1 Preliminary note The instructions are part of the unit� They are intended for authorised persons according to the EMC, Low Voltage Directive and Machinery directives 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�...
2 Safety instructions • Follow the operating instructions� • Improper use may result in malfunctions of the unit� This can lead to personal injury and/or damage to property during operation of the machine� For this reason note all remarks on installation and handling given in these instructions� Also adhere to the safety instructions for the operation of the whole installation�...
EN 61496-1) with contact output without simultaneity monitoring (indefinite simultaneity) or for mechanical switches (→ chapter 8.5). ifm electronic gmbh assumes no liability for the use of units made by external manufacturers� The safe state is when the output contacts 13-14, 23-24, 33-34, 43-44, 67-68 or 77-78 are open and the output contact 51-52 is closed�...
The safety relays type G1502S in operation have to be subjected to a self-test (switching off) within a period of maximum 1 month. The self-test can be carried out by switching the supply voltage off and on or by a safety request�...
23, 24: Connection of relay output without delay, 1 x normally open (closed when enabled) 33, 34: Connection of relay output without delay, 1 x normally open (closed when enabled) 43, 44: Connection of signal output without delay, 1 x normally open (closed when enabled) 51, 52: Connection of signal output without delay, 1 x normally closed (open when enabled)
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 (→...
7.3 Output circuit Last anschließen ► Connect the load to be controlled to the relay outputs on C1 (13, 14), C2 (23, 24), C3 (33, 34), C5 (67, 68) or C6 3,6 A (77, 78). Adhere to max. and min. contact rating (→ 11 Technical data). 3,6 A 3,6 A 3,6 A...
The signal output Y7 provides a non-safety related signal A2 Y4 Y5 Y6 Y7 for communication to a plc� The signal corresponds to that triggering the relays at the outputs C5 (67, 68) and C6 (77,78). The output data is compatible with the input data of the current-sinking inputs of type 1, 2, 3 to EN 61131-2�...
• Light curtain (ESPE to EN 61496-1) • Laser scanner 8.1.1 Connection Fail-safe sensor/switch with a current consumption of ≤ 50 mA: G1502S 1: Fail-safe sensor/switch Fail-safe sensor/switch with a current consumption of > 50 mA: G1502S 1: Fail-safe sensor/switch...
8.1.2 Function Input circuit Output status LED display td = 0...10 s td = 0...10 s Stop flashing: ► Activate inputs in correct time sequence (→ fig. above) * During the switch-off delay (td > 0 s)
Page 16
Input circuit Output status LED display td = 0...10 s td = 0...10 s * During the switch-off delay (td > 0 s)
Page 17
Input circuit Output status LED display td = 0...10 s td = 0...10 s * During the switch-off delay (td > 0 s)
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 •...
Page 19
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 ►...
Page 20
LED display Cause of the fault Troubleshooting • The rotary switch for ► Program it again (→ 9.1) programming the switch-off delay was changed • Faulty programming...
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: G1502S 1: Fail-safe sensor/switch Connection of 2 fail-safe sensors/switches: G1502S 1: Fail-safe sensor/switch 1...
Page 22
The use of the safety splitter box E11569 is recommended: G1502S 1: Fail-safe sensor/switch 1 3: E11569 wh = white 2: Fail-safe sensor/switch 2 4: e�g� EVC014 bk = black 5: e�g� EVC001 bn = brown bu = blue Connection of 3 to 10 fail-safe sensors/switches:...
Page 23
The use of the safety splitter box E11569 is recommended: G1502S 1: Fail-safe sensor/switch 1 4: E11569 wh = white 2: Fail-safe sensor/switch 2 5: e�g� EVC014 bk = black 3: Fail-safe sensor/switch 3 6: e�g� EVC001 bn = brown...
Page 24
8.2.2 Function Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: First or last fail-safe sensor/switch of a row of sensors/switches 2: td = max� 16 ms * During the switch-off delay (td > 0 s)
Page 25
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 •...
Page 26
LED display Cause of the fault Troubleshooting • Short circuit S43/L+ or S34/S44 ► Check wiring • Missing clock ► Check wiring • Wiring fault • Connection A2/A3 reversed • Short circuit S43/L- • Overvoltage ► Check wiring • Undervoltage ►...
Page 27
LED display Cause of the fault Troubleshooting • Short circuits ► Check wiring • The rotary switch for ► Program it again (→ 9.1) programming the switch-off delay was changed • Faulty programming...
Page 28
Example of electronic sensors/switches: • Capacitive sensors For product selection see www�ifm�com 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�...
Page 29
8.3.2 Function Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2 * During the switch-off delay (td > 0 s)
Page 30
Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2 * During the switch-off delay (td > 0 s)
Page 31
Input circuit Output status LED display td = 0...10 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2 * During the switch-off delay (td > 0 s)
Page 32
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 •...
Page 33
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 (→...
Page 34
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� G1502S 1: Mechanical fail-safe switch 1 2: Mechanical fail-safe switch 2...
Page 35
Connection of mechanical switches according to type IIIC to EN 574 G1502S 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...
Page 36
8.4.2 Function Input circuit Output status LED display td = 0...10 s td = 0...10 s : N�O� contact activated * During the switch-off delay (td > 0 s)
Page 37
Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 1 * During the switch-off delay (td > 0 s)
Page 38
Input circuit Output status LED display td = 0...10 s 1: Electronic fail-safe sensor 1 2: Electronic fail-safe sensor 2 * During the switch-off delay (td > 0 s) : N�O� contact activated...
Page 39
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 •...
Page 40
LED display Cause of the fault Troubleshooting • Undervoltage ► Check wiring ► Check power supply • Short circuits ► Check wiring • Inputs S34 and S43 not ► Check wiring activated within 0.5 s (→ 8.4.2) ► Deactivate inputs and •...
(ESPE) to EN 61496-1. The contacts of the sensors/switches must allow a minimum current of 6 mA� 8.5.1 Connection Connection e-stop / 2-channel fail-safe sensors/switches: G1502S 1: Fail-safe sensor/switch Connection of two mechanical switches: G1502S 1: Mechanical switch 1...
8.5.2 Function Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: Fail-safe sensor/switch 1 2: Fail-safe sensor/switch 2 3: Order and time difference insignificant (indefinite simultaneity) * During the switch-off delay (td > 0 s) : N�O�...
Page 43
Input circuit Output status LED display td = 0...10 s td = 0...10 s 1: Fail-safe sensor/switch 1 2: Fail-safe sensor/switch 2 * During the switch-off delay (td > 0 s) : 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 •...
Page 45
LED display Cause of the fault Troubleshooting • Connection A2/A3 reversed ► Check wiring • Missing link Y4/Y5 ► Check wiring • Overvoltage ► Check wiring • Undervoltage ► Check power supply • Overvoltage ► Check wiring • Undervoltage ► Check power supply •...
Page 46
LED display Cause of the fault Troubleshooting • Short circuits ► Check wiring • The rotary switch for ► Program it again (→ 9.1) programming the switch-off delay was changed • Faulty programming...
9 Programming In all described operating modes (8.1 - 8.5) a switch-off delay for the relay outputs on terminals C5 and C6 can be set� 9.1 Programming of the switch-off delay ► Set the rotary switch to position F� ► Switch the unit off and on again� >...
EPS Source Product Scale Drawing Frame Size: 80 mm x 45 mm 11 Technical data G1502S Safety relay with relay outputs Terminal block Phoenix Contact MSTBO Meets the requirements of: EN ISO 13849-1: 2008+AC2009, category 4 PL e, SIL 3 (IEC 61508)
Page 49
Contact rating 6 A , 250 V AC / 24 V DC (≥ 6 mA) max� total current: 12 A Minimum load current of the 10 mA feedback contacts Short-circuit protection / overload The contacts are to be protected by means of fuses protection with a nominal current of <...
= 365 days, t = 3600 s cycle 12 Tests/approvals The G1502S safety relay was tested and certified by TÜV-Nord� The safety relay was developed and tested in accordance with, for example, the following directives and standards: • 2006/42/EC Machinery Directive •...
Probability of (dangerous) Probability of a (dangerous) failure per (PFH Failure per Hour hour� Performance Level PL to EN ISO 13849-1 Safety Integrity Level SIL 1-4 to IEC 61508 Programmable Logic Controller Technical data and further information at www�ifm�com...