Jay electronique RADIOSAFE Series, RSEF, RSRD, RS Series Installation And User Manual
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DRAFT R revision5
RADIOSAFE (RS) series
Wireless safety logic signal
transmission system
Transmitter RSEF / Receiver RSRD (HOUSING VERSION ONLY)
Installation and user manual
- Original version -
Transmitter
RSEF
Receiver
RSRD
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DRAFT R revision5
TABLE OF CONTENTS
1 Safety rules and general precautions ............................................................... 4
2 Identification of components ............................................................................. 5
3 Product operating principle ................................................................................ 6
4 Check of functions, initial startup ..................................................................... 7
Parameters on delivery « ex-FACTORY » ................................................................................... 7 4.1
Preliminary steps before installation .......................................................................................... 8 4.2
Safety transmitter RSEF : terminal strip and test wiring diagram .......................................................................... 8
4.2.1
Transmitter test wiring (does not take account of application) ............................................................................... 8 4.2.2
Safety receiver RSRD: terminal strip and test wiring diagram ............................................................................. 10 4.2.3
Assignment of inputs connected to transmitter RSEF and static outputs of receiver RSRD : ............................... 11 4.2.4
Power supply of outputs .................................................................................................................................... 11 4.2.5
Receiver test wiring (does not take account of application) ................................................................................. 11 4.2.6
System test before installation ........................................................................................................................... 12 4.2.7
5 Modifying the product configuration ............................................................... 13
Transmitter RSEF ...................................................................................................................... 13 5.1
General process ............................................................................................................................................... 13 5.1.1
Configuring the radio transmit frequency ............................................................................................................ 14 5.1.2
Radio channel programming table for 433-434MHz range .................................................................................. 14 5.1.3
Radio channel programming table for 911-918MHz range .................................................................................. 15 5.1.4
Configuring the check function for inputs E1 to E10 on power up ........................................................................ 16
5.1.5
Configuring the restart mode of transmitter RSEF .............................................................................................. 17 5.1.6
Receiver RSRD .......................................................................................................................... 18 5.2
General process ............................................................................................................................................... 18 5.2.1
Safety delay ...................................................................................................................................................... 18 5.2.2
6 Wiring the components ..................................................................................... 19
Wiring the transmitter RSEF ..................................................................................................... 19 6.1
Typical wiring diagram....................................................................................................................................... 19 6.1.1
Example connection of a safety light curtain on transmitter safety input............................................................... 19 6.1.2
Example with static inputs (PLC for example) ..................................................................................................... 19 6.1.3
Wiring the receiver RSRD ......................................................................................................... 20 6.2
Multi-strand wires: use of wire end ferrules is mandatory .................................................................................... 20 6.2.1
Conductor wire sections to be observed............................................................................................................. 20 6.2.2
USA/Canada specifications for installation and conductor wires to be used ......................................................... 20 6.2.3
Operation of safety relays RS1-RS2 of receiver RSRD ...................................................................................... 21 6.2.4
Monitoring of main contactors ............................................................................................................................ 21 6.2.5
Enabling handle : Wiring and operating mode .................................................................................................... 21 6.2.6
Typical wiring diagram for receiver RSRD ......................................................................................................... 22 6.2.7
Example with wired emergency stop palmswitch ................................................................................................ 22 6.2.8
Example with wired enabling handle .................................................................................................................. 23 6.2.9
Example with contactor monitoring function ....................................................................................................... 23 6.2.10
Wiring an indicator light column ......................................................................................................................... 24 6.2.11
7 Instructions for safe installation and commissioning ................................... 25
General information ................................................................................................................... 25 7.1
Transmitter RSEF ...................................................................................................................... 25 7.2
Receiver RSRD .......................................................................................................................... 25 7.3
Positioning the components and antennas .............................................................................. 26 7.4
8 Options ............................................................................................................... 27
Switch RF control option ........................................................................................................... 27 8.1
Wiring the RF switch: ................................................................ ........................................................................ 27
8.1.1
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9 Antennas ............................................................................................................. 28
433-434MHZ bands ..................................................................................................................... 28 9.1
911-918MHz bands ..................................................................................................................... 29 9.2
10 Diagnosis ............................................................................................................ 30
Transmitter RSEF : Messages given by indicator lights V1 and V2 ................................... 30 10.1
Receiver RSRD : Error messages ......................................................................................... 31 10.2
11 Servicing ............................................................................................................. 32
12 MAINTENANCE .................................................................................................. 32
Replacement of a transmitter RSEF...................................................................................... 32 12.1
Inspection and servicing of the receiver RSRD .................................................................... 33 12.2
13 Warranty ............................................................................................................. 34
14 FCC Rules & Regulations (Federal Communications Commission) ........... 35
15 IC Regulations (Industry Canada) .................................................................... 36
16 Appendices......................................................................................................... 37
Component dimensions (mm)................................................................................................ 37 16.1
Technical characteristics ....................................................................................................... 38 16.2
Transmitter RSEF ............................................................................................................................................ 38 16.2.1
Receiver RSRD ................................................................................................................................................ 39 16.2.2
Environmental data ................................................................................................................. 40 16.3
Safety related parameters ...................................................................................................... 40 16.4
Characteristic data according to IEC 61508-1 till -7 and IEC 62061:2005 ............................................................ 40 16.4.1
Characteristic data according to EN ISO 13849-1:2015 ...................................................................................... 41 16.4.2
RSEF Transmitter case thermal capability ............................................................................ 42 16.5
Residual risks ......................................................................................................................... 42 16.6
Forseeable misuse.................................................................................................................. 42 16.7
Waste recycling and management ........................................................................................ 42 16.8
Products references ................................................................ ................................ ............... 42 16.9
Warning, avoid any mutual disturbance ............................................................................... 42 16.10
Countries limitation of the use ............................................................................................... 42 16.11
Manufacturer information ................................ ................................................................ ....... 42 16.12
17 Declaration of conformity ................................................................................. 43
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DRAFT R revision5
1 Safety rules and general precautions
The RADIOSAFE (RS) “wireless safety logic signal transmission system” is considered as a control and a safety
component ensuring an emergency stopping function under the terms of the European Machinery Directive. The following safety
rules apply to installation and use of the Radiosafe (RS) system.
For maximum safety when using the system, the instructions given in this manual must be strictly observed.
Radiosafe (RS) system operators must be appropriately trained and authorised to use the product.
Radiosafe (RS) system operators must have uninterrupted visibility at all times when performing manoeuvres.
Where several systems are implemented on a single site, different radio frequencies must be used. These should be
spaced by at least 2 channels (for example, channels 5, 7, 9, …) or by 5 channels when several systems are
operating within a radius of 10 meters.
Please contact us for the case of dense installations.
It is not advisable to install the safety transmitter RSEF and safety receiver RSRD in the same cabinet to prevent
disruption of the receiver. If need to install these two elements in the vicinity, please contact us.
In the event of a malfunction, the installation should be immediately shut down by pressing any emergency stop
palmswitch and particulary that connected to the safety transmitter RSEF.
If an enabling handle is used for the application, this device must comply with the requirements of EN 60947-5-
1:2004/A1:2009, EN ISO12100 and EN 60204-1:2016 standards.
All emergency stop plamswitches used for the application, must comply with the requirements of EN 60947-5-
1:2004/A1:2009 and EN 60204-1:2016 standards
The product described in this manual is designed to satisfy the requirements of Machinery Directive 2006/42/EC based on
application of the following standards :
• EN ISO 13849-1:2015 for performance level PLe (Category 4)
• IEC 62061:2005+AC:2010 + A1:2013+A2:2015 for SIL 3
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2 Identification of components
The "RADIOSAFE (RS) « Wireless safety logic signal transmission system » comprises the following components:
A safety transmitter ref. : RSEF (Fig.1), supplied with :
o A SIM card (already installed in the transmitter)
o A ¼ wave antenna, ref. : VUA00xx
o A BNC elbow, ref. : VUB060
o A 50 cm antenna extender, ref. : VUB170
o An installation and user manual (on USB stick)
Fig 1
A safety receiver, Housing version (Fig.2) ref. RSRDxxxx-0
o supplied with :
A ¼ wave antenna, ref. : VUA00xx
A BNC elbow, ref. : VUB060
A 50 cm antenna extender, ref. : VUB170
Fig.2
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3 Product operating principle
The RADIOSAFE (RS) « Wireless safety logic signal transmission system» is used to transmit logic safety signals from one
point of an installation to another.
The transmitter RSEF is designed to radio-transmit the following signals to the receiver RSRD :
- An emergency stop signal in the event of a problem occurring in the installation
- Up to 10 command signals
The receiver RSRD is integrated in the control component of the machine ; it enables (or not) operation of the machine and
transmits the possible commands assigned to the buttons connected to the transmitter RSEF.
The receiver RSRD stops operation of the machine when any of the following conditions are present :
Case 1 : Deactivation of a safety input (for example : contact on a gate or an emergency stop) connected to the
transmitter RSEF
Safety interlock subsequent to stop request.
Case 2 : Action on emergency stop device wired to receiver RSRD.
Safety interlock subsequent to stop request.
Case 3 : Interruption of radio link during use
When the system is in use, the transmitter RSEF has a continuous radio link with the receiver RSRD. Should this
link be interrupted for more than the passive stop time, the receiver automatically triggers stopping of the
installation.
Safety interlock prior to loss of control of stopping function.
Case 4 : Detection of a malfunction (see section : « Faults communicated by receiver »)
Schematic diagram :
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4 Check of functions, initial startup
This section details the procedure for familiarisation with the product.
It will allow you to test operation of the equipment in its « ex-factory » configuration.
Parameters on delivery « ex-FACTORY » 4.1
Transmitter RSEF
Radio channel number........................................... : No. 64 (434,675Mhz) or (918,2Mhz)
Radio transmit power level .................................... : According to model of transmitter RSEF
Self check of inputs E1 to E10 on power up.......... : Yes
Transmitter restart mode ....................................... : Manual restart
Receiver RSRD
Safety delay
(1)
........................................................ : 0s
Passive stop time
(2)
................................................ : 1s
(1) Safety delay can be configured between 0 to 10s (set by step of 1s) with dedicated software*.
(2) Passive stop time can be configured between 0.3 to 1.5s with dedicated software*.
IMPORTANT: According to Machinery directive section 4.1.1(EN ISO 13850:2015), this time delay must be determined by the risk
assessment of the machine (see also CEI 60204-1 :2005, 9.2.5.4.2).
Notes :
The SIM card (in the transmitter) contains the complete configuration of the system :
- system operating frequency,
- Identity code of pair formed by transmitter RSEF + receiver RSRD,
In the event of a transmitter failure, the SIM card can be used in a backup transmitter.
To modify the basic parameters, refer to section 5.
* The dedicated programming software is available on JAY Electronique website. The use of the programming software
is protected by a password, this password is only delivered to a skilled person “level 2” (a person who was trained by
JAY Electronique, and who is authorized to modify RSRD receiver parameters).
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Preliminary steps before installation 4.2
Once you have inserted the SIM card in the transmitter RSEF, proceed as follows to perform a quick test on the components
before final installation.
Safety transmitter RSEF : terminal strip and test wiring diagram 4.2.1
Transmitter test wiring (does not take account of application) 4.2.2
this wiring is intended to test : - a command input
- and the « emergency stop » safety input :
Step 1 Prepare a stabilized power supply, 24VDC (+/- 5 %) 500 mA minimum
Step 2 Wire the transmitter as follows :
Connect the +24VDC of the stabilized power supply to terminals 3 and 4
Connect the ground of the power supply to the 3 terminals 1 and 5 and 15 (ground ref. of inputs)
Connect an NC double contact emergency stop button to terminals 7, 8, 9 and 10.
Connect an NO button “Restart” across the +24VDC and terminal No. 17.
Connect an NO button simulating an input across the +24VDC and terminal No. 22 (E1).
Possibly, indicator lights giving the same indication as indicator lights V1 and V2 of the transmitter may
be connected to terminals 11 (V2) and 12 (V1) and 0V.
Step 3 Supply the transmitter.
Terminal
Function
Terminal
Function
1
V- E.S. 16
V- Inputs
2
V- E.S.
17
On / Restart
button input
3
V+ E.S.
4
V+ RSEF 5
V- RSEF 18
Input No.9
6
V- RSEF 19
Input No.7
7
E.S. contact 1
20
Input No.5
8
E.S. contact 2
21
Input No.3
9
E.S. mode
22
Input No.1
10
V+ E.S. 23
V- Input
11
Ind. light V2
output
24
Input No.10
12
Ind. light V1
output
25
Input No.8
13
Not used
26
Input No.6
14
Not used
27
Input No.4
15
V- Inputs 28
Input No.2
Ind. light
Function
V1
(GREEN) "On", "Radio transmission", "Diagnostic"
V2
(RED) "Diagnostic"
V3
(ORANGE) "Power supply"
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Step 4 Activate the safety input (unlock Emergency stop).
Step 5 Press on the Restart pushbutton.
Indicator light V3 of the transmitter should come on steady, indicator light V1 should flash regularly (radio
transmission) and indicator light V2 should be off; if this indicator light flashes, there is an error: refer to the
error message table.
Step 6 Switch off the supply to the transmitter.
Proceed as instructed in the following pages to wire the safety receiver RSRD.
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Safety receiver RSRD: terminal strip and test wiring diagram 4.2.3
J1 Terminal block : Safety outputs
Terminal
Function
Y1
1st safety output (NO contact)
Z3
Y2
2nd safety output (NO contact)
Z2
Y3
3rd safety output (NO contact)
Z1
J2 Terminal block : Safety Inputs and power supply
SW3/SW2 : Output power supply selection
Terminal
Function
Position “1” : Output power supply connected on
receiver RSRD 24VDC and GND (default)
12
Input for Enabling Handle Detection
11
Position “0” : Output power supply connected on
external V+ and V-
10
Input 2 for Enabling Handle
09
08
Input 1 for Enabling Handle
SW1 : Functioning mode
07
Position “1” : Receiving mode (default)
06
Input 2 for emergency stop or safety light curtain
05
Position “0” : Programming mode
04
Input 1 for emergency stop or safety light curtain
03
02
V- (GND)
01
V+ 24VDC
J3 Terminal block : Communication, Static outputs and Indicators
Function
Terminals
Function
RXD RS232*
1 2
not used / not connected
TXD RS232*
3 4 Configuration INPUT*
GND*
5 6 Configuration GND*
Error message (red indicator light) +
7 8 Error message (red indicator light) -
Radio reception status (orange indicator light) +
9
10
Radio reception status (orange indicator light) -
Machine operating status (green indic. light) +
11
12
Machine operating status (green indic. light) -
Input for main contactor monitoring function
13
14
Input for main contactor monitoring function
Power supply of outputs V+
15
16
Power supply of outputs V-
Output nb.1
17
18
Output nb.2
Output nb.3
19
20
Output nb.4
*(used with a dedicated software)
RS1&RS2
Safety relays
1
Red indicator light: status of safety relays RS1 and RS2
2
Antenna BNC / antenna extension connector
3
Radio module
LD1
Yellow indicator light : Transceiver power supply OK
LD2
Red indicator light: status of safety relays RS1 and RS2
LD3
Green indicator light : Radio reception + Diagnostics
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Assignment of inputs connected to transmitter RSEF and static outputs of
4.2.4
receiver RSRD :
Receiver RSRD with assignment of « standard » outputs
Assignment of outputs of receiver RSRD
(terminal No.)
17
18
19
20
Inputs of
transmitter
RSEF
E1 X
E2 X
E3 X
E4 X
Power supply of outputs 4.2.5
There are two operating modes for outputs voltage 1-4. Isolated from the main supply voltage (isolated mode) or linked to
the main supply voltage (non-isolated mode). In both cases, the maximum output current is 100mA per output.
Isolated mode:
SW3 and SW2 must be in position “0”
A continued supply voltage must be applied between points 15-16 of J3. This supply voltage must be between 530VDC. (input 15: V+ and input16 : V-)
Insulation voltage : > 4400 VRMS.
Not isolated mode :
SW3 and SW2 must be in position “1”.
Terminal points 15-16 of J3 must be unconnected.
Power supply of the ouputs is the supply voltage of the receiver RSRD.
Receiver test wiring (does not take account of application) 4.2.6
This wiring is aimed at testing a command output and an « emergency stop » safety input :
Step 1 Prepare a stabilized power supply, 24VDC (+/- 5 %) 500 mA minimum
Step 2 Wire the receiver as follows :
o Shunt the terminal pairs J2[03-04], J2[05-06] and J3[13-14]
o Connect the +24VDC of the stabilized power supply to terminals J2[1]
o Connect the ground of the power supply to the terminal J2[2]
Step 3 Supply the receiver.
Yellow indicator light LD1 on the receiver comes on steady.
Step 4 Switch off the receiver.
Perform the system test as detailed in the next section.
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System test before installation 4.2.7
Step A Supply the transmitter RSEF and the receiver RSRD
The receiver RSRD should be ready to receive the transmitter RSEF frame and the indicator light LD1
comes on steady.
The indicator light V3 on the transmitter RSEF comes on steady
Step B Activate the safety input (unlock Emergency stop) on the transmitter RSEF
The transmitter RSEF should be ready to transmit and its green indicator light V1 should come on
steady.
Step C On the safety transmitter RSEF:
Press on the restart pushbutton (If the transmitter is in « manual » restart mode ).
The indicator light V2 should blink.
On the receiver RSRD:
The safety relays (RS1 and RS2) should engage.
The two indicator lights LD2 and LD3 should come on steady.
Step D Press the emergency stop palmswitch connected to the transmitter RSEF
The receiver RSRD safety relays should immediately deactivate.
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5 Modifying the product configuration
Transmitter RSEF 5.1
General process 5.1.1
The various settings on the transmitter RSEF are made using a DIP switch and a validation button located inside the transmitter.
Remove the front panel to access these components:
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Configuring the radio transmit frequency 5.1.2
To limit accidental cut-outs due to radio interference, it is important to choose an available radio channel (frequency). This choice is governed by the
following principles:
The receiver point of installation must be considered as the centre of the radio link,
Estimate the maximum distance « D max » which there may be between the transmitter and the receiver,
Identify the frequencies used for all the radio transmitters located within a radius of 2xD max.
Chose a frequency which is as far as possible from those used by the nearest transmitters and which is not used by the transmitters
identified.
The procedure described below is used to modify the radio channel of the transmitter RSEF and receiver RSRD. The receiver must be supplied
throughout the channel modification procedure in order to receive the radio channel change command from the transmitter RSEF.
1- Deactivate the safety input of the transmitter RSEF (1)
2- Select the new radio channel using micro-switches 1 to 6 (see correspondence table below)
3- Activate the safety input of the transmitter RSEF (2)
4- The 2 indicator lights V1-V2 flash to indicate the new radio channel being programmed :
Indicator light V1 (GREEN) indicates the units (0 = off steady, 1 = 1 flash, 2 = 2 flashes, etc…)
Indicator light V2 (RED) indicates the tens (0 = off, 10 = 1 flash, 20 = 2 flashes, etc…)
Example :
5- Once you have chosen the radio channel, press the validation button BPV
6- The two indicator lights, V1 and V2, flash simultaneously and the transmitter sends the receiver RSRD the radio channel change
command (this action takes around 20 s., then indicator lights V1 and V2 go off).
Note : If the validation button BPV has not been pressed, you can cancel the frequency change by repositioning the micro-switches 1
to 6 to the initial radio channel code.
7- To exit the radio frequency setting modes, activate, then deactivate the safety input (1)(2).
8- If the transmitter is in « manual » restart mode, press the restart button wired to input 17
(1) If an emergency stop palmswitch is wired on this input, the component must be locked.
(2) If an emergency stop palmswitch is wired on this input, the component must be unlocked.
Note :
If the other setting has also been modified during this procedure (as “input check” or “restart mode”), each modified setting have to be performed
one by one.
Radio channel programming table for 433-434MHz range 5.1.3
Note : For the « extended range » version, only channels 40 to 64 are accessible.
Chan.
Freq.
(MHz)
Micro-switch position
Chan.
Freq.
(MHz)
Micro-switch position
1 2 3 4 5 6 1 2 3 4 5 6
01
433,100
OFF
OFF
OFF
OFF
OFF
OFF
33
433,900
OFF
OFF
OFF
OFF
OFF
ON
02
433,125
ON
OFF
OFF
OFF
OFF
OFF
34
433,925
ON
OFF
OFF
OFF
OFF
ON
03
433,150
OFF
ON
OFF
OFF
OFF
OFF
35
433,950
OFF
ON
OFF
OFF
OFF
ON
04
433,175
ON
ON
OFF
OFF
OFF
OFF
36
433,975
ON
ON
OFF
OFF
OFF
ON
05
433,200
OFF
OFF
ON
OFF
OFF
OFF
37
434,000
OFF
OFF
ON
OFF
OFF
ON
06
433,225
ON
OFF
ON
OFF
OFF
OFF
38
434,025
ON
OFF
ON
OFF
OFF
ON
07
433,250
OFF
ON
ON
OFF
OFF
OFF
39
434,050
OFF
ON
ON
OFF
OFF
ON
08
433,275
ON
ON
ON
OFF
OFF
OFF
40
434,075
ON
ON
ON
OFF
OFF
ON
09
433,300
OFF
OFF
OFF
ON
OFF
OFF
41
434,100
OFF
OFF
OFF
ON
OFF
ON
10
433,325
ON
OFF
OFF
ON
OFF
OFF
42
434,125
ON
OFF
OFF
ON
OFF
ON
11
433,350
OFF
ON
OFF
ON
OFF
OFF
43
434,150
OFF
ON
OFF
ON
OFF
ON
12
433,375
ON
ON
OFF
ON
OFF
OFF
44
434,175
ON
ON
OFF
ON
OFF
ON
13
433,400
OFF
OFF
ON
ON
OFF
OFF
45
434,200
OFF
OFF
ON
ON
OFF
ON
14
433,425
ON
OFF
ON
ON
OFF
OFF
46
434,225
ON
OFF
ON
ON
OFF
ON
15
433,450
OFF
ON
ON
ON
OFF
OFF
47
434,250
OFF
ON
ON
ON
OFF
ON
16
433,475
ON
ON
ON
ON
OFF
OFF
48
434,275
ON
ON
ON
ON
OFF
ON
17
433,500
OFF
OFF
OFF
OFF
ON
OFF
49
434,300
OFF
OFF
OFF
OFF
ON
ON
18
433,525
ON
OFF
OFF
OFF
ON
OFF
50
434,325
ON
OFF
OFF
OFF
ON
ON
19
433,550
OFF
ON
OFF
OFF
ON
OFF
51
434,350
OFF
ON
OFF
OFF
ON
ON
20
433,575
ON
ON
OFF
OFF
ON
OFF
52
434,375
ON
ON
OFF
OFF
ON
ON
21
433,600
OFF
OFF
ON
OFF
ON
OFF
53
434,400
OFF
OFF
ON
OFF
ON
ON
22
433,625
ON
OFF
ON
OFF
ON
OFF
54
434,425
ON
OFF
ON
OFF
ON
ON
23
433,650
OFF
ON
ON
OFF
ON
OFF
55
434,450
OFF
ON
ON
OFF
ON
ON
24
433,675
ON
ON
ON
OFF
ON
OFF
56
434,475
ON
ON
ON
OFF
ON
ON
25
433,700
OFF
OFF
OFF
ON
ON
OFF
57
434,500
OFF
OFF
OFF
ON
ON
ON
26
433,725
ON
OFF
OFF
ON
ON
OFF
58
434,525
ON
OFF
OFF
ON
ON
ON
27
433,750
OFF
ON
OFF
ON
ON
OFF
59
434,550
OFF
ON
OFF
ON
ON
ON
28
433,775
ON
ON
OFF
ON
ON
OFF
60
434,575
ON
ON
OFF
ON
ON
ON
29
433,800
OFF
OFF
ON
ON
ON
OFF
61
434,600
OFF
OFF
ON
ON
ON
ON
30
433,825
ON
OFF
ON
ON
ON
OFF
62
434,625
ON
OFF
ON
ON
ON
ON
31
433,850
OFF
ON
ON
ON
ON
OFF
63
434,650
OFF
ON
ON
ON
ON
ON
32
433,875
ON
ON
ON
ON
ON
OFF
64
434,675
ON
ON
ON
ON
ON
ON
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