6.

1 Switch Safely

The following circuit examples have An EMERGENCY OFF switch may • be simultaneously used as main
been harmonized with the German switch, if it additionally fulfills the
• be manually actuated;
Trade Association (BG) and have been requirements for a main switch
approved. • act on an undervoltage release via (however, a main switch must
one or several EMERGENCY OFF disconnect all circuits).
• Contactor circuits control devices (circuit diagram 6/1);
An example for such an EMERGENCY
• SIGUARD safety combinations • be provided with overload- and/ OFF switch for extremely simple
using contactors or short-circuit releases (version machines is illustrated in circuit dia-
using safety relays as circuit-breaker); gram 6/2.
Suitable for:
• EMERGENCY OFF
• Protective door monitoring
functions Manual To loads, which must
drive be shutdown for an
• Press controls mechanism EMERGENCY OFF
Switch lock
“EMERGENCY OFF switch” Release
Mushroom-head
EMERGENCY OFF circuits for ex- pushbutton
tremely simple machines To loads, which don’t have to
be/may not be disconnected
for EMERGENCY OFF
EMERGENCY OFF switch
The EMERGENCY OFF function may U<

only be fed through an EMERGENCY Main switch EMERGENCY

OFF switch for extremely simple OFF
machines, depending on the result of control device

a risk analysis. In this particular case, Supply

only Stop Category 0 is possible.
Such an EMERGENCY OFF switch
switches, contrary to usual EMER- Circuit diagram 6/1
EMERGENCY OFF switch with manual actuation or remote actuation via
GENCY OFF pushbuttons, the main undervoltage release
circuit (circuit diagram 6/1).
An EMERGENCY OFF switch must
be configured, so that
• There is only one EMERGENCY
OFF switch;
“EMERGENCY OFF switch”
• the EMERGENCY OFF switch is Control
located in the supply to those To loads which
circuits which can result in hazard- don’t have to Off off
ous motion in the system. The com- be/may not be
disconnected for
plete power supply to all of the cir- EMERGENCY OFF
cuits does not have to be interrup- On K1 on K2

ted;
Main K1 K2
• the EMERGENCY OFF switch must switch

be able to interrupt the current of e.g. plant protective conductor

the largest motor when the motor Supply To loads which must be shutdown
stalls; for EMERGENCY OFF

• the sum of the currents of all of the

loads which must be disconnected
using the EMERGENCY OFF switch
must be able to be safely interrup-
ted.
Circuit diagram 6/2
Example of a machine control with EMERGENCY OFF switch
(this is only permissible with some restrictions)

6/2 Safety Integrated Application Manual Siemens AG

 6
EMERGENCY OFF contactor
Generally, a so-called EMERGENCY
OFF contactor is not permitted. Such
a contactor is only permissible in pre-
cisely defined exceptional cases: This To loads which don’t
have to be/may not be
contactor may only be used as an disconnected for
EMERGENCY-STOP contactor in the EMERGENCY OFF
branch to be shutdown. Additional
contactors in series are not permit-
ted. This means that this concept is Main EMERGENCY
switch OFF control
restricted for applications on extreme- device located
ly simple machines (refer to circuit in the control
diagram 6/3). circuit

An EMERGENCY OFF contactor must Supply To loads which must be shutdown

be configured, so that for EMERGENCY OFF

• each EMERGENCY OFF contactor

Circuit diagram 6/3
must be immediately de-energized Example of a machine control with 2 EMERGENCY OFF contactors,
by the EMERGENCY OFF control only permitted with some restrictions
device;
• there are no additional contactors in
series.
F1 Enable signals
L1

Safety circuits using individual EMERGENCY OFF device,

if required several in series
contactors K1

Configured using two auxiliary Actuator “On”

contactors or “On” after
EMERGENCY K2
Safety circuits of any complexity can OFF
be configured using auxiliary con- K1 K1
tactors. Up to several years ago, the - no positively-driven contacts
circuit with two auxiliary contactors K2 K2
- no self-monitoring
and overlapping auxiliary contacts
(circuit diagram 6/4) was considered
to be state-of-the-art. K1 K2 This circuit is no longer used.
N
This circuit offers redundancy. How-
ever, due to the fact that the contacts
are not positively driven, the two Circuit diagram 6/4
auxiliary contactors do not mutually This contactor combination consists of two auxiliary contactors with overlapping contacts
monitor each other for correct func-
tioning. This means, that if a contact
welds, this fault is not detected and
the circuit still continues to function.
A subsequent fault in the second
contactor could completely disable
the combination. This would mean
that the level of safety would no
longer be guaranteed. Thus, today,
this circuit is no longer used (circuit
diagram 6/4).

Safety Integrated Application Manual Siemens AG 6/3

Using three auxiliary contactors Several auxiliary contactors are com- can also be implemented using indi-
bined to form a safety circuit in the vidual contactors.
Today, circuits with three auxiliary
form of the 3TK28 contactor safety
contactors represent state-of-the-art
combinations. Naturally, the circuits
technology. Three auxiliary contactors,
with positively-driven contacts are
used, as shown in circuit diagram 6/5.
F1
The three auxiliary contactors guaran- L+/L1 Enable signals
tee redundancy and function monitor-
EMERGENCY OFF device, K1
ing. The positively-driven contacts if required several
guarantee that the auxiliary contactors
mutually monitor themselves. Faults
K1
are therefore detected and the circuit Actuator “On” K2
or control
can no longer be closed after shut- K3
voltage “On”
down, therefore eliminating subse-
quent faults. K2 K1 K2
K3
With this circuit, using today’s state-
of-the-art technology, it can be as- K3 K1 K3
sumed that if the auxiliary contactors
incorrectly function this will not result
K1 K2 K3
in a hazardous status in the system. L–/N

Circuit diagram 6/5

Contactor combination using three auxiliary contactors with self-monitoring,
single-channel

Connecting several
EMERGENCY OFF control devices
In the previous circuit diagrams, only
one EMERGENCY OFF device was
shown. Generally, there are several
EMERGENCY OFF control devices
(e.g. at different locations) on a
machine. The contacts of these
EMERGENCY OFF control devices
are then connected in series.
Circuit examples to monitor switches per protective device. The
protective devices number of position switches which
are required for each protective door
Circuits to monitor protective devices
can be taken from Section 2 of the
use position switches. Various possi-
Manual.
bilities of the different devices are
shown in the examples for EMER-
GENCY OFF. These circuit examples
will not be repeated here as the
EMERGENCY OFF control device is
only replaced by one or two position

Single-channel Two-channel

EMERGENCY EMERGENCY
OFF control OFF control Doors
devices devices

Open

Closed

Closed

Open

Circuit diagram 6/6 Circuit diagram 6/7

Several EMERGENCY OFF SIGUARD position switches used to monitor moving protective equipment
control devices

6/4 Safety Integrated Application Manual Siemens AG

6.2 3TK28 SIGUARD Contactor Safety Combinations
6
The internal circuit diagrams are valid
for DC-operated devices. The AC- 3 4 1 2
L+ X1 X2 X3 X4 X5 X6 13 23 25 1 Enabling contacts
operated SIGUARD combinations
2 Signaling contacts
essentially correspond to those for U
K3 3 Signal transmitter
DC operation. Only the polarity pro- R3
4 “Ready ON“
tection diode V1 is eliminated and a K1
For 3TK28 01-3TK28 04
bridge rectifier is located in front of K1 K2 K1 K1 and 3TK29:
R2 K2 K2 K2 5 “Ready” LED
every contactor. This means that AC- K2 6 “ON” LED
operated SIGUARD contactor safety K3
combinations can also be used for DC H2
K3 K3 K3

voltages with some restrictions. K1 V1 K3 V3 R1 K2 V2

H1
5 6
L- 14 24 (26)

Circuit diagram 6/8

Internal circuit diagram of 3TK28 01, 3TK28 02 contactor safety combination
(DC operation) NC signaling contact for 3TK28 02. For 3TK 2801/02, terminals “X2, X4,
X6” are at the top, for TK 2803, there is no terminal “X3”

L1/L+
1 Enable
N/L-
2 Signal

F1 3 EMERGENCY
OFF signal
transmitter
3 4 1 2
4 “Ready ON”

L1/L+ X1 (X2) (X3) (X4) X5 (X6) 13

K1

K2

K3

N/L- X2 X4 X6 14

Circuit diagram 6/9

Contactor safety combinations 3TK28 01 to 3TK2804 for EMERGENCY OFF circuits

Safety Integrated Application Manual Siemens AG 6/5

Immediately ready after the power
returns (it is not necessary to open L1/L+
1 Enable
N/L-
and close the protective device):
2 Signal
The “Ready ON” f is not required F1
Door
3 Signal transmitter
(jumper X5-X6), if the resulting auto- Open
3
4 “Ready ON”
4 1 2
matic reclosure (restart) does not Closed
represent potential danger. L1/L+ X1 (X2) (X3) (X4) X5 (X6) 13

K1

K2

K3

N/L- X2 X4 X6 14

Circuit diagram 6/10

Contactor safety combinations 3TK28 01 to 3TK28 04 to monitor moving protective
devices. For 3TK 2801/02, terminals “X2, X4, X6” are at the top, for TK 2803, there
is no terminal “X3”.

L1/L+
1 Enable
N/L-
2 Signal

F1 3 Signal transmitter
3 EMERGENCY
OFF
4 1 2
4 “Ready ON”

L1/L+ X1 (X2) (X3) (X4) X5 (X6) 13

K1

K2

K3

N/L- X2 X4 X6 14

Circuit diagram 6/11

Contactor safety combinations 3TK28 01 to 3TK28 04 for an EMERGENCY OFF circuit.
For 3TK28 01/02, terminals “X2, X4, X6” are at the top, for 3TK 2803, there is no
terminal “X3”.

6/6 Safety Integrated Application Manual Siemens AG

 6
3 4 1 2
L+ X1 X2 X3 X4 X5 X6 13 23 33 43 57 65 1 Enabling contacts
2 Signaling contacts
V1
U
3 Signal transmitter
K3
R3 K1 4 “Ready ON”
K1
K3
5 “Ready” LED
R2 K1 K2 K1 6 “ON” LED
K2

K3 H2 K1 K3 K2

R1
K1 K2 K3 H1

5 6

L– 14 24 34 44 58 66

Circuit diagram 6/12

Internal circuit diagram of a 3TK28 04 contactor safety combination (DC operation)

4 3 1 2
L+ X1 X3 X5 13 23 33 43 53 65 1 Enabling contacts
V1 2 Signaling contacts
3 Signal transmitter
4 “Ready ON”
K3
H1 5 “Ready” LED
R3 K3 D3
K1 K2 K2 6 “ON” LED
K2
H3 For 3TK28 05:
R1 R5 5 “Line supply” LED
H2 K1
U K3
6 H2 = LED “Channel 2”
H3 = LED “Channel 1”
D1 K1 D2 K2 R2 H2 + H3 = Enable
K1 K1 K3
8 Terminal X2 is not connected-up

5 8 6 6 8 For 3TK28 06:

Special circuit is possible for terminal X2
L- (X2) X4 X6 14 24 34 44 54 66

Circuit diagram 6/13

Internal circuit diagram of a 3TK28 05, 3TK28 06 contactor safety combination
(DC operation); terminal X2 is only connected-up for the 3TK28 06 device

Safety Integrated Application Manual Siemens AG 6/7

 L1/L+ L1
N/L- L2
L3
F1

“Ready
ON”
EMERGENCY OFF

L1/L+ X1 X3 X5 13 23 33 43 53 65
V1

K3 KM1
KM1 H1
R3 K3 D3
K1 K2 K2
K2
H3
R1 R5 H2 K1
U K3

D1 K1 D2 K2 R2
K1 K1 K3 M
3~

N/L- X2 X4 X6 14 24 34 44 54 66
KM1
N/L-

Circuit diagram 6/14

Contactor safety combination 3TK28 06 for a single-channel EMERGENCY OFF circuit.
This circuit can also be used for the 3TK28 05 (Cat. 2).

L1/L+ L1
N/L- L2
L3
F1

“Ready EMERGENCY
ON” OFF

L1/L+ X1 X3 X5 13 23 33 43 53 65
V1

K3 KM1
KM1 H1
R3 K3 D3
K1 K2 KM2
KM2 K2
K2
H3
R1 R5 H2 K1
U K3

D1 K1 D2 K2 R2
K1 K3 M
3~

N/L- X4 X6 14 24 34 44 54 66

KM2
KM1
N/L-

Circuit diagram 6/15

Contactor safety combination 3TK28 06 for a two-channel EMERGENCY OFF circuit.
This circuit can also be used for the 3TK28 05 (Cat. 3).

6/8 Safety Integrated Application Manual Siemens AG

 6
L1/L+ L1
N/L- L2
L3
F1

“Ready EMERGENCY
ON” OFF

L1/L+ X1 X3 X5 13 23 33 43 53 65
V4

K3 KM1
KM1 H1
R3 K3 D3
K1 K2 KM2
KM2 K2
K2
H3
R1 R5 H2 K1
U K3

D1 K1 D2 K2 R2
K1 K3 M
3~

N/L- X4 X6 14 24 34 44 54 66

KM2
KM1
N/L-

Circuit diagram 6/16

Contactor safety combination 3TK28 06 for a two-channel EMERGENCY OFF circuit with cross-circuit protection.
This circuit can also be used for the 3TK28 05 (Cat. 4).

4 3 1 2 5 1 Enabling contacts
L+ X1 X3 X5 13 23 33 43 53 65 77 87 97 2 Signaling contacts
3 Signal transmitter
V1 4 “Ready ON”
5 Enable contacts, delayed
7 Jumper Y1-Z1 and Y2-Z2
K3 to extend the delay
L1/L+ time by 10x
K3 L1/L+ 8 A special circuit can be connected
K2 Timer module
Channel 2 Timer module K4 at terminal X2
R2 R1 K2 K1 K3 K1 K2 tv = 0.5...30s Channel 1
K1 tv = 0.5...30s
U K1 K5
K1 K3 R4 K2 R3 IN2 N/L- Y2 Z2
H1
IN1 N/L- Y1 Z1
V2 V4 H3 V3 H2

L- X2 X4 14 24 34 44 54 66 Y2 Z2 Y1 Z1 78 88 98
8 t v x 10 7 t v x 10

Circuit diagram 6/17

Internal circuit diagram of a 3TK28 07 contactor safety combination (DC operation)

Safety Integrated Application Manual Siemens AG 6/9

 L1/L+ L1
N/L- L2 1 Enable, instantaneous

L3 2 Motor OFF, delayed

F1 3 Signal transmitter, EMERGENCY OFF
F2 F2 4 “Ready ON”
4 3

1 5 Motor control device

2
L1/L+ X1 X3 X5 13 23 33 43 53 65 77 87 97 6 Braking trigger signal
7 Fault signal, motor control device
8 Mechanical brake

K3 K4 KM1

K2 K5

K1 5

M
3~
8

6
N/L- X2 X4 14 24 34 44 54 66 78 88 98
KM1

7 KM1
N/L-

Circuit diagram 6/18

Contactor safety combination 3TK28 07 for controlled actuation of EMERGENCY OFF.

L1/L+
1 Enabling signals
N/L-
4 Ready ON
F1
Door

Open
Closed 1
L+ X1 X3 X5 13 23 33 43 53 65

K3
4
K2

K1

L- X2 X4 X6 14 24 34 44 54 66

Circuit diagram 6/19

Contactor safety combination 3TK28 06 to monitor moving protective devices

6/10 Safety Integrated Application Manual Siemens AG

 6
L1/L+ L1
N/L- L2
L3
Automatic restart is only
F1
permitted for protective
Door
monitoring in exceptional cases.
If an automatic restart cannot
Open result in a hazardous condition,
Closed then “Ready ON” is not required.

L+ X1 X3 X5 13 23 33 43 53 65

KM1
K3
KM2
KM1 K2

K1

KM2 M
3~

L- X4 X6 14 24 34 44 54 66
KM2
KM1
N/L-

Circuit diagram 6/20

Contactor safety combination 3TK28 06 for two-channel and cross-circuit proof
monitoring of moving protective devices with automatic restart

Classification in Categories
according to EN 954-1
The classification of circuits into cate-
gories according to EN 954-1 has
now been made clear using the pre-
vious examples.
The classification below, is valid when
the wiring is correctly realized accord-
ing to the published circuit diagrams,
also under difficult ambient condi-
tions, for example dirty industrial
environments (pollution level 3).
If special care is taken connecting-up
the wiring, it may be possible to
achieve a higher safety category, e.g.
using separate cables or routing the
cable to EMERGENCY OFF contacts
and position switches so that it is
mechanically protected (e.g. in spe-
cial cable ducts). Thus, Category 4
can be achieved without having a
cross-circuit proof configuration,
under the assumption, that the appro-
priate peripheral devices are used.

Category acc. to EN 954-1 Circuit version Possible equipment

B, 1, 2 Single channel Possible with all basic- and expansion devices

3 Two channel 3TK2805, 3TK28 06, 3TK28 07, also in conjunction with
one or several expansion units

4 Two channel and 3TK28 05 and 3TK2806 also in conjunction with one or
cross-circuit proof several expansion units

Safety Integrated Application Manual Siemens AG 6/11

 Interface for expansion units A circuit with the 3TK28 06 and two
expansion units to multiply the
The 3TK29 SIGUARD combination
contacts of the 3TK28 07 is illustra-
expansion units must always be used
ted in circuit diagram 6/21.
together with a basic 3TK28 unit. One
expansion unit can be connected for The 3TK29 . 3 expansion units can
each enabling contact in the basic be used for drop-out delayed contacts
unit. The signaling contact in the ex- of up to 8 seconds (circuit diagram
pansion unit must always be connec- 6/23). The delay time is set using dif-
ted in series with “Ready ON”. ferent jumpers at connecting termi-
nals Y2, Z1, Z2 and Z3.
The Category which a circuit with an
expansion unit can achieve according
to EN 954-1 depends on the Cate-
gory of the basic unit with interface.
If the expansion unit is located next
to the basic unit in the cabinet, the
connecting cables between the basic
unit and expansion unit are so short,
that a fault (electrical fault) can be
completely ruled-out in these
connecting cables.

L1/L+ 3TK28 06 (or 3TK28 05) with two-channel If required, more than one
N/L- and cross-circuit-proof connection of the expansion unit can be connected
EMERGENCY OFF control devices can to a basic unit as shown here in
achieve Category 4 according to EN 954-1, the example. In this example, 5
F1
also using one (or two) expansion unit(s). expansion units can be connected.

EMER-
Ready GENCY-
ON STOP

103 123 103 123

L1/L+ X1 X3 X5 13 23 33 43 53 65 X7 73 83 93 113 133 X7 73 83 93 113 133
V1

R3 K3 D3 K3 R1 K3 R1 K3
H1
K2
K1 K2 K2
R1 R5 K3 R3 R3
U H3 U U
H2 K1 R2 K4 R2 K4

D1 K1 D2 K2 R2 K3 K4 H1 K3 K4 H1
K1 K3

K1

N/L- X2 X4 X6 14 24 34 44 54 66 A1/ A2/ X8 74 84 94 114 134 A1/ A2/ X8 74 84 94 114 134

L+ L- 104 124 L+ L- 104 124

Circuit diagram 6/21

Contactor safety combinations 3TK28 06 for two-channel and cross-circuit-proof
connection of the EMERGENCY OFF control device and two 3TK29 07 expansion units.
This circuit can also be realized using the 3TK28 05 unit.

6/12 Safety Integrated Application Manual Siemens AG

 6
L1/L+
N/L-

F1 3TK28 06 (or 3TK28 05) with two-channel and cross-circuit-proof

connection of the EMERGENCY OFF control devices can achieve
Ready EMER- Category 4.
GENCY
ON OFF

L1/L X1 X3 X5 13 23 33 43 53 65 X7 77 87 97
+ V1
V1

R3 K3 D3 K3 V2 R4 R7 R1 K1
H1 R3 R5
K2
K1 K2 K2 U
R1 R5 K3
U H3 H2 K1 R2 K2
+ + + + R6 K1 K2 H1
D1 K1 D2 K2 R2
K1 K3 C1 C2 C3 C4

K1

N/L- X2 X4 X6 14 24 34 44 54 66 A1/L+ A2/L- Y2 Z1 Z2 Z3 X8 78 88 98

Circuit diagram 6/22

Contactor safety combination 3TK28 06 for two-channel and cross-circuit-proof
connection of the EMERGENCY OFF control device and a 3TK29 . 3 expansion unit.
This circuit can also be used with the 3TK28 05.

Expansion units

1 1
X7 77 87 97 X7 73 83 93 103 113 123 133
V1

V2
R4 R7 R1 K1 R1 K3
R3 R5
U R3 U K3 K4

R2 K2 R2 K4
+ + + + R6 K1 K2 H1
H1
C1 C2 C3 C4

6
A1/L+ A2/L- Y2 Z1 Z2 Z3 X8 78 88 98 A1/L+ A2/L- X8 74 84 94 104 114 124 134

1 Enabling contacts 1 Enabling contacts 6 “ON” LED

Circuit diagram 6/23 Circuit diagram 6/24

Internal circuit diagram of a contactor safety combination delay Internal circuit diagram of a contactor safety combination
module 3TK29 23, 43, 83 (DC operation) supplementary module 3TK29 07 (DC operation)

Safety Integrated Application Manual Siemens AG 6/13

Press control devices
Circuit examples for presses
The two devices, two-hand control
device 3TK28 11 and overtravel tester
3TK28 15 are used for press controls.
6/14 Safety Integrated Application Manual
Two-hand control device 3TK28 11 3TK28 15 overtravel tester
The two-hand control device 3TK28 This unit is used to check overtravel
11 is a control which allows presses for linearly operated presses, such as
to be controlled using two hands. For spindle, hydraulic and pneumatic
presses, it must be ensured that both presses.
hands are required to control the
Each time that the power supply is
presses.
switched-on at the two-hand control
The two-hand control device fulfills device 3TK28 11, the braking travel is
Category 4 in accordance with EN checked using the 3TK28 15.
954-1 and achieves type 3 according
3TK28 15 must always be used in
to EN 60 204-1 (VDE 0113 Part 1) as
conjunction with the two-hand control
well as type IIIc according to EN 574
unit 3TK28 11.
for two-hand control systems. This
means that both control devices of For press control units using relays,
the 3SB33 SIGUARD two-hand con- refer to Pages 6/28 to 6/31.
trol must be simultaneously actuated
(≤ 0.5 s) with both hands and they
have to be continually actuated while
the press is in a hazardous condition.
If one actuator device is released,
then the control stops the hazard-ous
motion. If the 0.5 s is exceeded, or if
one of the control devices is relea-
sed, then both control devices must
be released before a restart can be
initiated.
It should also be observed that the
switching currents for the control
devices are 50 mA at 24 V DC. The
3SB3 SIGNUM® control devices, as
well as the SIGUARD two-hand oper-
ator unit 3SB33G3 are suitable. It
may be necessary to use gold-plated
contacts.
Control interlocking functions are
switched in the feedback circuit.
Siemens AG
 6
L1/L+
N/L-

1 2
F1 F2 F3 KM2 KM1
S1 KM1 KM2

A1 T11 T12 T13 X1 X2 13 23 31 41

3TK2811

A2 T21 T22 T23 14 24 32 42

S2
1

Circuit diagram 6/25

Two-hand control device 3TK28 11

L1/L+ F1
Powering-up a press
N/L-
• Power-up the pump (S4)
X1 13 31 23
• Travel to upper dead center (S5)
K3
S1 3 • Actuate the two-hand operation console
K4 (3TK2811), until S3 opens
X2 14 32 3TK2811 24
• Actuate the two-hand operation console a
4 second time. After the two-hand operation
K4 console is released, the ram automatically
K1 travels to upper dead center.
PE
S3 K4 K2

A1+ 3 7 9 12 5 16 8 1 1 Two-hand pushbutton

10 7
2 Feedback
3TK2815

S5
3 OFF
H1 4 PE: Test limit switch, defines the overtravel
5 OT: Upper dead center
K3 6 Hydraulic pump ON
7 UP (wards)
K1 Hydraulic pump contactor
5 K2 Ram up
A2- 4 6 11 13 14 15
OT S2 K3 Ram down, 1st channel
K4 Ram down, 2nd channel
S4 6

Circuit diagram 6/26

Overtravel tester 3TK28 15 and two-hand control device 3TK28 11

Safety Integrated Application Manual Siemens AG 6/15

6.3 3TK28 SIGUARD Relay Safety Combinations

Y33 Y34 Y22 Y21 13 23

A1/A2 power supply
A1
ϑ K1 K2 Y33/34 “ready ON”
Feedback circuit
4 K1
3 Y11/12 sensor
1
2 (e.g. EMERGENCY OFF pushbutton)
K1
Y21/22 sensor
K1 (e.g. EMERGENCY OFF pushbutton
C1 K1 K2 two-channel)
K2
13/14 enable circuit
V1 K2
23/24 enable circuit
K2 1 “POWER” LED
2 “Channel 1” LED
A2
3 “Channel 2” LED
Y11 Y12 14 24 4 PTC fuse

Circuit diagram 6/27

Internal circuit diagram of the 3TK2823

Function description
Power-on
Connect the power;
Y33 Y34 Y22 Y21 13 23
the “Power” LED is lit, EMERGENCY OFF closed,
A1 C1 is charged, press ON,
ϑ K1 K2 C1 is charged, K1, V1 are energized,
4 …K2 starts, K1 + K2 latch,
K1 “Channel 1” and “Channel 2” LEDs are lit.
1 3
2 K1 ON monitoring
H1 H2 H3 ON is pressed fault!
K1
EMERGENCY OFF closed,
C1 K1 K2 V1 immediately starts K2, C1 is not charged
K2 K1 does not start.
V1 K2 Only the “Channel 2” LED is lit
K2
Cross-circuit
If EMERGENCY OFF 1 and EMERGENCY OFF
A2 2 are short-circuited, a short-circuit
current flows through the PTC fuse.
Y11 Y12 14 24 The PTC goes into a high-ohmic state.
None of the LEDs are lit.

Circuit diagram 6/28

Function description 3TK2823

Y2 Y1 13 23 (33) (41)
A1/A2 power supply
A1 via EMERGENCY OFF pushbutton
ϑ
Y1/Y2 “ON”
4
K1 K1 feedback circuit

1 13/14 enable circuit

K1
K2 23/24 enable circuit
33/34 enable circuit
K2
41/42 signaling circuit
2 3 1 “POWER” LED
K2
2 “Channel 1” LED
K1 K2
3 “Channel 2” LED
A2 4 PTC fuse
14 24 (34) (42)

Circuit diagram 6/29

Internal circuit diagram of the 3TK2821/24

6/16 Safety Integrated Application Manual Siemens AG

 6
The following circuit diagrams have
been harmonized with the German 24 V AC/DC
L/+
Trade Association (BG) and also
approved. K1

K2 ON K1
EMERGENCY
6.3.1 EMERGENCY OFF OFF K3 M
(EMERGENCY-STOP) circuits A1 Y1 Y2 13 23 (33) (41)

3TK2821/24
Circuit diagrams
K2

A2 14 24 (34) (42)
K3
K1 K2 K3 H1
Circuit diagram 6/30 M
3TK2821/24 for EMERGENCY OFF, N/– N/–
Category 2, single-channel,
with feedback circuit

24 V AC/DC L/+

EMERGENCY A1 Y1 Y2 13 23 (33) (41)

OFF
3TK2821/24

ON
K1

K1

K2
K2
M
A2 14 24 (34) (42)
Circuit diagram 6/31 K1 K2 H1
3TK2821/24 for EMERGENCY OFF,
Category 3 (4), two-channel, N/– N/–
with feedback circuit

24 V AC/DC
L/+

K1
ON
K2
A1 Y11 Y12 Y33 Y34 13 23
3TK2823

EMER-
GENCY K1
OFF

K2

Y21 Y22 A2 14 24 M

Circuit diagram 6/32 K1 K2

3TK2823 for EMERGENCY OFF,
N/– N/–
Category 4, two-channel,
with feedback circuit, monitored start

Safety Integrated Application Manual Siemens AG 6/17

 L/+

L/+

A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51

EMER-
3TK2825

GENCY
ON OFF

K1

K2 K1 K2 K3

K3 M M M

Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52

K1 K2 K3 H1 H2
PE
N/– N/–

Circuit diagram 6/33 3TK2825 EMERGENCY OFF, Category 2, single-channel, according to EN 954-1, monitored start

L/+

L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
3TK2825

ON EMER-
GENCY K2
OFF
K1

K2 K1

M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52

K1 K2 H1 H2
PE
N/– N/–

Circuit diagram 6/34 3TK2825 EMERGENCY OFF, Category 4, two-channel, according to EN 954-1, monitored start

L/+

L/+

A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57

EMER-
3TK2827

GENCY
OFF
K2 K1
ON

K1
M M
K2

Y33 Y34 PE A2 14 24 32 48 58
H1 K1 K2

N/–
PE
N/–

Circuit diagram 6/35 3TK2827 EMERGENCY OFF, Category 2, single-channel, according to EN 954-1, monitored start

6/18 Safety Integrated Application Manual Siemens AG

 6
L/+

L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57

3TK2827
EMER-
GENCY
OFF

ON K1

K1 K2

K2

Y33 Y34 PE A2 14 24 32 48 58
H1 K1 K2
Circuit diagram 6/36
3TK2827 EMERGENCY OFF with shut- PE
down, stop Category 1, for Category 3 N/– N/–
according to EN 954-1, two-channel, with
feedback circuit, monitored start

24 V AC/DC

K1
ON
L/+

K5
A1 Y11 Y12 Y33 Y34 13 23 A1 13 23 33 43 51
3TK2823

EMER- 3TK2830
GENCY
OFF

Y21 Y22 A2 14 24 A2 14 24 34 44 52
Circuit diagram 6/37
3TK2823 expanded with 3TK2830 K1 K2 K3 K4 K5
for EMERGENCY OFF, Category 4 acc.
N/–
to EN 954-1, two-channel, with feedback N/–
circuit

Safety Integrated Application Manual Siemens AG 6/19

 L/+

24 V AC/DC

A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51 A1 13 23 33 43 51

3TK2830
3TK2825

ON
EMER-
K1 GENCY
OFF

K5

K6

Y33 Y34 PE A2 14 24 34 42 52 A2 14 24 34 44 52

K1 K2 H1 H2 K3 K4 K5 K6
PE N/–
N/– N/– N/–

Circuit diagram 6/38

3TK2825 expanded by 3TK2830 for EMERGENCY OFF, Category 4 acc. to EN 954-1, two-channel acc. to EN 954-1, monitored start

L/+

24 V AC/DC

A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57 A1 13 23 33 43 51

3TK2830

EMER-
3TK2827

ON GENCY
OFF

K1

K7

Y33 Y34 PE A2 14 24 32 48 58 A2 14 24 34 44 52

K1 K2 H1 K3 K4 K5 K6 K7
PE N/–
N/– N/– N/–

Circuit diagram 6/39

3TK2827 expanded by 3TK2830 for EMERGENCY OFF, Category 4, two-channel, monitored start

6/20 Safety Integrated Application Manual Siemens AG

 6
6.3.2 Protective door 24 V AC/DC
monitoring L/+

K1

K2
closed
open K3

A1 Y1 Y2 13 23 (33) (41)

3TK2821/24
closed
open

K1 K2 K3

M M M

Circuit diagram 6/40 A2 14 24 (34) (42)

3TK2821/24 for protective door monitoring K1 K2 K3 H1
(2 protective doors are cascaded, each with N/–
1 SIGUARD position switch), Category 2
acc. to EN 954-1, single-channel, with N/–
feedback circuit, autostart

open 24 V AC/DC L/+

closed
K1
K1
K2

K3 M
A1 Y1 Y2 13 23 (33) (41)
3TK2821/24

K2
open
closed
M

Circuit diagram 6/41

3TK2821/24 for protective door monitoring A2 14 24 (34) (42) K3
with tumbler (2 protective doors are K1 K2 K3 H1
cascaded, each with 2 SIGUARD position M
switches with tumbler), Category 2 acc. N/– N/–
to EN 954-1, single-channel, with feedback
circuit, autostart

Safety Integrated Application Manual Siemens AG 6/21

 L/+
24 V AC/DC
∞ K1

K2
∞A1 Y1 Y2 13 23 (33) (41)
3TK2821/24

open K1
closed

K2

M
Circuit diagram 6/42
A2 14 24 (34) (42) 3TK2821/24 for protective door monitoring
∞

K1 K2 H1 (2 protective doors are cascaded, each with

open closed
∞ 2 SIGUARD position switches), Category
N/– 3(4) acc. to EN 954-1, two-channel with
feedback circuit, autostart, (∞ for Category 4
N/– – the cable has to be routed so that it is
especially protected)

24 V AC/DC
L/+

K1

K2

A1 Y11 Y12 Y33 Y34 13 23

3TK2822

open closed
K1

K2

M
Y21 Y22 A2 14 24 Circuit diagram 6/43
K1 K2 3TK2822 for protective door monitoring
(2 protective doors are cascaded, each with
N/– N/– 1 SIGUARD position switch), Category 4
acc. to EN 954-1, two-channel with
feedback circuit, autostart

6/22 Safety Integrated Application Manual Siemens AG

 6
L/+

L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
closed
3TK2825
open
K1

K2
open closed K1 K2 K3
K3
M M M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52

K1 K2 K3 H1 H2
PE
N/–
N/–

Circuit diagram 6/44

3TK2825 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position switch),
autostart, Category 2 acc. to EN 954-1, single-channel, with feedback circuit

L/+

open closed
L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51
3TK2825

K1
K1

K2
K2

M
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52

K1 K2 H1 H2
PE
N/–
N/–

Circuit diagram 6/45

3TK2825 for protective door monitoring with 2 SIGUARD position switches, autostart, Category 4 acc. to EN 954-1,
two-channel, with feedback circuit

Safety Integrated Application Manual Siemens AG 6/23

 L/+

L/+
A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57
closed

3TK2828
open

K1 K2
K1
open closed

K2 M M
Y33 Y34 PE A2 14 24 32 48 58

H1 K1 K2

N/–
PE
N/–

Circuit diagram 6/46

3TK2828 for protective door monitoring (2 protective doors are cascaded, each with 1 SIGUARD position
switch), stop Category 1, Category 2 acc. to EN 954-1, single-channel, with feedback circuit, autostart

L/+

L/+

A1 Y10 Y11 Y12 Y21 Y22 13 23 31 47 57

3TK2828

K1

K1 open closed K2

K2

Y33 Y34 PE A2 14 24 32 48 58 M

H1 K1 K2

N/–
PE
N/–

Circuit diagram 6/47

3TK2828 for protective door monitoring with 2 SIGUARD position switches,
stop Category 1, Category 3 acc. to EN 954-1, two-channel, with feedback circuit, autostart

6/24 Safety Integrated Application Manual Siemens AG

 6
24 V AC/DC

L/+

A1 Y10 Y11 Y12 Y21 Y22 13 23 33 41 51 A1 13 23 33 43 51

3TK2825

3TK2830
K1

K6
open closed
Y33 Y34 Y43 Y44 PE A2 14 24 34 42 52 A2 14 24 34 44 52

K1 K2 H1 H2 N/– K3 K4 K5 K6
PE
N/ N/– N/–

Circuit diagram 6/48

3TK2825 expanded by 3TK2830 for protective door monitoring with 2 SIGUARD position switches,
Category 4 acc. to EN 954-1, two-channel, with feedback circuit, autostart

Safety Integrated Application Manual Siemens AG 6/25

Protective door monitoring
with contactless SIGUARD L1 5
magnetically-operated switches 0V START

Protective doors are monitored using +24 V DC

an evaluation unit up to Cat. 3 acc. to
EN 954-1 (circuit diagram 6/50).
The evaluation unit can be operated, A1 A2 Y1 X1 13 23
both with automatic restart as well as
with monitored start. The start button
is not necessarily required. 100 mA
I max.

Monitoring several protective

doors with evaluation unit
K1
up to Cat. 3 acc. to EN 954-1 µP1

A maximum of eight SIGUARD

magnetically-operated switches can µP2
be connected to the 3SE6808-6DB K2
evaluation unit. If one of the eight
magnetically-operated switches is
actuated (the protective door is ope-
S13 S14 S21 S22 14 24
ned), then the unit stops. There is a
PLC signaling output (switching to p)
ws/wh 22
sw/bk 13

br/br 21
bl/bl 14

for each input. The fail-safe shutdown

is realized using two relay safety
K3
outputs.
K4
If an input is not used, then the ap-
propriate terminals of the NO contact
must be jumpered. 0V M
Enable 3~
For limited safety requirements, the SK3
evaluation unit can also be used with-
out a start button. For this particular
application contact X1 must be sup- Circuit diagram 6/49
plied with 24 V DC (Y1 or external). SIGUARD magnetically-operated switch with evaluation unit 3SE6801-1CC
for Category 3 acc. to EN 954-1

6/26 Safety Integrated Application Manual Siemens AG

 6
Connecting example 3SE6808-6DB
Magnetically-operated switch 5 Magnetically-operated switch 6 Magnetically-operated switch 7 Magnetically-operated switch 8
+24 V

4AT
Signaling outputs
to the PLC
+SPS
S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 Y5 Y6 Y7 Y8 Y+ L+ 13 23

S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 S13 S14 S21 S22 Y1 Y2 Y3 Y4 X4 L– 14 24
Signaling outputs
to the PLC

START

0V
Magnetically-operated switch 1 Magnetically-operated switch 2 Magnetically-operated switch 3 Magnetically-operated switch 4 (C)1998

Circuit diagram 6/50

A max. of 8 protective doors can be monitored using SIGUARD magnetically-operated
switches and evaluation unit 3SE6808-6DB for Category 3 acc. to EN 954-1

Technical data of the evaluation unit for SIGUARD 3SE6808-6DB magnetically-operated switches
Connection cross-section: Max. 2 x 2.5 mm2 with end Supply voltage, acc. to IEC 38: 24 V DC +10%/-10%
sleeves, min. 1.5 mm2
Own power drain: 24 V DC nom. 6.5 W, max. 9.1 W
Mounting in an enclosure: Snapped onto 35 mm standard
Safety outputs: 13–14, 23–24
mounting rails
acc. to DIN EN 50022 Fusing, output circuits: 4 AT
Degree of protection acc. to Terminals: IP 20 Limiting continuous 4A
DIN VDE 0470 Part 1: Enclosure: IP 40 current at the max.
ambient temperature:
Weight: Approx. 300 g
Switching current, max.: 8A
Mounting position: Any, front panel visible
when the cabinet is open Switching voltage, max.: 400 V ~ 50/60 Hz, 250 V
Fusing, power supply voltage: 4 AT Switching capacity: AC 15-C 250
Permissible ambient temperature: Operation: -10°C/+55°C AC: Max. 1500 VA
Storage: -55°C/+80°C
DC voltage: Refer to the load limiting
Overvoltage Category: 2 (2.5 kV) characteristic, SR4 safety relay
Degree of pollution: 2 Category: 3 (acc. to EN 954-1)
Rated insulation voltage: 250 V acc. to DIN VDE
0110 Part 1 (1997-04)

Safety Integrated Application Manual Siemens AG 6/27

 6.3.3 Press control
devices
Press control devices with contactors
also refer to Pages 6/14 – 6/15

A1 Y11 Y12 Y21 Y22 Y23 13 23 31 41

Operating A1 L/+ 1 Power supply unit
3TK2834

voltage A2 N/–
2 PTC fuse
Outputs 13, 14 Enable circuit 1 (NO contact)
23, 24 Enable circuit 2 (NO contact) 3 Control logic
1 2 31, 32 NC contact
41, 42 NC contact 4 Channel 1
3 4
Inputs Y11, Y12 Feedback circuit 5 Channel 2
Y21, Y22, Y23 Pushbutton S1
ϑ 6 6 Safety circuits
Y31, Y32, Y33 Pushbutton S2
5

A2 Y31 Y32 Y33 14 24 32 42

Circuit diagram 6/51

Internal circuit diagram of the 3TK2834 two-hand control device

L/+ L/+

S1
K1

K2

A1 Y11 Y12 Y21 Y22 Y23 13 23 31 41

S1, S2 buttons on the two-hand operating console
3TK2834

H1 Signaling lamps
K1, K2 must be contactors with positively-driven contacts

K1

K2

A2 Y31 Y32 Y33 14 24 32 42

K1 K2 H1
N/– S2 N/–

Circuit diagram 6/52

3TK2834 two-hand control device, Category 4 acc. to EN 954-1

6/28 Safety Integrated Application Manual Siemens AG

 6
A1 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41
Operating A1 L/+
3TK2835

voltage A2 N/–
Outputs 13, 14 Enable circuit (tool down)
23, 24 NO contact (tool up)
1 2 3 4 33, 34 NO contact (overtravel OK)
41, 42 NC contact (hydraulic pump on)
Inputs Y11, Y12, Y13, Y14 Feedback circuit (K4)
Y21, Y22 Position switch (S4) for test cams
ϑ
Y31, Y32, Y33, Y34 Upper dead center, switch (S3)

1 Power supply unit

2 PTC fuse
3 Control logic
4 Safety circuits
A2 Y31 Y32 Y33 Y34 14 24 34 42

Circuit diagram 6/53

Internal circuit diagram of the 3TK2835 overtravel tester

S0 L/+
S0 Main switch
L/+
S1, S2 Button on the two-hand
operating console
S3 Postitioning switch at the
upper dead center
S1 S4 Position switch for
test cams
K3 S4
K4 S5 Hydraulic pump “ON”
S6 Tool
K4 “UP” (manual operating)
A1 Y11 Y12 Y21 Y22 Y23 13 23 31 41 A1 Y11 Y12 Y13 Y14 Y21 Y22 13 23 33 41 K1 Contactor for the
hydraulic pump
3TK2834

3TK2835

K1 K2 Tool “UP”
K3, K4 Tool “DOWN”
H1 Signal lamp

A2 Y31 Y32 Y33 14 24 32 42 A2 Y31 Y32 Y33 Y34 14 24 34 42

S5
S3
S6

S2 K4 K3 K2 H1 K1
N/–
N/–

Circuit diagram 6/54

3TK2834 two-hand control device in conjunction with a 3TK2835 overtravel tester to
monitor the overtravel in linear hydraulic-, pneumatic- and spindle presses acc. to VBG 7
n 5.2 § 11, Category 4 acc. to EN 954-1

Safety Integrated Application Manual Siemens AG 6/29

 Sequence after the press has
been powered-up:
LEDs Operation
1. The hydraulic pump is powered-
POWER RELEASE
up with S5, the ram is moved up
to upper dead center, if required, Overtravel OK
using S6. Overtravel erronous or test still not executed

2. Press S1, S2 at the two-hand

operating console until the posi-
tion switch for the test cams
(S4) opens.
3. Release S1, S2.
4. Depress S1, S2 again: Signal
lamp H1 lights-up (bright), if the
overtravel is OK.
5. Release S1, S2: The ram returns
to the upper dead center.
6. If the overtravel is OK, all of the
outputs remain active until the
control voltage is disconnected.
Fig. 6/1
Fault situation A more detailed description of the
function of the 3TK2834 two-hand
If the cam actuates position switch
control device is provided in the
S4, then the signal lamp H1 is not
Instruction Manual, Order No.
lit-up. The machine part, which is
3ZX1012-0TK28-7CA1, for the over-
potentially hazardous, can then only
travel tester 3ZX1012-0TK28-6CA1.
be moved to the upper dead center
using S6.
This press can then no longer be
used. Contact the technician to check
the press.

A B C
Overtravel OK
Us
1 Power (Vs) on
S1, S2 2 S5 is pressed, K1 pulls-in (latches).
3 S6 is pressed, K2 pulls-in (the ram moves upwards in the manual mode).
3TK2834 4 The upper dead center is reached, S3 is actuated.
23/24 (K4)
5 S6 is released, K2 drops-out.
S3 6 S1 and S2 are pressed on the two-hand operating console, the two-hand
control device 3TK2834 outputs an enable signal, K3 and K4 pull-in.
S4
7 The ram moves downwards, S3 is no longer actuated.
S5
8 Test cams are reached, S4 is actuated, K3 drops-out.
S6 9 The ram remains stationary, S1, S2 are released, K4 drops-out.
3TK2835 10 S1, S2 are pressed, K4 pulls-in again, H1 lights up.
13/14 (K3) 11 S1, S2 are released, K4 drops-out. K2 pulls-in, the ram moves upwards.
23/24 (K2) 12 S4 is no longer actuated.
13 Upper dead center is reached, S3 is actuated.
33/34 (H1)
14 S1 and S2 are pressed; K2 drops-out, K3 and K4 pull-in.
41/42 15 The ram moves downwards, S3 is no longer actuated.
16 S1, S2 are released, K3 and K4 open. K2 pulls-in.
K1
points 14 to 16 are repeated at each stroke of the press.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Fig. 6/2

6/30 Safety Integrated Application Manual Siemens AG

 6
A B D
Overtravel too long
US
1 Power (Vs) on
S1, S2 2 S5 is pressed, K1 pulls-in (latches).
3 S6 is pressed, K2 pulls-in (the ram moves upwards in the manual
3TK2834 mode).
23/24 (K4)
4 The upper dead center is reached, S3 is actuated.
S3 5 S6 is released, K2 drops-out.
6 S1 and S2 on the two-hand operating console are pressed,
S4
the 3TK2834 two-hand control device outputs enable signals,
S5
K3 and K4 pull-in.
S6 7 The ram moves downwards, S3 is no longer actuated.
8 Test cams are reached, S4 is depressed, K3 drops-out.
3TK2835
13/14 (K3) 9 The ram does not remain stationary, S4 is no longer actuated
(is passed-over), K3 pulls-in.
23/24 (K2)
10 S1 and S2 are released, K3 and K4 drop-out.
33/34 (H1)
11 S1, S2 are actuated, K4 pulls-in again. Overtravel tester is inhibited.
41/42

K1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Fig. 6/3

S3

S S4
S

A B C D!

Fig. 6/4
Function schematic of the press control.
The permissible overtravel “s” corresponds to the length of
the cam which actuates position switch S4.
According to ZH 1/456, the press manufacturer must define “s”.

Safety Integrated Application Manual Siemens AG 6/31

6.4 Contactless Protective Devices

6.4.1 Circuit examples L N

Receiver Sender
for SIGUARD light
curtains Power
supply
24 V DC 2 1 3 4 2 1 3 4
SIGUARD light curtains can be sup- – + – + – +

plied externally from 24 V DC. All of Jumper for the

the connecting cables must be test function
screened. Feedback
circuit
Standard evaluation for SIGUARD Start
light curtains (3RG7817-1DB2) A1(+) T11 T24 X1 X2 T12 T44 PE T22 13 23 41

The system, as standard is operated X3

with a monitored start, which re- K2
K2 K2 K2 K2
V7 K1 X2 K1
quires a start button. For an automa- + K1
K3 K3
tic re-start, a jumper must be inser- –
ted between terminals T11 and X2. K1 K2 D1 K3 D2
K1 K1 K3

The muting evaluation unit can also

be used to monitor SIGUARD light 3RG7817-1DB2
curtains, without actually using the A2(–) 14 24 42
muting function. Safety outputs

Terminals AML and 53 must be jum-

pered to simulate a muting lamp (as Circuit diagram 6/55
this isn’t required in this case). The Connecting-up the standard evaluation unit for SIGUARD light curtains
NC contacts of external contactors
must be connected in the feedback • It is mandatory to use a muting
circuit between terminals ERK and lamp (white) and this is monitored
ERK+. via the evaluation unit (terminal 53).
If one of the safety outputs at the • The start button cannot be bypas-
light curtain opens, the evaluation T11 T34 X1 X2
sed. Automatic re-start is not possi-
unit shuts down. Refer to circuit ble. Evaluation unit
diagram 6/59 for connecting-up the
electronic outputs. • Terminal 63 can have a maximum
1.5 A load. In order to avoid an over-
Circuit diagram 6/56
Fault monitoring with muting load condition, the receiver ground Automatic restart
function must be connected to terminal 63.
The use of the light curtain in the
muting mode with four muting sen- Connection possibilities
sors with floating NO contact outputs Muting sensor Muting sensor
is shown in circuit diagram 6/60. with floating with PNP output
output

GND VCC PNP

MSxN

MSxN
MSx+

MSx+
MSxP

MSxP
MSx–

MSx–

Evaluation unit Evaluation unit

Circuit diagram 6/57

Connecting different muting sensors

6/32 Safety Integrated Application Manual Siemens AG

 6
Receiver Sender

2 1 3 4 2 1 3 4
– + – +
GND Jumper for the
test function
+24 V +24 V

RESET

MS1+ MS1N MS1P MS1– BWS1N BWS1P

1

A1+ A1+ ESS+ ERK+ ERK MS2+ MS2N MS2P MS2– 13 23 33 53 63 AML PE

3RG7817-3FA2
ESS EST+ EST BWSE+ BWSE– MS4+ MS4N MS4P MS4– 14 24 34 54 64 A2– A2–

MS3+ MS3N MS3P MS3– BWS2N BWS2P

START
1 Feedback circuit between terminal ERK and ERK+

Circuit diagram 6/58

Connecting-up the muting evaluation unit without using the muting function

Sender Receiver
MS1 MS4
R

2 1 3 4 2 1 3 4
– + – +
MS2 S MS3 Jumper for the test
function, optional
+24 V

+24 V GND +24 V DC

max. 1,5A
RESET MS2 MS1 ML

MS1+ MS1N MS1P MS1– BWS1N BWS1P

Key- A1+ A1+ ESS+ ERK+ ERK MS2+ MS2N MS2P MS2– 13 23 33 53 63 AML PE
operated
switch 3RG7817-3FA2
ESS EST+ EST BWSE+ BWSE– MS4+ MS4N MS4P MS4– 14 24 34 54 64 A2– A2–

MS3+ MS3N MS3P MS3– BWS2N BWS2P

START MS4 MS3

Circuit diagram 6/59

Connecting-up the muting evaluation unit using the muting function

Safety Integrated Application Manual Siemens AG 6/33

Connecting-up the safety-related
semiconductor outputs
+24 V
K2 ext.
K2 ext.
14, 24 33 ERK
Evaluation
unit
ERK
Circuit diagram 6/60
Safety-related outputs
14, 24: Safety-related semiconductor
outputs (p switching) with cyclic
testing function. If the evaluation unit
has been started, and the light cur-
tain is not interrupted, these outputs
switch through 24 V DC. The output is
open when the evaluation units swit-
ched-off.
33: Safety-related semiconductor out-
put (n switching) with cyclic testing
function. If the evaluation unit has
been started, and the light curtain is
not interrupted, the output switches
to ground.
6/34 Safety Integrated Application Manual
Note
The electronic safety-related outputs
are destroyed by voltage spikes
exceeding approx. 60 V. Thus, the
motor contactors used must be provi-
ded with diode damping circuits,
which act as arc quenching elements.
The arc quenching elements must be
connected in parallel with the loads,
but not in parallel to the outputs.
We recommend, as external con-
tactors, Siemens auxiliary contactors
with integrated diode, type 3RH1122-
1JB40 or the combination consisting
of the auxiliary contactor (without
free-wheeling diode) 3RH1122-1BB40
and the 3RT1916-1DG00 diode.
Using the key-operated switch
Muting operation can be simulated
using the key-actuated switch. This is
necessary, if, when the muting sen-
sors are actuated, the power supply
of the muting evaluation unit fails. In
this condition, the evaluation unit
would always detect a fault, and it
would no longer run-up at the start.
The plant or system would not be
able to be started
If the key-operated switch is actua-
ted, the evaluation unit switches-into
the muting mode for max. 10 min so
that the material being transported or
conveyed can be removed from the
muting zone. If a muting sensor is no
longer actuated, the device stops and
must be re-started.
Siemens AG
 6
6.4.2 Circuit examples
for SIGUARD light
barriers
Evaluation unit and light barriers
for Category 2 acc. to EN 954-1

Power supply START

voltage

+24 V 0V
+24 V (Internal) IN OUT 0 V (Internal)

3RG7821-7BG00 3RG7821-7CD00 A1 A2 X1 X2 X3 X4 3RG7821-7BG00 3RG7821-7CD00

Sender 1 Receiver 1 Sender 2 Receiver 2

X5 X6 X7 X8 X9 X10 X11 X12

BN WH BN WH BN WH BN WH

3RG7826-1CB1

Ext. feedback circuit

TEST

+24 V 0V +24 V 0 V (Internal)

(Internal) IN OUT (Internal) (Internal) IN OUT

X13 X14 X15 X16 X17 X18 X19 X20

13 14 X21 X22 Y1 X23

+24 V PNP-
K1 (Internal) OUT

Contactor

Circuit diagram 6/61

Safety Integrated Application Manual Siemens AG 6/35

Evaluation unit and light barriers
for Category 4 acc. to EN 954-1

3RG7821-7BG00 3RG7821-7CD00
Sender Receiver Sender Receiver

1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3

L1
S
S

+24 V DC

A1 X1 X2 X3 X4 X5 X6 X7 X8 + – 13 23 39 41

24V T1 Q1 T2 Q2 RESTART Cont.M UB OUT

RESTART Relay
3RG7827-1DE2

0V T3 Q3 T4 Q4 PM Indic. UB OUT

A2 X9 X10 X11 X12 X13 X14 Y1 Y2 + – 14 24 34 42

0V 0V

1 2 4 3 1 2 4 3 1 2 4 3 1 2 4 3
K4

K5

M
Sender Receiver Sender Receiver 3~
N

Circuit diagram 6/62

6/36 Safety Integrated Application Manual Siemens AG

6.5 SIGUARD Switching Strips
6
Circuit examples with evaluation The power supply voltage of the eva-
unit luation unit is 24 V DC. 2 relay out-
puts are available as safety-related
SIGUARD switching strips, together
outputs. A semiconductor output
with the 3RG78 57-1BD evaluation
(n-switching) can be used to issue a
unit, can be used as a safety system
signal to a PLC. After the switching
up to Category 3 acc. to EN 954-1.
strip has been actuated, the device
The evaluation electronics in the
must be enabled using a manual start
22.5 mm enclosure is used to eva-
button, so that the system can
luate the sender/receiver signal and
restart.
to monitor the complete system for
faults and errors.

Receiver 3RG7855-1R Sender Power supply

24 V DC

Signal output Start button Safety-related outputs

wh gn bn A1(+) X1 X2 X3 13 23
3RG7857-1BD

K1 K1

K2 K2
12 V
controller
K1 K2

Safety-related signal
processing

K1 K2

A2(–) 14 24
Safety-related outputs

Circuit diagram 6/63

Safety Integrated Application Manual Siemens AG 6/37

6.6 SIMATIC S5-95F – Safe Shutdown
using Approved EMERGENCY OFF
Function Modules
EMERGENCY OFF with
SIMATIC S5-95F
S5-95F can be used to implement
EMERGENCY OFF circuits, as it
fulfills the requirements of EN 954-1
and/or IEC 61508.
Standard function modules have been
written, and have been approved by
the German Trade Association.
These function modules either permit
inputs and outputs to be assigned
with a resolution of one bit (one input
= one output), or input/output assign-
ment, with a byte resolution. This
means, that after evaluation, several
EMERGENCY OFF pushbuttons can
be used to shutdown a common
EMERGENCY OFF circuit from the
S5-95F with user-friendly display
capability.
Under certain prerequisites, it is per-
missible to activate/deactivate light
barriers (muting).
Connecting-up the individual
functions
The sensors (EMERGENCY OFF
pushbuttons, light curtains etc.) can
either be connected to the fail-safe
onboard- or the fail-safe external I/O
of the S5-95F. In this case, for single-
channel sensors, the signal cables are
connected in parallel to the sub-units,
or for two-channel sensors, each sig-
nal cable is connected to a sub-unit.
In both cases, the signal is connected
redundantly to the automation unit
(PLC), however, from the perspective
of the user program, one single input
is addressed. If a cross-circuit test is
required, then the sensor connecting
cables are not fed from a constant
24 V supply voltage, but from an
onboard digital output, configured
using the COM 95F parameterizing
software.
This test output is then briefly swit-
ched-out for the test and the zero
signal checked at the associated
inputs.
6/38 Safety Integrated Application Manual
If the sequence chain has still not
START
button FB been started and there is a positive
PB START SEQUENCE CHAIN edge at the start and EMERGENCY
OFF logic operation “1” and inverted
EMERGENCY START
START feedback signal to the EMERGENCY
OFF button 1
EMERGENCY OFF output, then EMERGENCY OFF
NOT-AUS- OFF
Logic operation
logical operation output = “1”
Verknüpfung
EMERGENCY
OFF button 2
output
& Actuator
EMERGENCY
OFF button Feedback
FB
STOP SEQUENCE
CHAIN
Software interrupt (OB3) for EMERGENCY OFF pushbutton at onboard I/O
Time interrupt (OB13) for EMERGENCY OFF pushbutton an external I/O
Circuit diagram 6/64
Principle of identifying and shutting down EMERGENCY OFF sequence chains for
fail-safe S5-95F PLC
The feedback contact of the contacts The parameterized stop module swit-
and the start button can be connec- ches the set EMERGENCY OFF out-
ted-up to both non-fail-safe as well as put off, as soon as the associated
fail-safe inputs. intermediate flag has a 0 signal.
Depending on how the sensors are
Information regarding connected to the fail-safe onboard- or
circuit diagram 6/65 the fail-safe external I/O, this shut-
down is realized in the organization
The sensors can be logically combi-
block OB3 within a max. of 10 ms, or
ned with one another in a program
in the OB13 within a max. of 120 ms.
module, and the result assigned to
The EMERGENCY OFF output can
an intermediate flag, which in turn is
only be re-energized when the asso-
permanently assigned to an EMER-
ciated intermediate flag again has a
GENCY OFF output. In the most
logical 1 signal (e.g. the EMERGENCY
basic case, all of the inputs (NC con-
OFF pushbutton which was pressed,
tacts) are switched in series by the
has been released again), a positive
program, and assigned the flags. The
edge is read-in at the start button and
start module, logically combines, in
the checkback signal input has a 0
the cyclic program, the signals “inter-
signal.
mediate flag, start button and check-
back signal input” with one another.
The EMERGENCY OFF output may
only be energized, if the intermediate
flag, i.e. the logical combination of
the sensors, has a logical 1 signal, the
checkback signal input of the shut-
down element has a logical 0 signal,
and a positive edge from the start
button has been identified.
Siemens AG
 6
The following examples show how
the ON/acknowledge button and an
1 1 1 1 EMERGENCY OFF control device can
2 2 2 2 be connected to the onboard I/O of
O 32.2 3 3 3 3
4 4 I 0.1 4 4 I 1.1 the S5-95F.
5 5 5 5
6 6 6 6
7 7 O 32.2 7 7 Rule
8 8 8 8
9 9 9 9 The EMERGENCY OFF control de-
10 10 10 10
11 11 11 11 vices must be connected to fail-safe
12 12 12 12 EMER- inputs. EMERGENCY OFF control
13 13 13 13 K1
14 14 14 14 GENCY devices can be used both with fail-
15 15 15 15 OFF safe onboard- as well as fail-safe
16 16 16 16 device external I/O.
17 17 17 17
18 18 18 18 K2
19 19 19 19 The ON/acknowledge button can be
20 20 20 20
connected, both to the fail-safe on-
K3 board I/O, the fail-safe external I/O, as
K1 K2 K2 K1 well as the non-fail-safe external I/O.

L+ Example 1
L–
A circuit for indirectly controlling the
EMERGENCY OFF stop device via
two redundant auxiliary contactors
Circuit diagram 6/65 and with checkback signals via two
Controlling redundant auxiliary contactors with checkback signals via positively-driven
auxiliary contacts positively-driven auxiliary contacts via
the external I/O is illustrated in Fig.
6/66.
1 1 1 1
2 2 2 2
Example 2
3 3 DE 32.2 3 3 DE 32.2
4 4 4 4 Fig. 6/67 shows how the ON/acknow-
5 5 5 5 ledge button and an EMERGENCY
6 6 6 6
7 7 7 7 OFF control device can be connected
8 8 8 8 to the fail-safe onboard I/O.
9 9 9 9
10 10 10 10
11 11 DE 33.0 11 11 DE 33.0
12 12 12 12
DA 33.0 13 13 13 13
14 14 14 14
15 15 15 15
16 16 16 16
17 17 17 17
18 18 18 18
19 19 19 19
20 20 20 20

S1 S2a S2b
L+ L+
L–

S1= ON/acknowledge button S2= EMERGENCY OFF

pushbutton

Circuit diagram 6/66

Connecting the ON/acknowledge button and the EMERGENCY OFF control
devices with cross-circuit monitoring

Safety Integrated Application Manual Siemens AG 6/39

6.7 ET 200S SIGUARD

PM-X
Master

Terminating module
PM-D PM-D DS DS RS
F1 Power module SPS Circuit-
F1
breaker
DS Direct starter
PROFIBUS-DP IM
RS Reversing starter 151
Auxiliary contact block L+
F-Kit (for the feedback circuit) M F-Kit F-Kit F-Kit
Feeder
PM-X Connection modul A1+ contactor
A2– KO
Safety Category
1 2 3 4
ON
PM-D button
PM-DF1
F-Kit EMERGENCY L1 L2 L3
OFF button
PM-X
M M M
Feeder contactor ~ ~ ~ Terminating module cover

Circuit diagram 6/67

EMERGENCY OFF with monitored start, Category 4

Explanation
ON ON CH1 CH1 CH2 CH2 CON When commissioning the circuit, proceed
L+ + – + – + – A1+ as follows:
• Connect auxiliary voltage V1 to terminals
ϑ L+, M
ϑ
• Connect auxiliary voltage V2 to terminals
CON A1+, CON A2-
• The EMERGENCY OFF circuits at termi-
nals CH1+, CH1- and CH2+, CH2- must
be closed
• The system becomes operational as soon
as the ON button, connected to terminals
ON+, ON- is actuated.
EMERGENCY OFF circuits and ON buttons
are monitored for cross-circuit during opera-
ET 200S tion.
Bus
Cross-reference:
M CON OUT– OUT+ Also refer to Part 2.31 ET 200S SIGUARD,
A2– Page 2/49,
as well as the “SIMATIC ET 200S” Manual –
Order No. GE S7 151-1AA00-8AA0
The basic configuration of a SIGUARD Power Module is shown in the circuit diagram
using as an example PM-D F1, EMERGENCY OFF with monitored start

Circuit diagram 6/68

Block diagram of the SIGUARD Power Module PM-D F1

6/40 Safety Integrated Application Manual Siemens AG

 6
25
Power module EMER-
PM-DF1 GENCY
26 OFF
+ 1/8 27 K0
U1
– 2/9 28

22 ON
+ 4/11
U2 23
– 5/12
K0 K1
Feed-
back
circuit Q1 Q2 Q3
K2 K3
K1 K2 K3

K0 K1 K2 K3

Feeder Direct M M M
contactor starter

Circuit diagram 6/69

Monitoring load feeders, EMERGENCY OFF, stop Category 0, monitored start,
Category 4.
The load feeders are monitored, as the contactor NC contacts
(F kit) are switched as “feedback circuits” in series with the ON button.

Safety Integrated Application Manual Siemens AG 6/41

6.8 Controlling Drives

This section describes application The examples show how applications
examples using the SIMOVERT can be implemented. The solution
MASTERDRIVES drive system for required for the machine must be
applications with AC variable-speed harmonized with the machine func-
drives. tion. This results in individual parame-
terization or control commands for
applications, Stop Category 1.
The solutions shown are implemen-
ted using the SIMOVERT MASTER-
DRIVES and SIMODRIVE 611 drive
systems.
The “SAFE STANDSTILL” function can
be implemented with the device-
specific “SAFE OFF” functions or
“Start inhibit”. In this case, the appro-
priate information must be observed
in the product descriptions.
SIMOVERT MASTERDRIVES
Vector Control Catalog DA 65.10
SIMOVERT MASTERDRIVES
Motion Control Catalog DA 65.11
SIMODRIVE 611
Catalog NC 60.1 and NC 60.2

6.8.1 Application exam-

ples for EMERGENCY-
STOP stop Category 0

L1
L2
L3
PE

DC P 24 V
DC M K

F1

Ready U1 V1 W1
EMERGENCY X533
ON 1 Option K80
OFF
L1/L+ X1 X5 2
X3 13 23 33 43 53 65
4 PV
P24 V
3TK2806

K3
1) The checkback signals
M
from protective equipment
K2 and devices are connected
X101
C here e.g. protective doors,
light curtains.
X U
X: Digital input assigned to
OFF2 P556i001 and i002

The checkback signals

from protective equipment
SIMOVERT MASTERDRIVES are connected here
N/L- X2 X4 X6 14 24 34 44 54 66 Drive converter U2 V2 W2

M
3~

Circuit diagram 6/70

Stop Category 0, single-channel, with feedback circuit. Category 3 acc. to EN 954-1
function with motor which is coasting down

6/42 Safety Integrated Application Manual Siemens AG

 6
L1
L2
L3
PE

L/+
N/–

DC P 24 V
DC M K1

U1 V1 W1
X533
Option K80
1
2
PV
4 P24 V
EMER- K1 ON 3
GENCY-
STOP A1 Y1 Y2 13 23
3TK2824

X101
C
X U

1) The checkback signals

from protective equip-
ment are connected
here e.g. protective
SIMOVERT MASTERDRIVES doors, light curtains
A2 14 24 Drive converter U2 V2 W2 X: Digital input,
assigned to OFF2
P556i001 and i002
M
K1 Cable is routed so that
3~ it is especialy protected
N/–

Circuit diagram 6/71

Stop Category 0, two-channel, with feedback circuit. Category 3 acc. to EN 954-1.
Function with motor which is coasting down

Safety Integrated Application Manual Siemens AG 6/43

 6.8.2 Application examples
for EMERGENCY-STOP stop
Category 1

L1
L2
L3
1) The checkback signals
PE
from protective equip-
ment are connected
here e.g. protective
K doors, light curtains

Y: Digital input,
assigned to OFF3
P559i001 and i002
Rectifier X: Digital input,
assigned to OFF2
unit P556i001 and i002

L+/C
L–/D

L+ (C) L– (D) L+ (C) L– (D)

X533 X533
Option K80 Option K80
1 1
2 2
PV PV
4 P24 V 4 P24 V
3 3

M M

X101 X101
C C
X U X U
Y Y

SIMOVERT MASTERDRIVES SIMOVERT MASTERDRIVES

Inverter U2 V2 W2 Inverter U2 V2 W2

M M
3~ 3~

DC 24 V
DC M

ON
Y10
A1 Y11 Y12 Y33 Y34 13 23 31 43 53 A1 13 23 33 43 51
3TK2830
3TK2827

EMER-
GENCY-
STOP

A2 Y21 Y22 PE 14 24 32 44 54 A2 14 24 34 44 52

PE

Circuit diagram 6/72

Stop Category 1, two-channel with feedback circuit. Category 3 acc. to EN 954-1. Function with controlled motor stop along the torque limit.

6/44 Safety Integrated Application Manual Siemens AG

 6
L1
L2
L3
PE

L/+
N/–

DC 24 V
DC M K1

U1 V1 W1
X533
Option K80
1
2
PV
4 P24 V
K1 ON 3
Y10
A1 Y11 Y12 Y33 Y34 13 23 31 43 53
3TK2827

X101
C
EMER-
GENCY-
X U
STOP 1)
Y The checkback signals
from protective equip-
ment are connected
here e.g. protective
doors, light curtains
SIMOVERT MASTERDRIVES
X: Digital input,
Y21 Y22 PE A2 14 24 32 44 54 Drive converter U2 V2 W2 assigned to OFF2
P556i001 and i002
H1 K1
PE M Y: Digital input,
N/– 3~ assigned to OFF3
P559i001 and i002

Circuit diagram 6/73

Stop Category 1, two-channel, with feedback circuit. Category 3 acc. to EN 954-1.
Function with controlled motor stop along the torque limit.

Safety Integrated Application Manual Siemens AG 6/45

48