Safety Technique

SAFEMASTER
Emergency Stop Module
BD 5935

Your Advantages
• Safe disconnection of electrical circuits
• Line fault detection on ON pushbutton
• Gold plated contacts to switch low loads (signal to PLC)
0221548

• Optionally cross fault detection in emergency stop circuit

• Easy exchange of devices by removable terminal strips

Features
• According to
-- Performance Level (PL) e and category 4 to EN ISO 13849-1: 2008
-- SIL Claimed Level (SIL CL) 3 to IEC/EN 62061
-- Safety Integrity Level (SIL 3) to IEC/EN 61508
• 1- or 2-channel connection
• Operating state display
• LED display for channels 1 and 2
• Overvoltage and short circuit protection
• Wire connection: also 2 x 1.5 mm2 stranded ferruled (isolated),
Product Description DIN 46 228-1/-2/-3/-4 or
2 x 2.5 mm2 stranded ferruled DIN 46 228-1/-2/-3
The BD 5935 is used to interrupt a safety circuit in a safe way. It can be
• Output: optionally 1 NO / 1 NC or 3 NO / 1 NC contacts
used to protect people and machines in applications with e-stop buttons
• Optionally automatic ON function or activation via the ON pushbutton
and safety gates.
• With fast auto start as option
• Width 45 mm

Function Diagram Approvals and Markings

Pushbutton
On
*
Emergency- Canada / USA A025518
stop (Off)
* see variants
*
K2
Applications
K3 * Short-circuit detection Protection of persons and machines
at the On pushbutton -- Emergency-stop circuits on machines
M 6742 -- Monitoring of safety gates

Block Diagram Indication

upper LED: on when supply voltage connected

A1(+)A2(-) S11 S12 S22 S33 S34 13 23 33 41
lower LEDs: on when relay K2 and K3 active

overvoltage
and short circuit monitoring
logic K2
protection

24V K2 K3
K3
power K2 K3

M7023_a S21/PE(-) 14 24 34 42

All technical data in this list relate to the state at the moment of edition. We reserve the right
for technical improvements and changes at any time. 1 11.01.16 en / 625
 Unit Programming
M8305_a

plate M7483

Circuit Diagrams Notes

A1 A1 If the ON pushbutton was already closed before the voltage was applied at
S11 S12 S22 13 21 T11 T12 T22 13 21
(+) (+) S12, S22 (also in the case of line fault via the ON pushbutton), the output
S11
A1 S22 13 21
T11
A1 T22 13 21 contacts cannot be switched on.
S12 K2 T12 K2 A line fault at the ON pushbutton which occured after activation of the unit
S33 T33 is recognized when switching on takes place again and switching-on of the
S34 K3 T34 K3 output contacts is prevented. If a line fault occurs at the ON pushbutton
A2 S21/PE 14 22 A2 T21/PE 14 22
after the voltage has already been applied at S12 and S22, unwanted
S21 A2 T21 A2 activation occures because this line fault can not be distinguished from the
S33 S34 14 22 T33 T34 14 22 regular switching-on function. The PE testing terminal allows the units to
/PE (-) /PE (-)
M7792_b M10458 be also operated in IT networks with insulation monitoring. It also serves
as a reference point for checking the control voltage and as a connection
BD 5935.16 BD 5935.16/200 contact in the event of an emergency-stop with cross fault detection.

A1 A1 Because of the gold-plated contacts the BD 5935 can be used to switch

S11 S12 S22 13 23 33 41 T11 T12 T22 13 23 33 41
(+) (+) small loads 1 mVA ... 7 VA, 1 mW ... 7 W in the range of 0.1 ... 60 V,
S11
A1 S22 13 23 33 41
T11
A1 T22 13 23 33 41 1 ... 300 mA. The gold-plated contacts allow also to switch the maximum
S12 K2 T12 K2 current but the gold plating will be burnt off. After that the contacts cannot
S33 T33 be used any more to switch the small loads.
S34 K3 T34 K3
A2 S21/PE 14 24 34 42 A2 T21/PE 14 24 34 42
One or more extension modules BN 3081 or external contactors with
S21 A2 T21 A2 forcibly guided contacts can be used to multiply the number of contacts
S33 S34 14 24 34 42 T33 T34 14 24 34 42
/PE (-) /PE (-) of the emergency-stop module BD 5935.
M7372_b M7373_c The switches S1 and S2 are provided for the following selection possibi-
lities: Automatic-start, manual-start and emergency-stop with or without
BD 5935.48 BD 5935.48/200
cross fault detection. These switches are located behind the front cover
panel (see unit programming diagrams).
A1 Switch S2 is for selecting automatic or manual Start. In addition, terminals
S11 S12 S22 13 23 31 41
(+) S33 and S34 must be jumpered for "automatic start function".
S11
A1 S22 13 23 31 41 Selection of the operating mode with or without cross fault detection at
S12 K2 the emergency-stop pushbutton is performed via the switch S1. The unit
S33 must be connected as shown in the application example.
S34 K3
A2 S21/PE 14 24 32 42
ATTENTION - AUTOMATIC START!
S21 A2 According to IEC/EN 60 204-1 part 9.2.5.4.2 it is not allowed to
S33 S34 14 24 32 42
/PE (-) restart automatically after emergency stop.
M9245 Therefore the machine control has to disable the automatic
start after emergency stop.
BD 5935.52

Connection Terminals

Terminal designation Signal designation

A1(+) +/L
A2 (-) -/N
S12, S22, S33, S34,
Inputs
T12, T22, T33, T34
S11, S21/PE,
Outputs
T11, T21/PE,
Forcibly guided NO contacts for
13, 14, 23, 24, 33, 34
release circuit
21, 22, 31, 32, 41, 42 Forcibly guided indicator output

2 11.01.16 en / 625
 Technical Data Technical Data
Input General Data

Nominal voltage UN: AC 24, 42, 48, 110, 115, 120, 127, 230, 240 V Operating mode: Continuous operation
DC 24 V Temperature range
Voltage range: AC 0.85 ... 1.1 UN operation: - 15 ... + 55 °C
at 10% residual ripple: DC 0.9 ... 1.2 UN at max. 90% humidity
at 48% residual ripple: DC 0.8 ... 1.1 UN storage : - 25 ... + 85 °C
Nominal consumption: AC approx. 4 VA, DC approx. 2 W altitude: < 2.000 m
Nominal frequency: 50 / 60 Hz Clearance and creepage
Recovery time: 0.5 s after activating the emergency- distances
stop button. rated impulse voltage /
If the line fault detection of the ON- pollution degree: 4 kV / 2 (basis insulation) IEC 60 664-1
button is be active, the device must EMC: IEC/EN 62 061
stay off for approx. 5 sec. Interference suppression: Limit value class B EN 55 011
Control voltage at S11: DC 22 V Degree of protection: Housing: IP 40* IEC/EN 60 529
Control current via S12, S22: approx. 35 mA ± 25 % at UN Terminals: IP 20 IEC/EN 60 529
Minimum voltage at * when front plate is removed to
terminal S12, S22: DC 21 V when unit is activated set switches, protection class IP 40
is not valid
Output
Housing: Thermoplastic with V0 behaviour
according to UL subject 94
Contacts
Contacts Vibration resistance: Amplitude 0.35 mm IEC/EN 60 068-2-6
BD 5935.16: 1 NO / 1 NC contacts frequency 10 ... 55 Hz
BD 5935.48: 3 NO / 1 NC contacts Climate resistance: 15 / 055 / 04 IEC/EN 60 068-1
BD 5935.52: 2 NO contacts / 2 NC contacts Terminal designation: EN 50 005
Wire connection: 1 x 4 mm2 solid or
The NO contacts are safety contacts. 1 x 2.5 mm2 stranded ferruled (isolated or
ATTENTION! The NC contacts 21-22, 31-32 and 41-42 can only be 2 x 1.5 mm2 stranded ferruled (isolated)
used DIN 46 228-1/-2/-3/-4 or
for monitoring. 2 x 2.5 mm2 stranded ferruled
DIN 46 228-1/-2/-3
Operate time Wire fixing: Plus-minus terminal screws M3.5,
activation via ON pushbutton: 50 ms - 25 % + 50 % box terminal with wire protection
automatic ON function: 1 s - 25 % + 50 %, as option also Fixing torque: 0.8 Nm
with shorter on-delay (see variants)
Mounting: DIN rail IEC/EN 60 715
Release time
Weight: 450 g
opening in secondary circuit
(S12-S22): 25 ms - 25 % + 50 %
opening in supply circuit: 50 ms - 25 % + 50 % Dimensions
Contact type: relay, forcibly guided
Rated output voltage: AC 250 V Width x height x depth: 45 x 74 x 121 mm
DC: see arc limit curve
Thermal current Ith: see quadratic total current limit curve Safety Related Data
(max. 10 A in one contact path)
Switching capacity Values according to EN ISO 13849-1:
to AC 15 Category: 4
NO contact: 5 A / AC 250 V IEC/EN 60 947-5-1 PL: e
NC contact: 2 A / AC 250 V IEC/EN 60 947-5-1 MTTFd: 238,4 a
to DC 13 DCavg: 99.0 %
NO contact: 2 A / DC 24 V IEC/EN 60 947-5-1 dop: 365 d/a (days/year)
NC contact: 2 A / DC 24 V IEC/EN 60 947-5-1
hop: 24 h/d (hours/day)
to DC 13
tcycle: 3600 s/Zyklus
NO contact: 6 A / DC 24 V at 0.1 Hz
NC contact: 6 A / DC 24 V at 0.1 Hz =1 /h (hour)
Electrical life
to AC 15 at 2 A, AC 230 V: 105 switching cycles IEC/EN 60 947-5-1 Values according to IEC/EN 62061 / IEC/EN 61508:
Permissible operating SIL CL: 3 IEC/EN 62061
frequency: 600 switching cycles / h SIL 3 IEC/EN 61508
Short circuit strength HFT*): 1
max. fuse rating: DCavg: 99.0 %
NO contact: 10 A gL IEC/EN 60 947-5-1 SFF 99.7 %
NC contact: 6 A gL IEC/EN 60 947-5-1 PFHD: 1.95E-10 h-1
Mechanical life: 10 x 106 switching cycles
*)
HFT = Hardware-Failure-Tolerance

The values stated above are valid for the standard type.
Safety data for other variants are available on request.
nfo The safety relevant data of the complete system has to be
determined by the manufacturer of the system.

3 11.01.16 en / 625
 CCC-Data Characteristics

Nominal voltage UN: AC 24, 42, 48, 110, 115, 120, 127, 230 V 250
DC 24 V
200
Thermal current Ith: see quadratic total current limit curve

Switching voltage U [V]

(max. 5 A in one contact path)
150
Switching capacity
to AC 15 100
NO contact: 2 A / AC 230 V IEC/EN 60 947-5-1
to DC 13 50
NO contact: 1 A / DC 24 V IEC/EN 60 947-5-1
0
Technical data that is not stated in the CCC-Data, can be found 1 2 3 4 5 6 7 8 9 10
in the technical data section.
nfo Switching current I [A]
M 6732

Standard Type Arc limit curve under resistive load

BD 5935.48 DC 24 V
Article number: 0045456
• Output: 3 NO / 1 NC contacts
• Nominal voltage UN: DC 24 V
• Width: 45 mm

Variants

BD 5935._ _/61: with UL-approval

BD 5935.48/200: special terminal arrangement
see diagram
BD 5935.48/324: with fast auto start:
typ. 500 ms, without line fault
detection on ON-button
BD 5935.48/824: with fast auto start: Quadratic total current limit curve
typ. 110 ms, without line fault
detection on ON-button

Ordering example of Variants

BD 5935 .48 /_ _ _ AC 230 V 50/60 Hz Application Example

Nominal frequency
Nominal voltage
Variant, if required
Contacts
Type

Single-channel emergency-stop circuit. This circuit has no redundancy in

the emergency-stop control circuit.
Please note "Unit programming" !
Switches in pos.: S1 no cross fault detection
S2 manual start
Suited up tos SIL2, Performance Level d, Cat. 3

4 11.01.16 en / 625
 Application Examples

Two-channel emergency-stop circuit without cross fault detection. Two-channel emergency-stop circuit with cross fault detection.
Please note "Unit programming" ! Please note "Unit programming" !
Switches in pos.: S1 no cross fault detection Switches in pos.: S1 cross fault detection
S2 manual start S2 manual start
Suited up to SIL3, Performance Level e, Cat. 4 Suited up to SIL3, Performance Level e, Cat. 4

Contact reinforcement with external contactors, controlled with one con- Contact reinforcement by external contators, controlled with 2 contact
tact path. paths. With switching current > 10 A, the output contacts can be rein-
Please note "Unit programming" ! forced by external contactors with forcibly guided contacts. The function of
Switches in pos.: S1 no cross fault detection the external contactors is monitored by looping the NC contacts into the
S2 manual start making circuit (terminals S33-S34).
Suited up to SIL3, Performance Level e, Cat. 4 Please note "Unit programming" !
Switches in pos.: S1 no cross fault detection
S2 manual start
Suited up to SIL3, Performance Level e, Cat. 4

Two-pole emergency-stop with emergency-stop control device in the sup- Two-channel monitoring of a safety gate.
ply circuit. The switch of S12 must close simultaneously with S22 or later.
Application for long emergency-stop loops in which the control voltage Please note "Unit programming" !
dropped below the minimum voltage of 21 V. Switches in pos.: S1 no cross fault detection
Important: S2 manual start
Single faults (line shorts over the emergency-stop control device) are not Suited up to SIL3, Performance Level e, Cat. 4
identified with this external circuit.
Please note "Unit programming" !
Switches in pos.: S1 no cross fault detection
S2 manual start
Suited up to SIL3, Performance Level e, Cat. 4

5 11.01.16 en / 625
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e-mail: dold-relays@dold.com • internet: http://www.dold.com 6 11.01.16 en / 625