LS ELECTRIC XSR Series Safety Relay

Safety Instructions

For your safety and effective operation, please read the safety instructions thoroughly before using the product.

Safety instructions should always be observed to prevent accidents or risks with the safe and proper use of the product.

Instructions are separated into "Warning" and "Caution", and the meaning of the terms is as follows:

Warning

[Warning Symbol] This symbol indicates the possibility of serious injury or death if an applicable instruction is violated.

Caution

[Caution Symbol] This symbol indicates the possibility of slight injury or damage to products if an applicable instruction is violated.

The marks displayed on the product and in the user's manual have the following meanings:

• [Danger Symbol] Be careful! Danger may be expected.
• [Electric Shock Symbol] Be careful! Electric shock may occur.

The user's manual shall be kept available and accessible to any user of the product, even after reading.

Safety Instructions When Designing

Warning

• Install protection circuits on the exterior of the RELAY to protect the whole control system from any error in external power or the RELAY module. Any abnormal output or operation may cause serious problems in the safety of the whole system.
• Install applicable protection units on the exterior of the RELAY to protect the system from physical damage, such as emergency stop switches, protection circuits, upper/lowest limit switches, and forward/reverse operation interlock circuits.
• If any system error (watch-dog timer error, module installation error, etc.) is detected during CPU operation in the RELAY, the whole output is designed to be turned off and stopped for system safety. However, if a CPU error caused by an output device itself (such as a relay or TR) cannot be detected, the output may remain on, which may cause serious problems. Therefore, it is recommended to install an additional circuit to monitor the output status.
• Never connect an overload greater than the rated capacity to the output module, nor allow the output circuit to have a short circuit, which may cause a fire.
• Never let the external power of the output circuit be designed to be on earlier than the RELAY power, which may cause abnormal output or operation.
• In case of data exchange between a computer or other external equipment and the RELAY through communication or any operation of the RELAY (e.g., operation mode change), install an interlock in the sequence program to protect the system from any error. If not, it may cause abnormal output or operation.

Caution

• I/O signal lines shall be wired at least 100mm away from high-voltage cables or power lines. Failure to do so may cause abnormal output or operation.
• Use the RELAY only in the environment specified in the RELAY manual or general data sheet. Otherwise, electric shock, fire, abnormal operation of the product, or flames may be caused.
• Before installing the module, ensure the RELAY power is off. Failure to do so may cause electric shock or damage to the product.
• Ensure that each module of the RELAY is correctly secured. If the product is installed loosely or incorrectly, abnormal operation, error, or dropping may occur.
• Ensure that I/O or extension connectors are correctly secured. Failure to do so may cause electric shock, fire, or abnormal operation.
• If significant vibration is expected in the installation environment, do not let the RELAY be directly vibrated. This may cause electric shock, fire, or abnormal operation.
• Do not allow any metallic foreign materials inside the product, as this may cause electric shock, fire, or abnormal operation.

Safety Instructions When Wiring

Warning

• Prior to wiring, ensure that the power of the RELAY and external power is turned off. Failure to do so may cause electric shock or damage to the product.
• Before the RELAY system is powered on, ensure that all terminal covers are securely closed. Failure to do so may cause electric shock.

Caution

• Ensure wiring is installed correctly after checking the voltage rating of each product and the arrangement of terminals. Failure to do so may cause fire, electric shock, or abnormal operation.
• Secure terminal screws tightly with the specified torque when wiring. If terminal screws become loose, short circuits, fire, or abnormal operation may occur.
• Use the ground wire of Class 3 for PE terminals, which is exclusively used for the RELAY. If terminals are not grounded correctly, abnormal operation may occur.
• Do not allow any foreign materials, such as wiring waste, inside the module during wiring, as this may cause fire, damage to the product, or abnormal operation.

Safety Instructions for Test-Operation or Repair

Warning

• Do not touch the terminals when powered. Electric shock or abnormal operation may occur.
• Prior to cleaning or tightening terminal screws, turn off all external power, including the RELAY power. Failure to do so may cause electric shock or abnormal operation.
• Do not recharge, disassemble, heat, short, or solder batteries. Heat, explosion, or ignition may cause injuries or fire.

Caution

• Do not remove the PCB from the module case or remodel the module. Fire, electric shock, or abnormal operation may occur.
• Prior to installing or disassembling the module, turn off all external power, including the RELAY power. Failure to do so may cause electric shock or abnormal operation.
• Keep any wireless installations or cell phones at least 30cm away from the RELAY. Failure to do so may cause abnormal operation.

Safety Instructions for Waste Disposal

Caution

• Product or battery waste shall be processed as industrial waste. The waste may discharge toxic materials or explode.

Precautions for Building a Safety System

Caution

• Please ensure that all tasks related to building a safety system (design, installation, operation, maintenance, etc.) are conducted by technicians who have received sufficient education and training on safety standards and the system.
• For devices and components related to safety functions connecting to safety input/output modules, use products that meet the required safety level and category specifications.
• Before the system is operational, conduct a test run to ensure that all safety devices operate correctly according to expected functions, and complete the safety verification.
• Make sure the system does not operate without safety verification. There is a risk of severe injury to people if the safety functions are compromised.
• Confirm that the calculated safety response time meets the required specifications. There is a risk of severe injury to people if the safety functions are compromised.
• Do not use non-safe signals and data for controlling safety-related functions. There is a risk of severe injury to people if the safety functions are compromised.
• Do not use the LED of safety modules for controlling safety-related functions. There is a risk of severe injury to people if the safety functions are compromised.
• The responsibility for compliance of the entire established safety system falls on the customer.

Revision History

About User's Manual

Thank you for purchasing PLC of LS ELECTRIC Co., Ltd. Before use, make sure to carefully read and understand the User's Manual regarding the functions, performances, installation, and programming of the product. It is important to provide the User's Manual to the end user and maintenance administrator.

The User's Manual describes the product. If necessary, refer to the following description and order accordingly. You may also connect to the LS ELECTRIC website (https://ssq.ls-electric.com/) to download information as a PDF file.

Chapter 1 Introduction

1.1 How to Use this User's Manual

This user's manual provides information on the specifications, performance, functions, and operation required for using the XSR Series Safety Relay. The constitution of the user's manual is as follows:

1.2 Features

The XSR-FB3 Safety Relay has the following features:

The XSR-FB3 Safety Relay can monitor two inputs from a safety gate, safety guard, or similar (two-channel electromechanical safety switch).

1. Compatible with international safety standards
   A safety control system can be built to satisfy international safety standards:
   
   • SIL 3 (IEC 61508 : 2010)
   • Maximum SIL 3 (IEC 62061 : 2005 / A2:2015)
   • PLe, Category 4 (EN ISO 13849-1 : 2015)
2. Compact size
   Innovative compact size compared to its performance, saving valuable space.
3. System configuration
   A number of user convenience functions are provided to meet user requirements:
   
   • Photoelectric light curtain
   • Laser scanner
   • RFID sensor
   • 1 system monitor PNP output
   • 1 external contactor feedback input

1.3 Terminology

For the purpose of this document, the following terms shall have the following definitions:

Chapter 2 General Specifications

2.1 General Specifications

The general specifications of the XSR series are as follows:

Note:

1) IEC (International Electrotechnical Commission): An international nongovernmental organization that promotes internationally cooperated standardization in the electric/electronic field, publishes international standards, and manages applicable estimation systems related to them.

2) Pollution degree: An index indicating the pollution degree of the operating environment, which determines the insulation performance of the devices. For instance, Pollution degree 2 indicates a state where generally only non-conductive pollution occurs. However, this state may include temporary conduction due to dew formation.

Chapter 3 Safety Relay Module

3.1 Performance Specifications

The performance specifications of the XSR-FB3 are presented in the table below:

3.2 Part Names and Functions

Front View:

The front view shows terminal blocks numbered 1 through 16. Terminal 1-8 are for inputs and control signals, and 9-16 are for outputs. An "IN1 LED" is also visible. The device is labeled "LS XSR-FB3S".

Top View:

The top view shows the module's overall structure with terminal designations.

Connector Types:

Images show 'C: Clamp type' with terminals 4, 3, 2, 1 and 'S: Screw type' with terminals 4, 3, 2, 1.

3.3 IO Port Pinout and Functions

3.4 Example of connection of the XSR-FB3 module

3.4.1 Example of connection of the XSR-FB3

• Safety light curtain SAFEGATE S (low range operation):
  Diagram shows connection of SAFEGATE S to XSR-FB3. Inputs (OSSD1, OSSD2, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR".
• AX/VX/VXL safety light curtain in AUTOMATIC operation mode:
  Diagram shows connection of AX/VX/VXL to XSR-FB3. Inputs (SEL A, SEL B, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR".
• AX/VX/VXL safety light curtain in MANUAL operation mode:
  Diagram shows connection of AX/VX/VXL to XSR-FB3. Inputs (RESTART, SEL A, SEL B, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR".
• MXL safety light curtain in AUTOMATIC operation mode:
  Diagram shows connection of MXL to XSR-FB3. Inputs (CMUT_ENABLE, TIMEOUT, OVERRIDE, MUT LAMP, SENSOR1, SENSOR2, OSSD1, OSSD2, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR" and "REFER TO RECEIVER CONNECTION TABLE ON MXL MANUAL".
• MXL safety light curtain in MANUAL operation mode:
  Diagram shows connection of MXL to XSR-FB3. Inputs (CMUT_ENABLE, TIMEOUT, OVERRIDE, MUT LAMP, SENSOR1, SENSOR2, OSSD1, OSSD2, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR" and "REFER TO RECEIVER CONNECTION TABLE ON MXL MANUAL".
• EOS4X safety light curtain in AUTOMATIC operation mode:
  Diagram shows connection of EOS4X to XSR-FB3. Inputs (SEL A, SEL B, K1 K2 FBK IN) and power (+24VDC, 0VDC) are connected to the XSR-FB3 terminals. Feedback (FBK 1, FBK 2) and output relays (RELAY A, RELAY B) are shown. A note indicates "USE INTERFACE SUPPRESSOR".

Chapter 4 IO Port SIGNAL

4.1 OUTPUTS

4.1.1 THE OUTPUT CIRCUIT

For the output circuit, the safety relay uses two guided contact safety relays. These relays are rated by the manufacturer for voltage and current values above those indicated in the technical data. However, to assure correct insulation and to avoid damage or premature aging, protect each output line with an appropriate fuse (depending on the load). Check that load characteristics comply with the indications given in the table below.

Chapter 5 Installation and Wiring

5.1 Installation

5.1.1 Environment

The product offers high reliability regardless of environmental conditions. However, to maintain reliability and stability, please take care of the conditions described in this chapter.

1. Environmental conditions:
   • Install in a waterproof and dust-proof cabinet.
   • Avoid continuous impact or vibration.
   • Avoid direct sunlight.
   • Avoid rapid temperature changes that may form dew drops.
   • Ambient temperature shall be within 0 ~ 60 C.
   • Relative humidity shall be within 5 ~ 95%.
   • Avoid corrosive or flammable gases.
2. Installation Work:
   • Protect the MODULE from foreign materials during installation and wiring work.
   • Select a position suitable for operation.
   • Do not install in the same panel with a high voltage device.
   • Keep at least 50 mm of space between the wire duct and adjacent modules.
   • Ground the MODULE to a point where the noise environment is favorable.
3. Control panel heat dissipation design:
   • When installing the MODULE inside a sealed control panel, consider the heat generated by both other devices and the MODULE itself in the heat dissipation design.
   • When using vents and general fans to circulate air, it is recommended to install filters or use a sealed heat exchanger, as dust, gases, or other contaminants may affect the MODULE system.

5.1.2 Cautions for handling

• Do not drop the unit. Avoid shock.
• Do not separate the PCB from the case, as this may cause failure.
• Protect the module from debris generated during wiring work. Remove any foreign material that enters the module.
• Do not connect or disconnect the module while power is on.
• Use standard cables whose lengths do not exceed the maximum allowable length.
• Keep communication lines away from surges and induction noise generated in AC lines.
• If cables are laid in cable conduits, ground the conduits.
• When wiring using conduits, grounding of the conduit is necessary.

5.1.3 Cautions for wiring

• Do not lay AC power lines and external signal lines of the module close together. Provide at least 100 mm distance or lay the lines in conduits. Sufficient space must be provided to avoid interference from surges or induction noise from AC lines.
• Wires shall be selected considering ambient temperature and allowable current, with a minimum size of AWG 12...30 (solid/stranded) (UL).
• For power source monitoring, wires should be twisted as densely as possible and arranged in the shortest path (Max. wiring distance 15 m or less).
• Keep wires away from heat sources and oil or other harmful materials. Otherwise, short circuits may occur, leading to damage or malfunction of the system.
• Keep wires away from high voltage and power lines to avoid induction interference, which can cause malfunction or failure.
• The total wiring length for safety inputs and test pulse outputs should be less than 100m.
• The wiring length between safety outputs and output devices should be less than 100m for each.

5.1.4 Installation and removal of module

Fix the Safety Relay unit to a 35mm DIN rail as follows:

1. Fasten the Safety Relay to the rail. Press the unit gently until it snaps into place.
2. To remove the unit, use a screwdriver to pull down the locking latch on the back of the unit, then lift the unit upwards and pull.

5.1.5 Cautions for installation

1. General precaution:
   • The Safety Relay turns its output off when any problem in the external power source or the product itself is detected. The external circuit shall be configured to cut off the power supply to the load so that connected device(s) is shut down when the output is turned off. Otherwise, the entire line may result in a severe problem or accident.
   • When changing data, program, or status of an operating Safety Relay, provide an interlock circuit with the sequence program and system outside to ensure safe operation. Read the manual carefully and determine the operating sequence before operating the Safety Relay for safety. For online control of the Safety Relay via PC, prepare countermeasures against communication errors, which may be due to cable connection failure.
   • When a safety function is activated and the output has been cut off, prepare an interlock program using a reset button, etc., to prevent unauthorized manual restarting.
   • If the temperature inside the operation panel where the Safety Relay is installed may exceed the allowable temperature range, it is highly recommended to install a heat exchanger in the operation panel to control the temperature. Using an ordinary ventilation fan may introduce dust from outside, affecting the function of the Safety Relay.

Operation/Control Verification:

5.2 Wiring

This section provides information on system wiring.

5.2.1 Power supply

1. Use a power source with low line-to-line and line-to-ground noise. (If noise is high, connect an insulation transformer.)
2. Separate the power supply for the MODULE, input/output devices, and power devices as shown in the diagram.
3. Twist power cables as tightly as possible and connect them at the shortest distance.
4. Do not run DC24V cables close to main circuit (high voltage, high current) cables or input/output signal cables. Keep them at least 100mm apart if possible.
5. For surge protection against lightning and other surges, use a surge absorber as shown in the diagram below.

Diagram: A Lightning Surge Absorber is shown connected between E1 (surge absorber ground) and E2 (MODULE ground) for surge protection of a MODULE I/O Device.

Note:

1. Separate the grounding (E1) of the surge absorber from the grounding (E2) of the MODULE.
2. Select a surge absorber that does not exceed its maximum allowable voltage, even during the maximum voltage rise of the power supply.

• If noise interference is a concern, use an isolation transformer or a noise filter.
• Twist the wiring for each input/output power as tightly as possible and ensure that the wiring for the shielding transformer or noise filter does not pass through the duct.
• The same ground connection (0VDC) must be used for all system components.

5.2.2 Input/Output Device Wiring

• Wire size range: AWG 12...30, (solid/stranded) (UL).
• Separate input and output wires when wiring.
• Wire input/output cables at least 100mm away from main circuit cables with high voltage and high current.
• If it is not possible to separate main circuit cables and power cables, use a combined shielded cable and ground the MODULE side.
• When wiring through a conduit, ensure that the conduit is properly grounded.
• Terminal tightening torque: 5...7 lb-in (0.6...0.7 Nm).

5.2.3 Grounding circuit

1) The MODULE is implemented with sufficient anti-noise measures; thus, grounding is not necessary unless the system is subject to a very high noise level. If grounding is necessary, consider the following:

2) The ground circuit should be exclusive as possible. The grounding work shall be Class 3 (Ground resistance 100 Ω or less).

3) If exclusive grounding is unavailable, install a common grounding circuit as illustrated in the figures below:

Diagrams:

• a) Exclusive grounding: recommended
• b) Common grounding: acceptable
• c) Common grounding: unacceptable

4) Ground wire shall be at least 2 mm². The grounding point shall be as close to the MODULE as possible to reduce wire length.

5.2.4 Wire specification

• Wire size range: AWG 12...30, (solid/stranded) (UL).
• Use 60/75°C copper (Cu) conductor only.
• LS ELECTRIC recommends using separate power supplies for the Safety Relay and other electrical power equipment (electric motors, inverters, frequency converters) or other sources of disturbance.
• Cables used for connections longer than 50m must have a cross-section of at least 1mm² (AWG16).

Chapter 6 Maintenance

Daily and regular maintenance must be performed to maintain the Safety Controller in the best condition. The lifetime of the Safety Controller is about 20 years. However, environmental impact can cause damage to the devices. Results for all checks and administrative actions must be recorded. Please record information about the product's serial number.

6.1 Inspection and Maintenance

The table below presents items that should be inspected 1-2 times per half year:

6.2 Daily Inspection

Daily inspection shall be performed for the items listed below:

6.3 Regular Inspection

Check the following items biannually and take corrective actions as necessary:

NOTE:

1. Please comply with the instructions for daily and regular inspections as specified in each device's manual, including all devices configured in the safety application (e.g., safety sensors, actuators).
2. During daily/regular inspections, please ensure that all safety functions operate correctly as intended.

Chapter 7 EMC Compliance

7.1 Requirements Complying with EMC Specifications

EMC Directions describe "Do not emit strong electromagnetic wave to the outside: Emission" and "Do not have an influence of electromagnetic wave from the outside: Immunity." Applicable products are requested to meet these directions. This chapter summarizes how to structure a system using the XSR Relay to comply with EMC directions. The description provides data summarized for the requirements and specifications of EMC regulations acquired by the company, but it does not mean that every system manufactured according to this description meets the following specifications. The method and determination to comply with EMC directions should be finally determined by the system manufacturer.

7.1.1 EMC specifications

The EMC specifications affecting the PLC are as follows:

* 1: QP: Quasi Peak, Mean: average value

* 2: PLC is a type of open device (installed on another device) and is to be installed in a panel. For any applicable tests, the system is tested with the system installed in a panel.

7.1.2 Panel

The Safety Relay is an open device (installed on another device) and should be installed in a panel. This prevents a person from suffering an accident due to electric shock upon contact with the product, and the panel can attenuate noise generated by the PLC. For the Safety Relay, to restrict EMI emitted from the product, it should be installed in a metallic panel. The specifications of the metallic panel are as follows:

1. Panel: The panel for the PLC should be installed and manufactured as follows:
   
   • The panel should be made of SPCC (Cold Rolled Mild Steel).
   • The plate should be 1.6mm or thicker.
   • The power supplied to the panel should be protected against surge by using an insulated transformer.
   • The panel should be structured so that electric waves do not leak outside. For instance, the door should be designed as a box. The main frame should also be designed to be covered by the door to restrict any radiating noise generated from the PLC.

   Diagram: A diagram shows a "Panel Main frame" with a "Door" and "Visor".

   • The inside plate of the panel should have proper conductivity with as wide a surface as possible by eliminating the plating of the bolt used to be mounted on the main frame to secure electric contact with the frame.
2. Power cable and grounding cable: The grounding/power cable of the PLC should be treated as follows:
   
   • The panel should be grounded with a thick wire to secure a lower impedance, even at high frequencies.
   • The LG (Line Ground) terminal and PE (Protect Earth) terminal functionally allow noise inside the PLC to flow into the ground, so a wire with low impedance should be used.
   • Since the grounding cable itself may generate noise, thick and short wiring may prevent it from acting as an antenna.

7.1.3 Cable

1) Fixing a cable in the panel: If the extension cable of the XSR series is to be installed on the metallic panel, the cable should be 1cm or more away from the panel, preventing direct contact. The metallic plate of the panel may shield noise from electromagnetic waves, but if a cable acts as a noise source close to this plate, it can serve as an antenna. Every fast signal cable, as well as the extension cable, needs proper spacing from the panel.

Image: An image shows a "Ferrite core" which is recommended for use when cables are exposed outside the control panel and the shielding effect of the cable is insufficient for noise reduction.

Appendix 1 PFH Value

This section provides PFH (Probability of Failure per Hour) values for different load conditions.

* PFHd: Probability of Failure per Hour (calculated value)
# DCavg: Diagnostic Coverage
# MTTFd: Mean Time To Failure (dangerous)
# PL: Performance Level
# CCF: Common Cause Failure

Appendix 2 Dimensions

Dimensions (Unit: mm)

Diagram: Shows the physical dimensions of the XSR-FB3 Safety Relay. The width is 22.50 mm, the height is 113.50 mm, and the depth is 99.00 mm. Terminal block layouts are also depicted.

Warranty and Environmental Policy

Warranty

1. Warranty Period
The product is guaranteed for 36 months from the date of manufacturing.

2. Scope of Warranty

• The initial diagnosis of faults is primarily conducted by the customer. However, upon request, LS ELECTRIC or its service network can undertake this task for a fee. If the fault is due to LS ELECTRIC, the service will be provided free of charge.
• This warranty applies only if the product is used under normal conditions according to the specifications and precautions described in the handling instructions, user manuals, catalogs, and caution labels.
• Even within the free warranty period, the following cases will be subject to paid repairs:
  • Replacement of consumable and life-limited parts (e.g., relays, fuses, electrolytic capacitors, fans, LCDs, batteries, etc.).
  • Failures or damage caused by improper storage, handling, negligence, or accidents by the customer.
  • Failures resulting from the customer's hardware or software design.
  • Failures due to modifications without LS ELECTRIC's consent (Repairs will be refused, even for a fee, if recognized as modified or repaired outside LS ELECTRIC).
  • Failures that could have been avoided if the customer's equipment, incorporating the product, had safety devices required by legal regulations or common industry standards.
  • Failures that could have been prevented if maintenance and replacement of consumable parts were performed normally according to the handling instructions or user manuals.
  • Failures and damages to the product caused by using connected equipment or inappropriate consumables.
  • Failures caused by external factors such as fire, abnormal voltage, force majeure, and natural disasters (earthquakes, lightning, salt damage, wind, and flood damage).
  • Failures due to reasons that could not be predicted with the scientific and technical standards at the time of shipment.
  • Other failures, damages, or defects recognized as the responsibility of the customer.

Environmental Policy

LS ELECTRIC Co., Ltd supports and observes the environmental policy as below.

Environmental Management: LS ELECTRIC considers environmental preservation as a preferential management subject, and all LS ELECTRIC staff endeavor for the preservation of the earth's environment.

About Disposal: LS ELECTRIC's PLC unit is designed to protect the environment. For disposal, separate aluminum, iron, and synthetic resin (cover) from the product as they are reusable.