injury, or equipment damage. The pulsed output Z1 provides diagnostics information in the form of a bit pattern. (see page 55) for additional information on wiring the Z1.
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Diagnostics Bit sequence Description Correctives Type 0010001100 Cross circuit detected at Verify correct wiring. input terminal S12. Verify that the sensor/device providing the input signal is suitable for cross circuit detection by means of dynamization. If it is not, use an application function without dynamization or a sensor/device suitable for dynamization.
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Diagnostics Bit sequence Description Correctives Type 0010110101 Input S12 is expected to change its state. In the case of a configuration with antivalent inputs, inputs S12 and S13 are expected to change their states. 0010111100 Input S22 is expected to change its state.
Chapter 8 Accessories, Service, Maintenance, and Disposal What Is in This Chapter? This chapter contains the following topics: Topic Page Accessories Maintenance Transportation, Storage, and Disposal Service Addresses HR9Z-B2192 8/2020...
Accessories, Service, Maintenance, and Disposal Accessories Accessories The following accessories are available for the device: Description Type number Coding bits HR9Z-EC The coding bits are used if the terminal blocks are removed to help ensure correct insertion of the terminal blocks into the device. 30 pieces per packaging unit Sealing strips HR9Z-ES...
Accessories, Service, Maintenance, and Disposal Maintenance Service and Repairs The device contains no user-serviceable parts. Do not attempt to open, service, or repair the device. Maintenance Plan Maintenance plan: Ensure that a safety-related function implemented with the device is triggered at the minimum ...
Accessories, Service, Maintenance, and Disposal Transportation, Storage, and Disposal Transportation and Storage (see page 22) specified for transportation and storage Ensure that the environmental conditions are respected. Disposal Dispose of the product in accordance with all applicable regulations. HR9Z-B2192 8/2020...
Index monitoring of, 64 electromagnetic compatibility, 34 accessories, 84 EMC, 34 activation, safety-related inputs, 40 Emergency Stop circuits as per ISO 13850 alerts, 76 and IEC 60204-1, stop category 0, monitoring antivalent behavior, safety-related inputs, 40 of, 59 , 60 application functions environmental characteristics, 22 configuration, 72...
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Index signal interlock monitoring, 44 IEC 61496-1, 64 start functions, 65 monitoring of Emergency Stop circuits as per synchronization of safety-related inputs, ISO 13850 and IEC 60204-1, stop category 0, 59 , 60 monitoring of guards as per ISO 14119/14120 with coded magnetic switches, 61 monitoring of guards as per guards as per ISO 14119/14120 with coded...
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Index supply technical data, 26 response times wiring, 55 technical data, 29 synchronization, 42 RFID sensors, monitoring of, 64 technical data safe state, defined, 31 degree of protection, 24 Safety Integrity Level, 31 dimensions, 24 safety-related inputs electrical characteristics, 26 activation, 40 environmental characteristics, 22 antivalent behavior, 40...