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HONEYWELL

FF-SRE60292

FF-SRE6029

Extension Module

Instructions for use

(pending)

107137-20 -EN FR26 GLO 305 Printed in Germany 1

IMPROPER INSTALLATION

• Consult with US, Canadian and/or European safety

agencies and their requirements when designing a

machine control, interface and all control elements that

affect safety.

• Strictly adhere to all installation instructions.

Failure to comply with these instructions could result

in death or serious injury.

PRODUCT DESCRIPTION

The FF-SRE6029 Extension Module provides contact

multiplication for safety devices with External Device

Monitoring (EDM) capability (e.g. FF-SRS e-stop

modules, FF-SYB and FF-SB safety light curtains,

FF-SM safety mats).

This product has two safety relays with positive-guided

contacts to ensure redundancy and offers four NO and

one NC safety contact.

Its slim housing of only 22,5 mm (0.89 in) width allows

this safety control module to fit into most cabinets and

even helps to keep the overall cabinet size small.

APPROVALS

CE The product, packaging and documentation

of FF-SR Series products carry the CE

mark; the CE declaration of conformity is

attached on the last page.

cURus

(pending)

This product is currently being assessed

by Underwriters Laboratories Inc.

according to Canadian and U.S. safety

requirements.

DIRECTIVE COMPLIANCE

Machinery Directive 98/37/EC

Low Voltage Directive 73/23/EC

Electromagnetic Compatibility Directive 89/336/EC

REGULATION COMPLIANCE

Regulation Title

OSHA 29 CFR

1910.217

Requirements and

Safeguarding of Mechanical

Power Presses

STANDARD COMPLIANCE

Standard Title

EN 292 Safety of Machinery - Basic

Concepts, General Principles

for Design

EN 60204-1 Safety of Machinery - Electrical

Equipment of Machines

EN 954-1 Safety of Machinery - Safety

related parts of control system

ANSI B11.1 Construction, Care and Use of

Mechanical Power Presses

ANSI B11.2 Construction, Care and Use of

Hydraulic Power Presses

ANSI B11.19 Safeguarding Performance

Criteria for the Design,

Construction, Care and Use

ANSI/RIA R15.06 Safety Requirements for

Industrial Robots and Robot

Systems

UL 508 Industrial Control Equipment

NFPA79 Electrical Standard for Industrial

Machinery

2107137-20 -EN FR26 GLO 305 Printed in Germany

SPECIFICATIONS

Input

Nominal voltage 24 Vdc (-10 %, +10 %)

Nominal consumption dc: 1,5 W

Output

Contacts 4 NO, 1 NC (plus 1 NC for External Device Monitoring loop)

Contact type Safety relay, positive-guided

Response time Max. 15 ms (delay on de-energisation)

Delay on energisation Typ. 25 ms

Switching Capability Power factor = 1 with resistive load

Current Range (min. to max.) 10 mA to 5 A

Voltage Range (min. to max.) 0,1 to 250 Vac

Switching capability per

EN 60947-5-1

AC15: NO contact: 3 A/230 Vac, NC contact: 2 A/250 Vac

DC13: NO contact, NC contact: 8 A / 24 Vdc

Power factor = 1 at 230 Vac (see figure 1, note 1)

current operations current operations

0,5 A 5 500 000 2 A 1 000 000

Typical Electrical Life Expectancy

1 A 2 000 000 5 A 250 000

Limitation Factor F (see figure 2, note 2)

cos ϕF cos

0,3 0,45 0,7 0,85

Typical Power Factor (cos ϕ)

0,5 0,7 1 1

Operating frequency 1200 operating cycles/h

Fuse rating 6 A time delayed (max.)

Mechanical life 20 000 000 operating cycles

General

Temperature range -15 °C to + 55 °C (5 °F to 131 °F) at 90 % humidity (max.)

Sealing Housing IP 40; Terminals IP 20

Housing material Thermoplastic

Vibration resistance

(IEC/EN 60 068-2-6)

Amplitude 0,35 mm; Frequency 10 to 55 Hz

Wire connection Solid wire: 1 x 4 mm2[12 AWG] or 2 x 2,5 mm2[14 AWG]

Stranded wire with sleeve: 1 x 2,5 mm2[14 AWG] or 2 x 1,5 mm2[16 AWG]

Wire/conductor attachment M3.5 screw terminals

Mounting Quick install rail mounting IEC/EN 60715 (width: 35 mm (1.38 in))

Weight 205 g (0.45 lb)

NOTE 1: Install arc suppressors

across load to avoid module contact

arcing and ensure specified contact life

expectancy.

NOTE 2: Total operations = operations

(power factor 1) x limitation factor F.

Example:

U = 230 Vac, I = 1 A,

power factor cos ϕ= 0,5

Switching power P = U x I = 230 VA

Contact life (cos ϕ= 1, P = 230 VA) =

2 000 000 operations (see Figure 1)

Limitation factor F (cos ϕ= 0,5) = 0,7

(see Figure 2)

Contact life (cos ϕ= 0,5, P = 230 VA) =

F x contact life (cos ϕ= , P= 230 VA) =

2 000 000 x 0,7 = 1 400 000 operations.

FIGURE 1. TYPICAL CONTACT

LIFE FOR 100 % RESISTIVE LOAD

(power factor cos ϕ= 1, note 1)

70,5 1,0 1,5 2,0

Operations

Switching power [kVA]

FIGURE 2. LIMITATION FACTOR FOR

INDUCTIVE LOADS

(power factor cos ϕ< 1, note 2)

Limitation factor F

Power factor

FIGURE 3. QUADRATIC TOTAL CURRENT LIMIT

107137-20 -EN FR26 GLO 305 Printed in Germany 3

100

120

010 20 30 40 50 60 T (˚C)

32 50 68 86 104 122 140 T (˚F)

Ambient temperature

Quadratic total current (A

)

I2(A2)

Figure 3 shows the maximal recommended safety

contact currents at a certain ambient temperature to

avoid overheating of the safety module.

To use this curve, do the following:

1. Square the currents in each safety contact branch

and sum the square currents to obtain the total

square limit (in A²).

2. Determine the maximal recommended external

temperature at the total square current limit:

Example: 5 A current per normally open contact:

Total square current limit :

∑Ι2= (5A)2+ (5A)2+ (5A)2 +(5A)2 =100 A²

Max. external temperature: T = 39 °C (102 °F).

If the module is located in a higher temperature

environment, the lifetime of the electronic components

may be reduced. Ventilation of the cabinet may be

required.

MECHANICAL INSTALLATION

The FF-SRE6029 must be installed inside an IEC IP 54

(NEMA 3) rating enclosure or better. The module can be

clipped easily onto a 35 mm (1.38 in.) width rail (see

figure 5 for installation and removal).

FIGURE 4. MOUNTING DIMENSIONS

(for reference only)

Rail

a Width: 22,5 mm / 0.89 in.

b Height: 90 mm / 3.55 in.

c Depth: 121 mm 4.77 in.

FIGURE 5. INSTALLATION DIAGRAM

FSR1

FSRE5929 6

CONTROL RELIABILITY

“Control Reliability” essentially means that “the device,

system or interface shall be designed, constructed and

interfaced such that any single component failure within

the device, interface or system shall not prevent normal

stopping action from beeing applied but shall prevent the

initiation of a successive operation until the failure is

corrected”.

OSHA 29 CFR 1910.217 states that “the device shall be

constructed so that a failure within the system does not

prevent the normal stopping action from being applied to

the press when required, but does prevent initiation of a

successive stroke until the failure is corrected. The

failure shall be indicated by the system.”

SAFETY CATEGORY OF INTERFACES

The safety category of the interface is depending on the

safety category of the main safety device (emergency

stop module, safety light curtain, safety mat, etc.) and

the way of interconnecting it to the FF-SRE6029

Extension module.

Refer to the important application warnings (page 5)

for more details concerning safety.

FIGURE 6. INTERNAL CIRCUITRY

13 23 33 43 51 Y1

M8561

14 24 34 44 52 Y2

A1(+) A2(-)

A3(+) A4(-)

24V

AL6029

ELECTRICAL INSTALLATION

4107137-20 -EN FR26 GLO 305 Printed in Germany

ELECTRICAL SHOCK

Remove power from FF-SR Series control modules and

machine during installation.

Failure to comply with these instructions could

result in death or serious injury.

Multiple wiring configurations are possible for the

FF-SRE6029 extension control module and only general

guidelines are provided in this installation manual.

Refer to the important application warnings (page 5)

and the application examples (pages 6 through 7) for

more details.

FIGURE 7. TERMINAL ARRANGEMENT

FUNCTIONAL DESCRIPTION

In the case of an emergency stop condition, the safety

device connected to the FF-SRE6029 module is actuated

and the internal safety relays K1 and K2 de-energise. The

normally open safety contacts (13/14…43/44) will open

and the normally closed safety contacts (51/52) will close.

The emergency stop condition is signalled to the

machine

control circuitry by the module’s safety contacts to stop the

hazard and remove power.

As soon as the safety device is released, power is applied

to A1(+)/A2(-), A3(+)/A4(-) and the relays K1 and K2

energise. The normally open contacts will close and the

normally closed contact will open.

Both relays K1 and K2 must be energized to have the

normally open contacts in a closed condition. If one of the

safety relays de-energizes, the normally open contacts will

open.

One or more FF-SRE6029 Extension Modules can be

cascaded or external contactors with positive guided

safety contacts can be used to increase the number of

contacts.

If multiple safety contacts are used in parallel with one

load, the maximum admissible current can be increased.

LED INDICATORS

The FF-SRE6029 module has two green LED status

indicators (K1 and K2) as illustrated in Figure 8.

Illuminated K1 and/or K2 LEDs indicate(s) that the

corresponding internal safety relay is energized.

FIGURE 8. MODULE FRONT PANEL

24 34 44

(+)

(-)

Y1 Y2

33 43

(+)

(-)

51 52

13 23 33 43 51

14 24 34 44 Y2

Honeywell

FF-SRE60292

FSRE6029 10

APPLICATION WARNINGS

IMPROPER INPUT CONNECTIONS

• To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the

safety relay inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.

• When safety devices with relay outputs are used, always connect them using different potentials to A1(+)/A2(-) and

A3(+)/A4(-), in order to be able to detect cross-faults.

CONTACT WELDING

Always protect all safety contacts with correctly rated fuses. These fuse ratings must never exceed the max. safety

output switching currents of the FF-SRE6029 to prevent contact welding (see specifications page 2).

IMPROPER EXTENSION MODULE MONITORING

• Only connect the FF-SRE6029 extension module to safety devices offering the External Device Monitoring (EDM)

capabilities (e.g. FF-SYB, FF-SB, FF-LS safety light curtains, FF-SM safety mats, FF-SRS emergency stop

modules).

• Do NOT connect the FF-SRE6029 extension module to safety devices WITHOUT the EDM function (e.g. FF-SYA,

FF-SG, FF-SLG or FF-SLG30).

• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each

FF-SRE6029 activation and is able to detect failures of the internal relays (e.g. welded safety relay contacts).

• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring

(EDM) loop of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM.

• If the FF-SRE6029 is not activated often, the customer should perform additional test procedures of the safety

components. This testing may be done every day by removing the power from the FF-SRE6029 at machine power

up.

IMPROPER ARC SUPPRESSOR INSTALLATION

• NEVER install an arc suppressor across the safety output contacts of the extension module.

• ALWAYS install arc suppressors across the coils of external safety relays.

Failure to comply with these instructions could result in death or serious injury.

107137-20 -EN FR26 GLO 305 Printed in Germany 5

APPLICATION EXAMPLES

FIGURE 9. CONNECTION OF AN FF-SRS59352 EMERGENCY STOP MODULE

A2(-)

A1(+) S11 S12 S22

S21

S33 S34

13 23 33 41

Honeywell

FF-SRS59352

14 24 34 42

Power

Internal

switches

Fuse

24 Vdc

A1(+) A3(+) 13 23

A2(-) A4(-) 14

33 43 51

24 34 44

Honeywell

Machine control

Restart push-

button

1 NO and 1 NC

safety contacts 4 NO

and 1 NC

safety

contacts

Emergency stop

push-button (A)

(A)

0 Vdc

FF-SRE60292

FUNCTIONAL DESCRIPTION:

After activation of the safety device (see application note (A)), the normally open safety contacts of the FF-SRS59352

dual channel emergency stop module (13/14 to 33/34) and the connected FF-SRE6029 extension module (13/14, 23/24,

33/34, 43/44) will open. The normally closed contacts (41/42, 51/52) will all close. The LED relay output indicators (K2,

K3 and K1, K2) of both modules go off indicating that the internal safety relays are de-energized.

After removing the emergency stop condition, press and release the restart push-button to restart the FF-SRS59352

emergency stop module. If the FF-SRE6029 extension module is operating properly, the normally closed contact

(Y1/Y2) for the External Device Monitoring is closed and both safety modules are energising their internal safety relays.

The normally open contacts will close and the normally closed contacts will open. The LED relay output indicators all

illuminate. This action will allow the machine to operate.

FSRE6029_12

APPLICATION NOTES

Note (A): Dual channel output safety devices with relay outputs or safety switches (examples)

This may be a safety device with dual output safety switching devices (OSSD)

• emergency stop push-button

• safety limit or interlock switches (e.g. CPS, GK, GSS)

IMPROPER INPUT CONNECTIONS

• To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the

safety relay inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.

• When safety devices with relay outputs are used, always connect them using different potentials to A1(+)/A2(-) and

A3(+)/A4(-), in order to be able to detect cross-faults.

IMPROPER EXTENSION MODULE MONITORING

• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each

FF-SRE6029 activation and is able to detect failures of the internal relays (e.g. welded safety relay contacts).

• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring

(EDM) loop of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM monitoring.

Failure to comply with these instructions could result in death or serious injury.

6107137-20 -EN FR26 GLO 305 Printed in Germany

107137-20 -EN FR26 GLO 305 Printed in Germany 7

FIGURE 10. CONNECTION OF AN FF-SYB TYPE 4 SAFETY LIGHT CURTAIN

(+24 Vdc)

(0 Vdc)

FF-SYB

Receiver

FF-SYB

emitter

OSSD1

(B)

(A)

OSSD2

Fuse

4 (-)

2 (+)

M O NB P

#01

Rec

M : Manual

O : NC output

NB: No blanking

Towards

PLC input

Restart / EDM

Optional reset P/B

Optional

test input

Dual channel machine

control circuit

(recommended circuit)

A1(+) A3(+) 13 23

A2(-) A4(-) 14

33 43 51

24 34 44

Honeywell

FF-SRE60292

FUNCTIONAL DESCRIPTION:

After interrupting the sensing field of the FF-SYB safety light curtain, both static safety oututs (5, 6) of the receiver switch off.

Then, the normally open contacts of the connected FF-SRE6029 extension module (13/14, 23/24, 33/34, 43/44) will open and

the normally closed contacts (51/52, Y1/Y2) will close. The LED relay output indicators (K1, K2) of the module go off indicating

that the internal safety relays K1 and K2 are de-energized.

After clearing the sensing field of the FF-SYB safety light curtain, press and release the restart push-button to restart the

receiver. If the FF-SRE6029 extension module is operating properly, the normally closed contact (Y1/Y2) for the External Device

Monitoring (EDM) is closed and the static safety outputs of the FF-SYB receiver are energising. The normally open contacts of

the FF-SRE6029 module will close and the normally closed contacts will open. The LED relay output indicators K1 and K2

illuminate. This action will allow the machine to operate.

FSRE6029_13

APPLICATION NOTES

Note (A): Dual channel output safety devices with static safety outputs AND External Device Monitoring (EDM) function (e.g.

FF-SYB safety light curtains).

Note (B): CONFIGURATION CARDS

Various mode settings are possible with the FF-SYB safety light curtain (e. g. start / restart, muting, floating blanking) using

configuration cards. The example above uses the factory setting configuration card for the receiver (#1: manual start, no muting,

no blanking). Refer to the FF-SYB installation manual for more information.

IMPROPER INPUT CONNECTIONS

To ensure the highest level of safety, always connect the two redundant safety device outputs individually to the safety relay

inputs A1(+)/A2(-) and A3(+)/A4(-) of the FF-SRE6029 Extension Module.

IMPROPER EXTENSION MODULE MONITORING

• The External Device Monitoring (EDM) function checks the correct operation of the internal relays before each FF-SRE6029

activation and is able to detect failures of the internal relays (e.g: welded safety relay contacts).

• ALWAYS connect the normally closed contact (Y1/Y2) of the extension module to the External Device Monitoring (EDM) loop

of the connected safety device. NEVER use the normally closed contact (51/52) for the EDM monitoring.

Failure to comply with these instructions could result in death or serious injury.

FIGURE 11. FF-SRE6029 TROUBLESHOOTING FLOW DIAGRAM

Machine Down

Yes

Apply correct voltage AND/

OR check for correct

operation of previous

connected safety device.

Replace the

safety module.

Yes

Are K1 AND K2

LEDs ON?

Yes

The problem

is external to

the module.

Check for

external

causes

(wiring, etc.).

Damaged

contacts. Ensure

maximum load is

specification.

Replace module.

Are the

outputs contacts

13/14, ..., 43/44

closed?

Are K1 AND K2

LEDs OFF?

Are the contacts

51/52 AND Y1/Y2

closed ?

Replace safety

module and

activate restart

circuitry.

voltage between

A1/A2 AND A3/A4 present

AND within

specifications?

Yes

Machine

Working

Is the problem

resolved?

Yes

within

FSRE6029_14

8107137-20 -EN FR26 GLO 305 Printed in Germany

WARRANTY AND REMEDY

Honeywell warrants goods of its manufacture as being free

of defective materials and faulty workmanship. Contact

your local sales office for warranty information. If

warranted goods are returned to Honeywell during the

period of coverage, Honeywell will repair or replace without

charge those items it finds defective. The foregoing is

Buyer’s sole remedy and is in lieu of all other warranties,

expressed or implied, including those of

merchantability and fitness for a particular purpose.

Honeywell

21, chemin du Vieux Chêne

38240 Meylan

France

While we provide application assistance, personally and

through our literature and the Honeywell Website, it is up to

the customer to determine the suitability of the product in

the application.

Specifications may change at any time without notice. The

information we supply is believed to be accurate and

reliable as of this printing. However, we assume no

responsibility for its use.

TELEPHONE

+ 61 (0) 2 9370 4500 Australia

+ 33 (0) 1 60 19 80 40 France

+ 49 (0) 69 8064 444 Germany

+ 34 91 313 61 00 Spain

+ 1-815-235-6847 International

+ 44 (0) 1698 481 481 UK

+ 1-800-537-6945 USA & Canada

FAX

+ 61 (0) 2 9370 4525 Australia

+ 33 (0) 1 60 19 81 73 France

+ 49 (0) 69 8064 442 Germany

+ 34 91 313 61 29 Spain

+ 44 (0) 1698 481 676 UK

+ 1-815-235-6545 USA & Canada

INTERNET

http://www.honeywell.com/sensing/

[email protected]

ORDER GUIDE

FF-SRE6029

2 = 24 Vac/dc

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