En Wiring Examples

Wiring examples
for ASi Safety products from Bihl+Wiedemann
Release 1.0 / Revision date: 2023-02-02

Subject to modifications without notice.
Generally, this manual refers to products
without mentioning existing patents,
utility models, or trademarks.
The absence of any such references does
not indicate that a product is patent-free.
© Bihl+Wiedemann GmbH
Floßwörthstr. 41
D-68199 Mannheim
Wiring examples
Table of contents
Table of contents
Wiring examples
1 Introduction........................................................................................... 4
2 Product Overview ................................................................................. 5
3 Wiring Examples................................................................................... 6
3.1 Safety input modules for floating contacts ................................................... 6
3.1.1 2-channel switches/pushbuttons .................................................................................. 6
3.1.2 1-channel switches/pushbuttons .................................................................................. 7
3.1.3 Two 1-channel switches/pushbuttons on one 2-channel input.................................. 8
3.1.3.1 Diagnostics in the PLC................................................................................................... 9
3.1.3.2 Diagnostics in the Safety Monitor................................................................................. 10
3.2 Safety input modules for optoelectronic protective devices..................... 11
3.2.1 2-channel electronic sensors....................................................................................... 11
3.2.2 1-channel electronic sensors....................................................................................... 12
3.3 Safety input modules for safety mats .......................................................... 13
3.4 Safety output modules with relay outputs .................................................. 14
3.5 Safety output modules with electronic outputs .......................................... 15
3.6 Contact expander with relays ....................................................................... 16
3.7 Contact expander with electronic output .................................................... 16
3.8 E-STOP............................................................................................................ 17
3.8.1 E-Stop pushbutton module with integrated ASi module........................................... 17
3.8.2 E-Stop push button....................................................................................................... 18
3.9 Speed monitors for encoders ....................................................................... 19
3.9.1 Speed monitor without local outputs.......................................................................... 19
3.9.2 Speed monitor with local safety outputs .................................................................... 20
3.10 Speed monitors for sensors ......................................................................... 22
3.10.1 2-channel ....................................................................................................................... 22
3.10.2 1-channel ....................................................................................................................... 23
3.11 Safety analog module .................................................................................... 24
Issue date: 2023-02-02
Subject to technical modifications; no responsibility is accepted for the accuracy of this information © Bihl+Wiedemann GmbH
3
Internet: www.bihl-wiedemann.de • Flosswoerthstr. 41 • D-68199 Mannheim phone: +49 621 33 996-0 • fax: +49 621 3 39 22 399
Wiring examples
Introduction
1. Introduction
This collection of examples describes the various possibilities for connecting saf-
ety signals to ASi Safety products from Bihl+Wiedemann and indicates the resul-
ting safety levels that can be achieved.
Note!
Please also observe the specifications in the operating manual for the respective pro-
duct!
Issue date: 02.02.2023
4 Internet: www.bihl-wiedemann.de • Flosswoerthstr. 41 • D-68199 Mannheim phone: +49 621 33 996-0 • fax: +49 621 3 39 22 399
Wiring examples
Product Overview
2. Product Overview
Safety Monitors/Gateways with integrated Safety Monitor

• Process safety-relevant data from safety input
modules
• Shut-down using safety output modules
• Local safety in- and outputs
• Up to 32 release circuits
• Simple configuration using ASIMON360 software
Safety I/O modules
• Modules in IP20, IP67 or circuit board modules
• Single safety in- or outputs or multi-I/O modu-les
• Inputs for potential-free contacts, photoelectric pro-
tection barriers, safety mats
Safe contact expander modules

• One- or two-channel relays and EDM contact
or
• Electronic output 20 A or 10 A and EDM contact
E-STOP
• E-Stop pushbutton modules
• With/without illumination
• With mounting clip, screw mount or magnet
Speed monitors
• Monitor standstill, speed, direction, position, shaft
break, brake ramp etc. etc.
• For sine/cosine, SSI, TTL, HTL encoders or sensors
Safety analog modules

• Monitor analog signals 4 … 20 mA, 0 … 10 V,
Pt100
5
Wiring examples
Wiring Examples
3. Wiring Examples
3.1 Safety input modules for floating contacts
3.1.1 2-channel switches/pushbuttons
Connection to a module Connection to a module

with 2 terminals per input channel with common test outputs
Module Module
Termi nal s
Termi nal s
S11 T1
S12 ... S3 S1
Module
Module
S21 T2
S22 ... S4 S2
Configuration in ASIMON360
Safety characteristics
• up to Category 4, SIL 3, PL e
Wiring examples
Wiring Examples
3.1.2 1-channel switches/pushbuttons

Module
Termi nal s Module
Termi nal s
S11 T1
S12 ... S3 S1
Module
Module
S21 T2
S22 ... S4 S2
• up to Category 2, SIL 1, PL c
Notes:
• ASi Safety evaluates both inputs, so that the unused input can be jumpered.
• The signal line must be wired such that any fault due to contact with external
potentials can be precluded for the line.
• In this application the achievable category is typically limited by the connected
sensors to Category 1, since the sensors themselves only achieve Category 1.
The Bihl+Wiedemann module itself meets Category 2 in this application. If a sen-
sor is used in this application which achieves Category 2, this application can
meet the criteria for Category 2.
7
Wiring examples
Wiring Examples
3.1.3 Two 1-channel switches/pushbuttons on one 2-channel input

Two 1-channel switches/pushbuttons can be connected to one 2-channel safety
input. Both signals are used like a 2-channel safety input in the Safety Monitor
logic. The safety input is 'on' when both input signals are 'on'.
The information for each input signal is available separately in the non-safety di-
agnostics.

Module Module
Termi nal s
Termi nal s
S11 T1
S12 ... S3 S1
Module
Module
S21 T2
S22 ... S4 S2
Notes:
• The safety input in the Safety Monitor logic contains the AND operation for both
input signals
Wiring examples
Wiring Examples
3.1.3.1 Diagnostics in the PLC
The diagnostics information is sent in the input data map, coded for the input bits
of the address of the safe ASi input node. Bits 0 and 1 contain the switching state
of channels 1 and 2 of the safe input, made available very fast and for direct read-
ing:
Bit 3 Bit 2 Bit 1 Bit 0 Description

x x 0 0 Both channels open
x x 0 1 2nd channel open, 1st channel closed
x x 1 0 2nd channel closed, 1st channel open
x x 1 1 Both channels closed
Tab. 3-1.
Bits 2 and 3 contain the state of the safe input (the device color of ASIMON360):
Bit 3 Bit 2 Bit 1 Bit 0 Description

0 0 x x Device color: red, green or gray
0 1 x x Device color: yellow ("wait")
1 0 x x Device color: yellow flashing ("test")
1 1 x x Device color: red flashing ("error")
Tab. 3-2.
9
Wiring examples
Wiring Examples
3.1.3.2 Diagnostics in the Safety Monitor
Warning:
• The single-channel diagnostics module is not safe!
• It serves only for diagnosing the switching signals. The module is especially
unsuited for switching safety-relevant data!
Wiring examples
Wiring Examples
3.2 Safety input modules for optoelectronic protective devices
3.2.1 2-channel electronic sensors
Connection to a module
for floating contacts
for optoelectronic protective devices
or optoelectronic protective devices
Transmitter Receiver Transmitter Receiver

Module Module
0V 0V
0V 0V
Termi nal s
Termi nal s
24V 24V
24V (24V) S71
OSSD1 OSSD1
Module
Module
S1 S72
OSSD2 OSSD2
S2 S81
S82
11
Wiring examples
Wiring Examples
3.2.2 1-channel electronic sensors
for floating contacts
for optoelectronic protective devices
or optoelectronic protective devices
Transmitter Receiver Transmitter Receiver

Module Module
0V 0V
0V 0V
Termi nal s
Termi nal s
24V 24V
24V (24V) S71
OSSD OSSD
Module
Module
S1 S72
S2 S81
S82
Notes:
• The achievable SIL for this configuration may be limited by the sensor signal. If
the sensor signal corresponds to less than SIL 3, the overall safety level is corre-
spondingly lower.
Wiring examples
Wiring Examples
3.3 Safety input modules for safety mats
Connection
Module Module
Termi nal s
Termi nal s
Y3 Y3
Y2 Y2
Module
Module
1,2 kΩ 8,2 kΩ
Y1 Y1
nc nc
• up to Category 3, SIL 2, PL d
13
Wiring examples
Wiring Examples
3.4 Safety output modules with relay outputs
Connect contactor
L
Module
Termi nal s
L1 L2 L3 1.Y1
1.13
1.14 K1
Module
K2
I+ I+
Motor
N
1.Y1
Wiring examples
Wiring Examples
3.5 Safety output modules with electronic outputs
Connect contactor Connect actuator
Module Module Actuator

Termi nal s
Termi nal s
L1 L2 L3 1.Y1
1.14 SO1+ SO1
0V K1
IN
Module
Module
K2
I+
SO1- 0V 0V
Motor
AUX+
S3
15
Wiring examples
Wiring Examples
3.6 Contact expander with relays
Connection to an electronic output Connection to a relay output
24V +
Imax = 20mA
+3 >
(+24V) 1.13
1.13 1.23 1.33 1.43 1.51 Imax = 20mA
3.14 1.A1
+1 >
(SO1)
1.13 1.23 1.33 1.43 1.51
1.A1
1.14
1.A2
0V
1.14 1.24 1.34 1.44 1.52
1.A2 1.14 1.24 1.34 1.44 1.52
1.Y1
2.Y1
(SI1) 0V
3.7 Contact expander with electronic output
Connection to an electronic output
2.Y1 1.52
(SI1)
+3 1.51
(+24V)
3.14 1.A1
(SO1) L+
24V
1.14 0V
L-
Wiring examples
Wiring Examples
3.8 E-STOP
3.8.1 E-Stop pushbutton module with integrated ASi module
Direct connection to AS-i
17
Wiring examples
Wiring Examples
3.8.2 E-Stop push button
Connection to a safety input module
Module
Termi nal s
S11
S12
Module
S21
S22
• up to Category 4, SIL 3, PL e Issue date: 02.02.2023
Wiring examples
Wiring Examples
3.9 Speed monitors for encoders
3.9.1 Speed monitor without local outputs
Connecting encoders Connecting encoders

with encoder power from the module (5 V) with external power source
Module Module
AUX (24 VDC)
Termi nal s
Termi nal s
PELV
ENC 1 ENC 1
ENC ENC
1 1
Module
Module
ENC ENC
ENC 2 ENC 2
2 2
Notes:
spondingly lower.
• For HTL encoders Cat. 4, SIL 3, PL 3 can only be achieved if both connected
encoders are monitoring the same axis and synchronous mode is enabled.
19
Wiring examples
Wiring Examples
3.9.2 Speed monitor with local safety outputs
Connecting encoders
Module
AUX (24 VDC)
Termi nal s
PELV
ENC 1
ENC
1
Module
ENC
ENC 2
2
Wiring examples
Wiring Examples
The achievable safety level depends on the combination of the connected
encoders and the Couple axes setting.
Encoder combination and maximum achievable safety level
Encoder combination DC Achievable safety level
1 encoder Sin/Cos (SIL3/PLe certified) - 99% SIL3, PLe, Cat.41
per axis
Sin/Cos (standard) - 90% SIL2, PLd, Cat.21
TTL (standard) - 60% PLc, Cat.11
HTL (standard) - 60% PLc, Cat.11
2 encoders Sin/Cos Sin/Cos 99% SIL3, PLe, Cat.4
coupled Sin/Cos TTL
Sin/Cos SSI
SSI SSI
SSI TTL
TTL TTL
HTL HTL
1. Fault exclusion for mechanical shaft breakage required.

21
Wiring examples
Wiring Examples
3.10 Speed monitors for sensors
3.10.1 2-channel
Connecting sensors to the local inputs
Module cycle time

S1
Termi nal s
S61 S2
Module
cycle time
S1
S52
S2
• Speed monitor without stand still: up to Category 4, SIL 3, PLe
• Speed monitor with stand still: up to Category 3, SIL 2, PLd
Notes:
• The sensors must be arranged so that one is always damped!
Wiring examples
Wiring Examples
3.10.2 1-channel
Connecting sensors to the local inputs
Module
Termi nal s
S52 S2
Module
23
Wiring examples
Wiring Examples
3.11 Safety analog module
Connecting 4...20mA / 0...10V sensors

4-wire 3-wire 2-wire
Module Sensor Module Sensor Module Sensor

24V 24V 24V
Termi nal s
Termi nal s
Termi nal s
+ + +
I/U Sig.+
Sig+
I/U Sig.+
Sig
I/U Sig.+ -
Module
Module
Module
Sig-
I/U Sig.- I/U Sig.- I/U Sig.-
- -
0V 0V 0V
Connecting PT100 sensors

4-wire 3-wire 2-wire
Module Sensor Module Sensor Module Sensor

R+ R+ R+
Termi nal s
Termi nal s
Termi nal s
R Sig. + R Sig. + R Sig. +
Module
Module
Module
R Sig.- R Sig.- R Sig.-
R- R- R-
Connecting one sensor to both channels of a module

Current output Voltage output
Module Sensor Module Sensor

24V ext.out 24V in 24V ext.out 24V in
I1 Sig.+ I+ out U1 Sig.+ U+ out

Te rminal s
Te rminal s
I1 Sig.- I- out U1 Sig.- U- out

Module
Module
0V ext.out 0V in 0V ext.out 0V in
24V ext.out 24V ext.out
I2 Sig.+ U2 Sig.+
I2 Sig.- U2 Sig.-
0V ext.out 0V ext.out
Wiring examples
Wiring Examples
25
Wiring examples
Wiring Examples
Wiring examples
Wiring Examples
• The achievable safety level depends on the module mode.
Mode "Two sensors measure the same signal"
Mode "One sensor is connected to both channels"
Notes:
spondingly lower.
Mode "Two independent sensors"
27

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Wiring examples

for ASi Safety products from Bihl+Wiedemann

Release 1.0 / Revision date: 2023-02-02

2 Product Overview ................................................................................. 5

Issue date: 02.02.2023

Safety Monitors/Gateways with integrated Safety Monitor

Safe contact expander modules

Safety analog modules

3.1 Safety input modules for floating contacts

3.1.1 2-channel switches/pushbuttons

Connection to a module Connection to a module

3.1.2 1-channel switches/pushbuttons

Connection to a module Connection to a module

3.1.3 Two 1-channel switches/pushbuttons on one 2-channel input

Connection to a module Connection to a module

3.1.3.1 Diagnostics in the PLC

Bit 3 Bit 2 Bit 1 Bit 0 Description

Bit 3 Bit 2 Bit 1 Bit 0 Description

3.1.3.2 Diagnostics in the Safety Monitor

Issue date: 02.02.2023

3.2 Safety input modules for optoelectronic protective devices

3.2.1 2-channel electronic sensors

Transmitter Receiver Transmitter Receiver

3.2.2 1-channel electronic sensors

Transmitter Receiver Transmitter Receiver

3.3 Safety input modules for safety mats

3.4 Safety output modules with relay outputs

Issue date: 02.02.2023

3.5 Safety output modules with electronic outputs

Connect contactor Connect actuator

Module Module Actuator

3.6 Contact expander with relays

Connection to an electronic output Connection to a relay output

1.A2 1.14 1.24 1.34 1.44 1.52

3.7 Contact expander with electronic output

Connection to an electronic output

3.8.1 E-Stop pushbutton module with integrated ASi module

Direct connection to AS-i

3.8.2 E-Stop push button

Connection to a safety input module

3.9 Speed monitors for encoders

3.9.1 Speed monitor without local outputs

Connecting encoders Connecting encoders

3.9.2 Speed monitor with local safety outputs

Issue date: 02.02.2023

1. Fault exclusion for mechanical shaft breakage required.

3.10 Speed monitors for sensors

Connecting sensors to the local inputs

Module cycle time

Connecting sensors to the local inputs

3.11 Safety analog module

Connecting 4...20mA / 0...10V sensors

Module Sensor Module Sensor Module Sensor

Connecting PT100 sensors

Module Sensor Module Sensor Module Sensor

R Sig.- R Sig.- R Sig.-

Connecting one sensor to both channels of a module