LS ELECTRIC XSR Series Safety Relay User Manual

Safety Relay

Model: XSR-OS2C, XSR-OS2S

Description: This manual provides information on the specifications, performance, functions, and operation required for using the XSR Series Safety Relay.

Key Features:

• Monitors two inputs from safety gate, safety guard, or similar (two channels electromechanical safety switch).
• Compatible with international safety standards: SIL3 (IEC61508), SILCL3 (IEC62061), Category 4 (ISO 13849-1).
• Compact size for space saving.
• User convenience functions including inputs for safety barrier, selectable manual/automatic restart, 2 N.O. outputs, system monitor PNP output, and external contactor feedback input.
• Output lines are open when the connected device is in OFF status.
• Output lines are enabled only with correct response times.

Safety Instructions:

Warning:

• Read this manual carefully before installing, wiring, operating, servicing, or inspecting this equipment.
• Keep this manual within easy reach for quick reference.
• Instructions are separated into "Warning" and "Caution" to indicate the severity of potential risks.
• Install protection circuits on the exterior of the RELAY to protect the whole control system from external power or RELAY module errors.
• Never connect overload exceeding the rated capacity to the output module or allow the output circuit to have a short circuit.
• Never let the external power of the output circuit be designed to be on earlier than RELAY power.
• In case of data exchange, install interlock in the sequence program to protect the system from any error.

Caution:

• I/O signal lines should be wired at least 100mm away from high-voltage cables or power lines.
• Use RELAY only in the specified environment.
• Before installing, ensure RELAY power is off.
• Ensure all modules and connectors are securely fastened.
• Avoid direct vibration and metallic foreign materials inside the product.
• Prior to wiring, ensure RELAY and external power are turned off.
• Secure terminal screws tightly with specified torque.
• Use the ground wire of Class 3 for PE terminals.
• Do not let foreign materials enter the module during wiring.
• Do not touch terminals when powered.
• Do not let batteries be recharged, disassembled, heated, shorted, or soldered.
• Do not remove PCB from the module case or remodel the module.
• Keep wireless installations or cell phones at least 30cm away from RELAY.
• Product or battery waste shall be processed as industrial waste.

Precautions for Building a Safety System:

• Ensure all tasks are conducted by trained technicians.
• Use products that meet required safety levels for safety functions.
• Conduct test runs to ensure all safety devices operate correctly before system operation.
• Do not operate the system without safety verification.
• Confirm safety response time meets specifications.
• Do not use non-safe signals or data for safety-related functions.
• Do not use the LED of safety modules for controlling safety-related functions.
• The customer is responsible for compliance of the entire established safety system.

General Specifications

Ambient Temperature: 0~55°C

Storage Temperature: -25~+70°C

Ambient Humidity: 5~95%RH (Non-condensing)

Storage Humidity: 5~95%RH (Non-condensing)

Vibration Resistance:

• Occasional: 5 f 8.4Hz, 3.5mm; 8.4 f 150Hz, 9.8m/s²(1G)
• Continuous: 5 f 8.4Hz, 1.75mm; 8.4 f 150Hz, 4.9m/s²(0.5G)

Shock Resistance: Peak acceleration: 147 m/s²(15G), Duration: 11ms, Half-sine, 3 times each direction per axis.

Electrostatic Discharge: Voltage: 4kV (Contact discharge)

Radiated Electromagnetic Field Noise: 80~500 MHz, 10V/m

Fast Transient/Burst Noise: Power line: 2kV; Digital/analog I/O, signal lines: 1kV

Radiated Field AM Modulation: 10Vm, 26~1000 MHz, 80% AM modulation @ 1 kHz

Damped Oscillatory Wave Immunity: Power line: 1kV; Digital I/O(24V and higher): 1kV

Environment: Free from corrosive gasses and excessive dust.

Altitude: Up to 2,000 m

Pollution Degree: 2 or less

Cooling: Air-cooling

Related Standards: IEC61131-2, IEC61000-1-2, IEC61000-4-3, IEC61000-1-4

Safety Relay Module Performance Specifications

Part Names and Functions

Front View:

• 1: IN1 LED: Green ON: Input contact1 CLOSED. Green OFF: Input contact1 OPEN.
• 2: IN2/FAIL LED: Red ON: Fault detected. OFF: Input contact2 OPEN.
• 3: GUARD/BREAK LED: Green ON: Input contact2 CLOSED. Red ON: Output relays opened. Red blinking: Indicates the type of FAIL.
• 4: IN/Out Connector: DC 24V power supply terminal block (+24V, 24G, PE) and In/Out Port terminal block. Connector types: C (Clamp type), S (Screw type).

Top View: Shows terminal block layout.

IO Port Pinout and Functions

LED Indicator

Diagnostic Operation LED Indicator:

If it is not possible to clearly identify the malfunction and to remedy it, stop the machine and contact the LS A/S Department.

OPERATING MODES

3.5.1 AUTOMATIC MODE

In this operating mode, the outputs of the safety module follow the status of the barrier:

• With the protected area free (outputs of the barrier active), the relay outputs of the unit are active.
• With the protected area occupied (outputs of the barrier de-activated), the relay outputs of the safety module are de-activated.

Use in manual mode (start/restart interlock activated) is mandatory in case the safety device controls an access protecting a danger zone and once a person has passed through the opening, he/she may remain in the danger zone without being detected. Failure to comply with this rule may result in very serious risks for the persons exposed.

When the K1-1 and K2-1 N.C. control contacts are not used (or no control is provided), it is mandatory to connect the terminal 11 (K1 K2 FBK) to terminal 24VDC.

3.5.2 MANUAL MODE

In this operating mode, the outputs of the safety relay are activated only if the protected area is free and after sending the RESTART signal to the unit using the push-button or by means of a specific command on the RESTART input (terminal 4).

• Refer to the RESTART command at page 4-1 for a more detailed description of the command.
• Once the protected area has been occupied, the output relays are de-activated.
• The sequence described on RESTART command section must be repeated in order to re-activate the outputs relay.

Check correct functioning of the entire safety system (safety relay + barrier) following each re-installation. If the original operating mode was Manual, check that the unit has been reconfigured in this mode.

When the K1-1 and K2-1 N.C. control contacts are not used (or no control is provided), it is mandatory to connect the terminal 11 (K1 K2 FBK) to terminal 24VDC.

3.5.3 SIMULTANEITY CHECK

The XSR-OS2 Safety Relay module can monitor two inputs from a safety gate, safety guard, or similar. Short circuit between the two channels or between the channels and 24VDC are detected by means of the OUT TEST1, OUT TEST2 signals. A simultaneity check is performed between the two channels (within 1 sec).

If the simultaneity is not respected, the system remains in OFF with an alternate flashing of the LEDs IN1 - IN2/FAIL. To reactivate the outputs, it is necessary to open and close INPUT1 and INPUT2 again (respecting the simultaneity).

IO Port SIGNAL

4.1 INPUT

4.1.1 RESTART command

The RESTART command allows XSR-OS2 to manage Manual operation. The RESTART command must be sent to XSR-OS2 connecting terminal 4 to the 24VDC, respecting the behavior of the timing diagram. The contact used for the RESTART command must be able to switch a voltage of 24VDC and a current of 10mA (guaranteeing a closing time t1: 5s>t1>100ms). The whole SYSTEM RESET TIME is obtained by adding the reset time of any external contactors K1 K2 to the reset time of XSR-OS2.

This is important for automatic management of the RESTART command, for example using a PLC. In manual activation, a normally open external button can be used.

The Restart command must be installed outside the danger area in a position where the danger area and the entire work area are clearly visible. It must not be possible to reach the control from inside the danger area.

4.1.2 K1K2 FEEDBACK input (EDM)

Using K1 and K2 auxiliary safety contactors with guided contact safety type, connect +24VDC to the K1 K2 FBK through the series of K1-1 and K2-1 N.C. control contacts. The control of the correct switching of K1 and K2 is performed with a delay of 300ms. If required, the response time of external contactors must be verified by an additional device.

When K1-1 and K2-1 N.C. control contacts are not used, connect terminal 11 (K1K2 FEEDBACK) to terminal 12 (SYSTEM STATUS).

4.2 OUTPUTS

4.2.1 SYSTEM STATUS output

The SYSTEM STATUS output reports the output safety relays condition: When output relays are opened, it reports 0VDC. When output relays are closed, it reports +24VDC.

1. Characteristics of the output circuit: The safety relay module uses two guided contact safety relays. Protect each output line with an appropriate fuse.

2. Use of K1 and K2 auxiliary contact elements: For loads with higher voltage and current characteristics, use auxiliary external relays or contactors of the guided contact safety type. Pay attention to the configuration of control contacts on terminal 11 and the use contacts.

Control contacts K1-1 and K2-1 (terminal 11) must switch a current of 20mA and a voltage of 24VDC. To increase electrical life, use anti-disturbance devices across the coils of K1 and K2.

Installation and Wiring

5.1 Installation

5.1.1 Environment

1) Environmental conditions:

• Install in a waterproof and dust-proof cabinet.
• Avoid continuous impact or vibration.
• Avoid direct sunlight.
• Avoid rapid temperature change that may form dew drops.
• Ambient temperature: 0~60°C.
• Relative humidity: 5~95%.
• Avoid corrosive or flammable gases.

2) Installation Work:

• Protect the MODULE from foreign materials.
• Select a position suitable for operation.
• Do not install in the same panel with high voltage devices.
• Maintain at least 50 mm space between wire duct and adjacent modules.
• Ground the MODULE to a point with a favorable noise environment.

3) Control panel heat dissipation design: Consider heat generated by devices in the panel. Use filters or sealed heat exchangers for ventilation.

5.1.2 Cautions for handling

• Do not drop or shock the unit.
• Do not separate the PCB from the case.
• Protect the module from debris during wiring.
• Do not connect or disconnect the module while power is on.
• Use standard cables with lengths not exceeding the maximum allowable length.
• Keep communication lines away from surge and induction noise.
• If cables are laid in conduits, ground the conduits.

5.1.3 Cautions for wiring

• Keep AC power lines and external signal lines at least 100 mm apart.
• Twist power source monitoring wires densely and keep wiring path short (Max. 15 m).
• Keep wires away from heat sources, oil, or harmful materials.
• Keep wires away from high voltage and power lines to avoid induction interference.
• Total wiring length for safety inputs and test pulse outputs should be less than 100m.
• Wiring length between safety outputs and output devices should be less than 100m.

5.1.4 Installation and removal of module

Fix the Safety Relay unit to a 35mm DIN rail by fastening it gently until it snaps into place. To remove, pull down the locking latch on the back and lift the unit upwards.

5.1.5 Cautions for installation

• Safety Relay turns output off if any problem is detected. Configure external circuits to cut off power to the load.
• When changing data, program, or status, provide an interlock circuit.
• If a safety function is activated and output is cut off, prepare an interlock program to prevent unauthorized restarting.
• If the panel temperature may exceed the allowable range, install a heat exchanger.

Wiring

5.2.1 Power supply

• Use a power source with low line-to-line, line-to-ground noise.
• Separate power supply for MODULE, input/output devices, and power devices.
• Twist power cables tightly and connect at the shortest distance.
• Keep DC24V cables at least 100mm apart from main circuit cables.
• Use a surge absorber for surge protection.
• Use an isolation transformer or a noise filter if noise interference is a concern.
• Twist wiring for each input/output power tightly.
• Use the same ground connection (0VDC) for all system components.

5.2.2 Input/Output Device Wiring

• Wire size range: AWG 12...30.
• Separate input and output wires.
• Wire input/output cables at least 100mm away from main circuit cables.
• If separation is not possible, use a combined shielded cable and ground the MODULE side.
• Ensure conduit is properly grounded when wiring through conduit.
• Terminal tightening torque: 5...7lb-in (0.6...0.7 Nm).

5.2.3 Grounding circuit

• MODULE has sufficient anti-noise measures; grounding is not necessary unless the system is subject to high noise levels.
• The ground circuit should be exclusive if possible. Grounding work shall be Class 3 (Ground resistance ≤ 100 Ω).
• If exclusive grounding is unavailable, install common grounding circuit.
• Ground wire shall be at least 2 mm². Grounding point should be close to the MODULE.

5.2.4 Wire specification

• Wire size range: AWG 12...30.
• Use 60/75°C copper conductor only.
• Recommend separate power supplies for Safety Relay and other electrical equipment.
• Cables longer than 50m must have a cross-section of at least 1mm² (AWG16).

Maintenance

6.1 Inspection and Maintenance

Perform daily and regular maintenance for the best condition of the Safety Controller. Record results of all checks and administrative actions.

6.2 Daily Inspection

Perform daily inspection for the following items:

6.3 Regular Inspection

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

NOTE:

• Comply with instructions for daily and regular inspections as specified in each device's manual.
• During inspections, ensure all safety functions operate correctly.

EMC Compliance

7.1 Requirements Complying with EMC Specifications

EMC Directions aim to prevent strong electromagnetic waves from being emitted and to minimize the influence of external electromagnetic waves. This chapter summarizes how to structure a system using XSR Relay to comply with EMC directions.

7.1.1 EMC specifications

* 1: QP: Quasi Peak, Mean: average value
* 2: PLC is a type of open device (installed on another device) and 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 in a panel to prevent electric shock and attenuate noise. The metallic panel specifications are:

• Panel: Made of SPCC (Cold Rolled Mild Steel), plate thickness ≥ 1.6mm. Power supply should be protected against surge. The panel structure should prevent electric waves from leaking.
• Inside plate: Should have proper conductivity.
• Power cable and grounding cable: Panel should be grounded with a thick wire for low impedance. Use LG (Line Ground) and PE (Protect Earth) terminals to flow noise into the ground.

7.1.3 Cable

• Fix extension cables 1cm or more away from the metallic panel to prevent direct contact.
• Metallic plates can shield noise, but cables close to the panel can act as an antenna. Ensure proper spacing for fast signal and extension cables.
• Use ferrite cores for cables exposed outside the control panel if shielding is insufficient for noise reduction.

Appendix 1 PFH Value

Appendix 2 Dimensions (Unit : mm)

Diagrams showing the dimensions of the XSR Series Safety Relay.

Warranty and Environmental Policy

Warranty

1. Warranty Period: 36 months from the date of manufacturing.

2. Scope of Warranty: Covers faults due to the company's responsibility. Excludes failures from improper use, modifications, external factors, or lack of maintenance.

Environmental Policy

LS ELECTRIC Co., Ltd. is committed to environmental preservation. PLC units are designed to protect the environment. For disposal, separate aluminum, iron, and synthetic resin for reusability.

Contact Information

LS ELECTRIC Co., Ltd.

Headquarter: LS-ro 127(Hogye-dong) Dongan-gu, Anyang-si, Gyeonggi-Do, 14119, Korea

Seoul Office: LS Yongsan Tower, 92, Hangang-daero, Yongsan-gu, Seoul, 04386, Korea

Tel: 82-2-2034-4033, 4888, 4703 | Fax: 82-2-2034-4588

E-mail: automation@ls-electric.com

Website: www.ls-electric.com

Information on overseas subsidiaries and branches is also provided.