1. Introduction
The Weldmuller WSR-ES1-3O1C-S is a high-performance safety relay designed for monitoring safety functions in industrial applications. It is certified for safety integrity levels up to SIL3, PL e, and Cat.4 according to ISO 13849, making it suitable for critical safety circuits involving E-Stop buttons and safe gates. This manual provides essential information for the safe and effective installation, operation, and maintenance of the device.
2. Setup and Wiring
Proper installation and wiring are crucial for the safe and reliable operation of the WSR-ES1-3O1C-S safety relay. Ensure all power is disconnected before beginning installation.
2.1. Power Supply Connection
- Connect the power supply to terminals A1+ and A2-.
- The relay operates with a supply voltage of 24V DC/AC, with a tolerance of -15% to +10%.
2.2. Input Device Connection
The safety relay is designed to monitor input devices such as E-Stop buttons and safe gates.
- Connect input devices to terminals S11, S12, S21, S22, S34, S52 as per the application's safety circuit design. Refer to Figure 2 for the internal circuit representation.
- Ensure that the input devices are correctly wired to provide the necessary feedback for the safety function.
2.3. Output Connection
The relay provides multiple output contacts for controlling machinery or signaling status.
- Safety Outputs: Connect safety-related loads to terminals 13-14, 23-24, 33-34. These are Normally Open (NO) contacts.
- Auxiliary Output: Connect auxiliary loads or signaling devices to terminals 41-42. This is a Normally Closed (NC) contact.
- The output contacts have a drive capability of AC-15, 5A/230V and DC-13, 6A/24V. The maximum output is 250VAC/24VDC@5A.
2.4. Reset Function
The relay supports both automatic and manual reset modes. The specific configuration depends on the wiring of the reset circuit (RST terminals S34, S21, S22, S11).
- For Auto Reset, ensure the reset circuit is configured to automatically clear faults.
- For Manual Reset, a momentary push-button connected to the reset circuit is typically used to acknowledge and clear faults after the safety circuit is restored.
3. Operating Instructions
Once correctly installed and wired, the WSR-ES1-3O1C-S safety relay operates by monitoring the state of connected safety input devices and controlling its output contacts accordingly.
3.1. Normal Operation
- When all safety input conditions are met (e.g., E-Stop not pressed, safe gate closed), the safety outputs (13-14, 23-24, 33-34) will close, allowing power to flow to connected machinery.
- The auxiliary output (41-42) will open, indicating the safe state.
3.2. Safety Event Response
- If a safety input device is activated (e.g., E-Stop pressed, safe gate opened), the relay will de-energize its safety outputs within a response time of ≤30ms, bringing the connected machinery to a safe stop.
- The auxiliary output will return to its closed state.
3.3. Resetting the Relay
- After a safety event, the cause of the event must be resolved.
- Depending on the configured reset mode (Auto/Manual), the relay will either automatically reset or require a manual reset action to re-energize the safety outputs.
- Switch ON delay: ≤300ms after reset.
- Switch OFF delay: ≤30ms upon activation of a safety input.
4. Maintenance
The Weldmuller WSR-ES1-3O1C-S safety relay is designed for long-term, reliable operation with minimal maintenance. However, periodic checks are recommended to ensure continued safety and performance.
- Visual Inspection: Regularly inspect the relay and its wiring for any signs of damage, loose connections, or corrosion.
- Functional Testing: Periodically test the safety function by activating the connected E-Stop buttons or safe gates to ensure the relay responds correctly and de-energizes the outputs.
- Cleaning: Keep the device free from dust and debris. Use a soft, dry cloth for cleaning. Do not use abrasive cleaners or solvents.
- Environmental Conditions: Ensure the operating environment remains within the specified temperature range of -20°C to +60°C and free from excessive humidity or corrosive atmospheres.
Any maintenance or repair work should only be performed by qualified personnel.
5. Troubleshooting
If the safety relay does not function as expected, consider the following troubleshooting steps:
| Problem | Possible Cause | Solution |
|---|---|---|
| Relay does not energize outputs |
|
|
| Relay does not reset |
|
|
| Outputs de-energize unexpectedly |
|
|
If problems persist after following these steps, contact technical support.
6. Specifications
| Parameter | Value |
|---|---|
| Model | WSR-ES1-3O1C-S |
| Part Number | 2825510000 |
| Input Voltage (Supply A1+, A2-) | 24V DC/AC (-15% ~ +10%) |
| Input Devices | E-Stop Button, Safe Gate |
| Safety Outputs | 3 NO (Normally Open) |
| Auxiliary Output | 1 NC (Normally Closed) |
| Output Drive Capability (AC) | AC-15, 5A/230V |
| Output Drive Capability (DC) | DC-13, 6A/24V |
| Max Output | 250VAC/24VDC@5A |
| Response Time | ≤30ms |
| Switch ON Delay | ≤300ms |
| Switch OFF Delay | ≤30ms |
| Reset Type | Auto/Manual reset |
| Operating Temperature | -20°C to +60°C |
| Certifications | TÜV Rheinland, SIL3 SC3, PL e, Cat.4, ISO 13849, CE |
| Dimensions (L x W x H) | 10 cm x 5 cm x 5 cm (approximate package dimensions) |
| Weight | 0.2 kg (approximate package weight) |
7. User Tips
- Always double-check wiring against the provided diagram before applying power to prevent damage or unsafe conditions.
- Regularly test the entire safety circuit, including the relay and connected input devices, to ensure proper functionality and compliance with safety standards.
- Keep the relay's ventilation clear to ensure optimal operating temperature and longevity.
8. Warranty and Support
For warranty information, technical support, or service inquiries, please refer to the official Weidmuller documentation or contact your authorized distributor. Ensure you have the model number (WSR-ES1-3O1C-S) and part number (2825510000) available when seeking support.
