Schneider Electric XPS-AC Safety Relay

Product Overview

The XPS-AC safety relay provides reliable monitoring for emergency stop circuits and protective door circuits. It is designed to meet stringent safety requirements in industrial automation, ensuring the safety of personnel, machinery, and materials.

• Complies with EN/IEC 60204-1, EN ISO/ISO 13849-1, and EN ISO/ISO 13850 standards.
• Achieves Performance Level (PL) e and Safety Category 3 according to EN ISO/ISO 13849-1.
• Offers SILCL 3 safety integrity level according to EN 62061.
• Supports Stop Category 0 as per EN/IEC 60204-1.
• Features manual or automatic start modes.
• Provides 3 safety outputs and 1 signaling output.
• Includes a feedback loop for monitoring external contactors.

Safety Information and Precautions

DANGER: HAZARDOUS VOLTAGE

• Installation, startup, modification, and retrofitting must only be performed by qualified electricians.
• Always disconnect the device/system from all power sources before starting any work.
• Failure to follow these instructions can result in death or serious injury.

CAUTION: UNINTENDED USE

• Improper or incorrect use renders the device unusable and voids the warranty.
• Avoid conditions such as strong mechanical stress, voltages, currents, temperatures, or humidity outside specified limits.
• Always check safety functions according to regulations before initial machine startup and observe specified test cycles.
• Failure to follow these instructions can result in injury or equipment damage.

CAUTION: RISKS ON INSTALLATION

• Disconnect supply voltage and lockout/tagout the equipment before installation.
• Confirm absence of voltage, ground phases, and protect adjacent live components.
• Install devices in an electrical cabinet with a protection class of at least IP 54.
• Failure to follow these instructions can result in injury or equipment damage.

CAUTION: LIMITED CONTACT PROTECTION

• Protection type according to EN/IEC 60529.
• Housing/terminals: IP40 / IP20.
• Finger-proof according to EN 50274.
• Failure to follow these instructions can result in injury or equipment damage.

RESIDUAL RISK (EN ISO/ISO 12100-1)

• While wiring diagrams are tested, residual risks may remain if:
• The circuit concept is modified without proper integration of new components.
• The user fails to adhere to safety regulations for operation, adjustment, and maintenance.
• Devices connected to safety outputs lack mechanically-linked contacts.
• Failure to follow these instructions can result in injury or equipment damage.

Device Description and Function

The XPS-AC receives supply voltage via the normally closed (NC) contacts of Emergency Stop buttons connected to terminals A1/A2. A feedback loop is established between terminals Y1 and Y2, in series with the START button and the NC contacts of external safety relays. This ensures the device only starts if external contactors have reset after an E-stop command.

When the Emergency Stop is deactivated, the 'A1/A2' LED is lit. Activating the START button energizes internal relays (K1, K2) and switches the three safety outputs (13-14, 23-24, 33-34) and the transistor output (Y43-Y44). Both 'A1/A2' and 'K1/K2' LEDs illuminate. Activating an Emergency Stop button immediately opens the output circuits and extinguishes both LEDs.

The device is intended for monitoring safety sensors such as E-stop buttons and position switches as part of machine safety equipment.

Technical Specifications

Dimensions and Connections

XPS-AC....

• Single Wire Connection:
  • Rigid/Stranded: 0.14-2.5 mm² (AWG 26-14)
  • Stripping Length: 7 mm
  • Flexible with cable end (without/with plastic sleeve): 0.25-2.5 mm² / 0.25-1.5 mm²
  • Tightening Torque (min): 0.5 Nm
• Multiple Wire Connection (max 2 wires):
  • Without cable end (rigid/stranded): 0.14-0.75 mm² (AWG 26-20)
  • Stripping Length: 7 mm
  • Flexible with cable end (without plastic sleeve): 0.25-1 mm²
  • Flexible with TWIN-cable end (with plastic sleeve): 0.5-1.5 mm²
  • Tightening Torque (min): 0.5 Nm

XPS-AC....P

• Single Wire Connection:
  • Rigid/Stranded: 0.2-2.5 mm² (AWG 24-12)
  • Stripping Length: 7 mm
  • Flexible with cable end (without/with plastic sleeve): 0.25-2.5 mm² / 0.25-1.5 mm²
  • Tightening Torque (min): 0.5 Nm
• Multiple Wire Connection (max 2 wires):
  • Without cable end (rigid/stranded): 0.2-1 mm² / 0.2-1.5 mm² (AWG 24-18 / 24-16)
  • Stripping Length: 7 mm
  • Flexible with cable end (without plastic sleeve): 0.25-1 mm²
  • Flexible with TWIN-cable end (with plastic sleeve): 0.5-1.5 mm²
  • Tightening Torque (min): 0.5 Nm

Mounting and Environmental

• Mounting: On 35 mm DIN rail according to EN/IEC 60715.
• Degree of Protection: Terminals IP20, Enclosure IP40.
• Weight: Approx. 0.21 kg (115V/230V, 48V), 0.16 kg (24V).
• Mounting Position: Any.
• Ambient Operating Temperature: -10°C to +55°C.
• Overvoltage Category: III (4kV).
• Pollution Degree: 2.
• Rated Insulation Voltage: 300V (EN/IEC 60664-1).

Electrical Specifications

• Supply Voltage (UE): 230V AC, 115V AC, 48V AC, 24V AC, 24V DC (with specified tolerances).
• Max. Protection: 4A gG fuse.
• Power Consumption: Varies by voltage version (e.g., 2.1 VA for 230V AC).
• Safety Outputs (13-14, 23-24, 33-34): Potential-free.
• Cumulative Current Limit: Σ Ith ≤ 10.5 A.
• Output Protection: Max. 4A gG or 6A fastblow fuse.
• Max. Switching Capacity: AC15 (230V/0.75A), DC13 (24V/2A).
• Mechanical Service Life: 10 x 10⁶ operations.
• Transistor Output (Y43-Y44): Normally Open (NO), contactless; typically 24V DC / 20mA.
• Response Time: ≤ 100 ms.
• Feedback Circuit Resistance: Max. 50 Ω between Y1 and Y2.

Diagrams and Indicators

Dimensions

Diagrams illustrate the physical dimensions of the XPS-AC...P module, showing a height of 99 mm (3.89 in), width of 35 mm (1.38 in), and depth of 114 mm (4.48 in). A smaller dimension of 22.5 mm (0.89 in) is also indicated.

Terminal Marking

Diagrams show the terminal layout for XPS-AC... and XPS-AC...P modules, including power inputs (A1, A2), feedback loop (Y1, Y2), safety outputs (13-14, 23-24, 33-34), signaling output (Y43-Y44), PE terminal, and internal relay indicators (K1, K2).

Front View and LEDs

The front panel features LEDs for system diagnostics: 'A1/A2 - Fuse' (indicating supply voltage presence) and 'K1/K2' (indicating the status of safety outputs). These LEDs are typically green.

Wiring Diagrams

Two wiring diagrams are provided:

• Diagram 1: Illustrates the connection of the XPS-AC with an Emergency Stop button using two NC contacts (recommended configuration) and a START button (S2). It details the connection of power supply, E-stop, START button, feedback loop (Y1-Y2), safety outputs, signaling output, PE terminal, and external contactors (K4, K5) via fuses.
• Diagram 2: Shows a similar wiring setup for an Emergency Stop button with a single NC contact.

Key labels in the diagrams include:

• ESC: External start conditions.
• (1): Indicates 3 safety outputs.
• (2): Indicates 1 transistor output.
• (3): Refers to Technical Data for maximum fuse ratings.
• (4): Indicates Y1-Y2 jumper for automatic start.

A DANGER: HAZARDOUS VOLTAGE warning is prominently displayed.

Functional Diagrams

Functional timing diagrams illustrate the module's operation:

• With START Button: Shows the sequence of events from Supply On, Emergency Stop deactivated, START button pressed, to Emergency Stop activated. It tracks the state changes of inputs (E-stop A1/A2), feedback loop (Y1-Y2), and outputs (13-14, 23-24, 33-34, Y43-Y44).
• Without START Button: Depicts operation with a jumpered Y1-Y2 for automatic start, showing similar input/output state changes during E-stop activation/deactivation.

A legend indicates states as 'Activé' (On) and 'Désactivé' (Off).

Electrical Life Graph

The electrical life graph plots operation cycles against switching current (x 0.1A) for various load types (AC15, DC13, AC1, DC1) and voltages. This graph is used to determine the maximum number of switching cycles permissible for a given load, ensuring the specified performance level is maintained.

Compliance and Declarations

The document includes EC Declarations of Conformity in French, English, and German. These declarations confirm that the XPS-AC safety relay complies with relevant European directives, including the Low Voltage Directive (2006/95/EC), Electromagnetic Compatibility Directive (2004/108/EC), and Machinery Directive (98/37/EC, 2006/42/EC). Compliance is stated with harmonized European standards such as EN 60204-1, EN ISO 13849-1, EN 62061, and others. A notified body (TÜV NORD CERT GMBH) has issued a positive declaration. Compliance is conditional upon correct installation, maintenance, and use according to the manufacturer's instructions and applicable regulations.