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Zander Aachen TETHYS IP65 Operating Instructions Manual

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TETHYS IP65
Operating instructions
English translation - Errors and technical changes reserved.
Decentralized safety relay and safe coupling relay
with forcibly guided relay contacts and IP65 rating

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Summary of Contents for Zander Aachen TETHYS IP65

  • Page 1 TETHYS IP65 Operating instructions English translation - Errors and technical changes reserved. Decentralized safety relay and safe coupling relay with forcibly guided relay contacts and IP65 rating...

  • Page 2: Table Of Contents

    TETHYS IP65 About this document ....................4 1.1 Validity ..........................4 1.2 Supplementary documents....................4 1.3 Target group ........................4 Features ........................5 Variant selection ......................6 3.1 Coding key .......................... 7 Safety instructions ....................... 8 Intended use ....................... 8 Exclusion of liability and warranty ................
  • Page 3 17.1 Operating altitude up to 2000m ..................35 17.2 Operating altitude over 2000 m ..................46 Pin assignment and flange configuration ..............47 18.1 TETHYS IP65 SR - PAS ......................47 18.2 TETHYS IP65 SR - PDS ......................48 18.3 TETHYS IP65 SR - OAS ......................49 18.4 TETHYS IP65 SR - ODS .......................

  • Page 4: About This Document

    TETHYS IP65 SR - PDS 478010 TETHYS IP65 SR - OAS 478100 TETHYS IP65 SR - ODS 478110 TETHYS IP65 SR - C NN Customized - 4783NN TETHYS IP65 KR - S 478200 TETHYS IP65 KR - C NN Customized - 4783NN 1.2 Supplementary documents...

  • Page 5: Features

    TETHYS IP65 2 Features Decentralized emergency-stop safety relay for safety-related stop functions • 3 safe, redundant, forcibly guided relay contacts • 1 NC auxiliary contact • 1 auxiliary output PNP • Supported safety sensors: − Safety sensors with potential-free contacts −...

  • Page 6: Variant Selection

    The TETHYS IP65 is available in different versions. These differ in terms of function, pin assignment and flange coding. To make it easier to select your TETHYS IP65, follow the four steps below and select the desired configuration in each case.

  • Page 7: Coding Key

    TETHYS IP65 3.1 Coding key The various standard configurations of the TETHYS IP65 are coded according to the following key: TETHYS IP65 FUNCTION - SENSOR/START/VOLTAGE Parameters Code Description Safety relay - independent operation and evaluation of safety sensors FUNCTION Safe coupling relay - actuation by safety relay or safe control system...

  • Page 8: Safety Instructions

    5 Intended use The TETHYS IP65 is a safety relay that can be used to shut down the moving parts of a machine or system quickly and safely in the event of danger. The TETHYS IP65 has been specially designed and type-tested for use on machines and systems as well as combustion systems in continuous operation in accordance with EN 50156-1 and EN ISO 13577-2.

  • Page 9: Exclusion Of Liability And Warranty

    ATTENTION! We would like to point out that ensuring system availability is the sole responsibility of the operator. With the use of the TETHYS IP65, a safety switching device in accordance with • EN ISO 13849-1 •...

  • Page 10: Functions

    8 Functions The TETHYS IP65 safety relay is designed for the safe isolation of safety circuits in accordance with EN 60204-1 and can be used in safety applications up to PL e, Cat. 4 (EN ISO 13849-1) or SIL 3 (EN 61508). It can be used in combustion systems in continuous operation in accordance with EN 50156-1 and EN ISO 13577-2, please refer to the information in section 16.

  • Page 11: Functions Of The Power Supply

    8.7 Functions of the LED Three LEDs are installed to indicate the status of the TETHYS IP65. PWR lights up green when supply voltage is applied to A1. No check for correct voltage range is carried out. K1 and K2 indicate the status of the internal channels. If there is no internal fault, these LEDs indicate the switching status of the safety contacts.

  • Page 12: Assembly

    TETHYS IP65 Assembly 9.1 Mounting instructions The following instructions must be observed to ensure error-free installation. • The surface must be level to avoid mechanical stresses on the housing. Mechanical stresses can damage the appliance and jeopardize its functional safety.

  • Page 13: Fastening

    TETHYS IP65 9.3 Fastening The device is attached to the carrier medium via two screw points. The screws must be selected depending on the carrier medium and are not included in the scope of delivery. Use washers. If strong mechanical vibrations or shocks are expected, use safety washers.

  • Page 14: Electrical Connection

    The dimensioning of the fuses depends on the application and the technical data in section 17. ATTENTION! The TETHYS IP65 is not protected against static voltages greater than 60 VDC! The power supply unit for the supply must meet the requirements for safe extra-low voltage (SELV/PELV) and be designed with reinforced insulation to the supply grid.

  • Page 15: Connection Of The Safety Circuit - Sr Variants

    SIL-dependent upper limit. To achieve a PL or SIL level (e.g. PL e / SIL 3), qualified sensors and a correspondingly safe control system are required. The selection, assessment and use of these sensors is the responsibility of the user. The safety characteristics of the TETHYS IP65 can be found in section 15. ATTENTION! When using tactile sensors, a maximum short-circuit resistance of the entire arrangement between S11/S12 and S10/S13 must be observed in accordance with section 17.
  • Page 16 See section 17. wire detection automatically. Ground fault is monitored by the TETHYS IP65. Hermann ZANDER GmbH & Co KG - Am Gut Wolf 15 - 52070 Aachen - Germany - Tel +49 241 9105010...
  • Page 17 For applications in accordance with Figure 8 and Figure 12, it must be ensured that the reference potential of the sensor or fail-safe base unit and the TETHYS IP65 is the same. Hermann ZANDER GmbH & Co KG - Am Gut Wolf 15 - 52070 Aachen - Germany - Tel +49 241 9105010...

  • Page 18: Connection Of The Start Circuit - Sr Variants

    ATTENTION! When the safety circuit is closed, the TETHYS IP65 starts automatically as soon as the supply voltage is applied! This also applies in the case where the current flow is restored by the overcurrent protection after a short circuit event.
  • Page 19 The TETHYS IP65 is started via an falling edge at S21. By using a falling edge, the correct function of the start button is monitored and unwanted starts are prevented. For error-free switch-on, a voltage level of 24 VDC must be applied to S21 for at least 5 ms before the falling edge.

  • Page 20: Connecting The Power Supply - Sr Variants

    The power supply of 24 VDC is applied to the TETHYS IP65 SR via pin 1 (A1). If the supply voltage is correct, the PWR LED lights up green. The device is now ready for operation.

  • Page 21: Connection To Fail-Safe Base Unit - Kr Variant

    The control voltage of 24 VDC is applied to the TETHYS IP65 KR via pin 1 (A1). If the control voltage is applied, the device is activated and the safety contacts close. Test pulses at A1 are tolerated in accordance with the technical data in section 17.

  • Page 22: Connecting The Load - All Variants

    Before connecting the load, carry out commissioning in accordance with section 11.1 or 11.2 to check the correct behavior of the TETHYS IP65. Defective devices can lead to property damage and personal injury! Three potential-free safety contacts are available. There is reinforced insulation between the three contacts (6000V, OVC III), allowing them to safely switch off any combination of low- and high-voltage signals.
  • Page 23 TETHYS IP65 The fuses and the load must be connected in accordance with Figure 16. V1-V3 can be freely selected within the technical specification. See section 17. Figure 16 : Connection of the load Hermann ZANDER GmbH & Co KG - Am Gut Wolf 15 - 52070 Aachen - Germany - Tel +49 241 9105010...

  • Page 24: Notes On The Auxiliary Contact And Auxiliary Output - All Variants

    TETHYS IP65 10.7 Notes on the auxiliary contact and auxiliary output - All variants Notes on the auxiliary contact The NC auxiliary contact is designed as a potential-free contact and indicates the switching status of the device. As it is a potential-free contact, the control unit must apply a signal to 41 and can thus read out the switching status at The signal applied to 41 is forwarded to 42 if the device is in a safe state or has not switched faultlessly.

  • Page 25: Commissioning

    TETHYS IP65 Commissioning 11.1 Commissioning – function variant SR ATTENTION! All the safety instructions described above apply. To commission the SR function variant, follow the procedure described. After the procedure and if errors occur, please refer to section 11.3. 1. Connecting the safety circuit Connect the safety circuit in accordance with section 10.2.

  • Page 26: Commissioning - Function Variant Kr

    TETHYS IP65 11.2 Commissioning – function variant KR ATTENTION! All the safety instructions described above apply. To commission the KR function variant, follow the procedure described. After the procedure and if errors occur, please refer to section 11.3. 1. Connecting the feedback loop If your application requires external contactors or expansion modules, connect them according to Figure 13 or Figure 14.

  • Page 27: Troubleshooting

    Some errors can be rectified by the user. If the error is still present even after attempting to rectify it, there may be an internal device error. In this case, please contact our team. ATTENTION! Opening the TETHYS IP65 is not permitted and will invalidate the warranty in any case. 12.1 Troubleshooting - function variant KR Error image...

  • Page 28: Troubleshooting - Function Variant Sr

    TETHYS IP65 12.2 Troubleshooting - function variant SR Error image Possible cause Approaches to troubleshooting Device does not switch Connection or Check the electrical connection according to section 10. faulty supply Check the supply voltage at A1. Device only switches on...

  • Page 29: Activated Overcurrent Protection

    TETHYS IP65 Error image Possible cause Approaches to troubleshooting PWR LED lights up, Connection faulty Check the electrical connection device does not according to section 10. respond Make sure that the safety circuit and, if used, the feedback circuit are closed.

  • Page 30: Inspection, Maintenance And Replacement

    13.2 Maintenance The TETHYS IP65 is designed for a service life of 20 years, maintenance work on the device itself is not required. The decommissioning of a device is the responsibility of the user; decommissioned devices must be disposed of in accordance with the applicable regulations or submitted to us for testing.

  • Page 31: Proof Test

    TETHYS IP65 Proof test The following steps must be carried out to check that the device is working properly: • Trigger the safety function via the safety circuit. Check that the safety contacts (13-14; 23-24; 33-34) have been opened by triggering the safety function.

  • Page 32: Safety Characteristics

    TETHYS IP65 Safety characteristics 15.1 Safety characteristics according to EN ISO 13849-1 Load - AC-15/DC-13 ≤ 1A / ≤ 1A ≤ 2A / ≤ 2A ≤ 5A / ≤ 5A Max. Operating time [years] Category PFHd [1/h] 1.2E-8 1.2E-8 1.2E-8 Nop [cycl./year] - AC-15/DC-13...

  • Page 33: Safety Parameters For The Process Industry

    TETHYS IP65 15.3 Safety parameters for the process industry Safety parameters as an alternative 1oo1 structure for the process industry - High Demand Assumptions: Operating days/year: 365; Operating hours/day: 24; Switching frequency/hour: 1; Full load AC-15 / DC-13 5A Device type SFF [%] 99.97%...

  • Page 34: Notes On Application Standards

    The characteristic values according to IEC 61508 - High Demand specified in the section 15.2 apply to a test interval of up to 1 month (31 days). The TETHYS IP65 can therefore be used, for example, in systems where uninterrupted operation does not last longer than 1 month.

  • Page 35: Technical Data

    TETHYS IP65 Technical data 17.1 Operating altitude up to 2000m General Certifications CE, TÜV Rheinland, cULus Listed* *Certification not yet completed Electrical data Voltage variant -S Supply voltage A1/A2 Nominal voltage 24 V Form Tolerance -15% / +10% Power 2.4W, typ.
  • Page 36 TETHYS IP65 Safety circuit input Quantity 1 two-channel, safe input Control voltage Voltage 24 V Form Tolerance -15% /+ 10% Destruction limit 30 VDC Power on Channel A (S12) 50 mA, typ. at 24 VDC Channel B (S13, S14) 50 mA, typ. at 24 VDC Short-circuit resistance, overall structure 50 Ω, max.
  • Page 37 TETHYS IP65 Safety contacts Quantity 3 safe non-delayed relay contacts (NO) Switching frequency 6 min , max. Switching capacity 2000 VA, 250V, 8A for AC-1 120 W, 300V, 0.4 A for DC-1 320 W, 40V, 8A for DC-1 Utilization category AC-1...
  • Page 38 TETHYS IP65 Safety contacts - Derating Derating Distance to neighboring device min. 10 mm Max. Total current 108 A² Max. Current via one contact 8 A, other contacts according to max. total current Max. Current via three contacts 6 A each...
  • Page 39 TETHYS IP65 Auxiliary contact Quantity 1 relay contact (NC) Switching frequency max. 6 min Switching capacity 60 VA / 60 VAC, max. 24 W / 24 VDC, max. Utilization category AC-1 According to standard IEC 60947-4-1 At switching voltage 24 VAC Switching current, min.
  • Page 40 TETHYS IP65 Auxiliary output Quantity 1 semiconductor signal output Type Output voltage Voltage Form Tolerance -15% Output current 100 mA, max. Reverse polarity protected Short-circuit proof Fuse Internal to A1 500 mA, PPTC Utilization category according to IEC 60947-1 DC-12...
  • Page 41 TETHYS IP65 Timing Switch-on delay, typ. Conditions: 24 VDC at A1, T = 21°C 35 ms S12/S13 25 ms S12/S14 25 ms Switch-on delay, max. Conditions: min. A1, max. T 100 ms S12/S13 50 ms S12/S14 50 ms Switch-off delay, typ.
  • Page 42 TETHYS IP65 Environmental data Temperature range T Standard EN 60068-2-14 Storage and transportation -40 to 70 °C Operation -25 to 65 °C Moisture ≤ 93 % r. H. from 40 °C Cyclical temperature/humidity test Standard EN 60068-2-38 Condensation during operation...
  • Page 43 TETHYS IP65 Environmental data - EMC Product standard DIN EN 61326-3-1 Standard DIN EN 61000-4-2 Discharge onto metal parts 6 kV, pos. and neg. Discharge via coupling plate 6 kV, pos. and neg., all sides, vertical and horizontal Discharge onto housing 8 kV, pos.
  • Page 44 TETHYS IP65 Electrical isolation according to EN 60664-1 Signal networks - SELV/PELV Voltage, typ. 24 VDC Voltage, max. 60 VDC Type of insulation Basic Overvoltage category Rated impulse voltage 1000 V Creepage and clearance distance, min. 0.2 mm Signals A1, A2, S10, S11, S12, S13, S14, S20, S21, C1 Signal contacts - SELV/PELV Voltage, typ.
  • Page 45 TETHYS IP65 Mechanics Orientation Mounting type screwed Connection type Dimensions Height 59.3 mm Width 86.4 mm Length 190.2 mm Weight approx. 320 g Material Housing Front foil Fastening straps M12 flanges Zinc die-cast, nickel-plated Flammability Housing UL94 V-0 Front foil...

  • Page 46: Operating Altitude Over 2000 M

    TETHYS IP65 17.2 Operating altitude over 2000 m All technical data apply to the use of the TETHYS IP65 up to an altitude of 2000 m above sea level. ATTENTION! Above an operating altitude of 2000 m, there is no safe separation between the safety contacts and SELV/PELV networks in accordance with overvoltage category III.

  • Page 47: Pin Assignment And Flange Configuration

    TETHYS IP65 Pin assignment and flange configuration 18.1 TETHYS IP65 SR - PAS Pin assignment X1 - TETHYS IP65 SR - PAS Pin 1 24 VDC power supply Pin 2 NC auxiliary contact, potential-free, Highside Pin 3 0 VDC Power supply...

  • Page 48: Tethys Ip65 Sr - Pds

    TETHYS IP65 18.2 TETHYS IP65 SR - PDS Pin assignment X1 - TETHYS IP65 SR - PDS Pin 1 24 VDC power supply Pin 2 NC auxiliary contact, potential-free, Highside Pin 3 0 VDC Power supply Pin 4 Auxiliary output 24 VDC...

  • Page 49: Tethys Ip65 Sr - Oas

    TETHYS IP65 18.3 TETHYS IP65 SR - OAS Pin assignment X1 - TETHYS IP65 SR - OAS Pin 1 24 VDC power supply Pin 2 NC auxiliary contact, potential-free, Highside Pin 3 0 VDC Power supply Pin 4 Auxiliary output 24 VDC...

  • Page 50: Tethys Ip65 Sr - Ods

    TETHYS IP65 18.4 TETHYS IP65 SR - ODS Pin assignment X1 - TETHYS IP65 SR - ODS Pin 1 24 VDC power supply Pin 2 NC auxiliary contact, potential-free, Highside Pin 3 0 VDC Power supply Pin 4 Auxiliary output 24 VDC...

  • Page 51: Tethys Ip65 Kr - S

    TETHYS IP65 18.5 TETHYS IP65 KR - S Pin assignment X1 - TETHYS IP65 KR - S Pin 1 24 VDC control voltage Pin 2 NC auxiliary contact, potential-free, Highside Pin 3 0 VDC Reference potential Pin 4 Auxiliary output 24 VDC...
  • Page 52 TETHYS IP65 Zander GmbH & Co KG Am Gut Wolf 15 52070 Aachen, Germany info@zander-aachen.de www.zander-aachen.de Part No.: E61-600-00 Issue: T05 Ver. A This document is the original document. Errors and technical subject to change without notice. Hermann ZANDER GmbH & Co KG - Am Gut Wolf 15 - 52070 Aachen - Germany - Tel +49 241 9105010...

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