BG 5925.22/61 AC/DC24V

**Safety Technique** 

**SAFEMASTER Emergency Stop Module BG 5925** 

- **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** 

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- **Safety Integrity Level (SIL) 3 to IEC/EN 61508** 

- Output: max. 3 NO contacts, see contacts 

- Single and 2-channel operation 

- Line fault detection on On-button 

- Manual restart or automatic restart, switch S2 

- With or without cross fault monitoring in the E-stop loop, switch S1 

- LED indicator for channel 1 and 2 and Power 

- Removable terminal strips 

- Wire connection: also 2 x 1.5 mm[2] stranded ferruled (isolated), DIN 46 228-1/-2/-3/-4 or 2 x 2.5 mm[2] stranded ferruled DIN 46 228-1/-2/-3 

- Width 22.5 mm 

## **Approvals and Marking** 

**Function Diagram** 

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/ y ect * *<br>c US<br>Canada / USA Canada / USA<br>cel{UUTUVRheiCERTIFIED Se nland) = easier) | . vo Ge<br>* see variants<br>Applications<br>Protection of people and machines<br>• Emergency stop circuits on machines<br>• Monitoring of safety gates<br>Indicators A afety @ ¢<br>LED Power:  on when supply connected<br>LED K1/K2:  on when relay K1/K2 energized<br>Circuit Diagrams<br>A1 S33 S34 A1 S33 S34<br>-—-e. 13 23 24 —.-.-. .—-e. 13 23 24 33 —.-.e.<br>! S12 A1 S11 13 23 : ! S12 A1 S11 13 23 33<br>I S22 K1 ---L-- i I S22 K1 --f--4--- i<br>. S33 I. S33<br>i] S34 K2 oT 1 ] S34 K2 oT TT 1<br>A2 S21 14 24 A2 S21 14 24 34<br>! |i! aoe<br>‘eee. 14 S11 S12 ee 14 S11 S12 34 _..-!<br>M7390_b M7389_b<br>S21 S22 A2 S21 S22 A2<br>BG 5925.02 BG 5925.03<br>A1 S33 S34 A1 S33 S34<br>13 21 22 13 23 24 31<br>aii Se may<br>A1 S11 13 21 A1 S11 13 23 31<br>S12 S12<br>! S22 K1 ] 1! S22 K1 } } I<br>S33 S33<br>! S34 K2 .}-- 1! S34 K2 f+} - I<br>A2 S21 14 22 A2 S21 14 24 32<br>: | I | | !<br>14 S11 S12 14 S11 S12 32<br>M7388_b M7387_b<br>S21 S22 A2 S21 S22 A2<br>OTL oot<br>BG 5925.16 BG 5925.22<br>**----- End of picture text -----**<br>


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pushbutton<br>On<br>emergency-<br>stop<br>K1<br>*<br>K2<br>=<br>BG5925.__/___ not for /105, /106 BG5925.__/105,<br>* line fault detection at the On pushbutton BG5925.__/106 M8303<br>**----- End of picture text -----**<br>


## **Block Diagram** 

|3 

## **Connection Terminals** 

|A1+<br>+ / L<br>A2<br>- / N|+ / L<br>- / N|
|---|---|
|S12,S22,S33,S34<br>In|Inputs|
|S11,S21<br>Out|Outputs|
|13, 14, 23, 24, 33, 34<br>Forcibly guided NO contacts for<br>release circuit|Forcibly guided NO contacts for<br>release circuit|
|21,22,31,32<br>Forcibl|Forcibly guided indicator output|



~~oo~~ All technical data in this list relate to the state at the moment of edition. We reserve the right for ~~ss,>»>ic—ec HH~~ technical improvements and changes at any time. 

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## **Unit programming** 

||S1|S2|Function|
|---|---|---|---|
||available in<br>unti|||
|BG 5925|yes|yes||
|BG 5925._ _/101|yes|yes||
|BG 5925._ _/102|no|no|automatic + without|
|BG 5925._ _/103|no|no|manual + with|
|BG 5925._ _/104|no|no|automatic + with|
|BG 5925._ _/105|no|yes|without|
|BG 5925._ _/106|no|yes|with|



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Disconnect unit before setting of S1 Drawing shows setting at the state of delivery 

## **Technical Data** 

## **Notes** 

Line fault detection on On-button: 

## **Input circuit** 

The line fault detection is only active when S12 and S22 are switched simultaneously. If The On-button is closed before S12, S22 is connected to voltage (also when line fault across On-Button), the output contacts will not close. A line fault across the On-button which occurred after activation of the relay, will be detected with the next activation and the output contacts will not close. If a line fault occurs after the voltage has been connected to S12, S22, the unit will be activated because this line fault is similar to the normal On-function. The gold plated contacts of the BG 5925 mean that this module is also suitable for switching small loads of 1 mVA - 7 VA, 1 mW - 7 W in the range 0.1 - 60 V, 1 - 300 mA. The contacts also permit the maximum switching current. However since the gold plating will be burnt off at this current level, the device is no longer suitable for switching small loads after this (not for variant BG 5925.22/102). 

## DC 24 V, AC/DC 24 V 

## **Nominal Voltage UN:** 

AC 230 V with variant /105 and /106 **Voltage range** DC AC/DC at 10% residual ripple: 0.9 ... 1.1 UN 0.95 ... 1.1 UN at 48% Rresidual ripple: 0.8 ... 1.1 UN 0.8 ... 1.1 UN AC: — 0.85 ... 1.1 UN **Nominal consumption:** DC approx. 2 W **Min. Off-time:** 250 ms **Control voltage on S11:** DC 23 V at UN **Control current over S12, S22:** 40 mA at UN 

**Voltage range** at 10% residual ripple: at 48% Rresidual ripple: AC: 

**Min. voltage between terminals S12, S22 and S21:** DC 21 V when relay activated and UN on A1 - A2 **Short-circuit protection:** Internal PTC **Overvoltage protection:** Internal VDR 

The terminal S21 permits the operation of the device in IT-systems with insulation monitoring, serves as a reference point for testing the control voltage and is used to connect the E-stop loop when cross fault monitoring is selected. 

## **Output** 

Connecting the terminal S21 to the protective ground bridges the internal short-circuit protection of Line A2 (-). The short-circuit protection of line A1 (+) remains active. 

**Contacts** BG 5925.02: 2 NO contacts BG 5925.03: 3 NO contact BG 5925.16: 1 NO, 1 NC contact BG 5925.22: 2 NO, 1 NC contact The NO contacts are safety contacts. **ATTENTION! The NC contacts 21-22 or 31-32 can only be used for monitoring. Operate delay typ. at UN:** Manual start: 40 ms automatic start: 250 ms BG 5925._ _ /101: 100 ms **Release delay typ. at UN:** Disconnecting the supply: 50 ms Disconnecting S12, S22: 15 ms **Contact type:** forcibly guided **Nominal output voltage:** AC 250 V DC: see limit curve for arc-free operation **Switching of low loads:** ≥ 100 mV (contact 5 µ Au) ≥ 1 mA (contact AgNi) ≥ 10 mA / DC 24 V **Thermal current Ith:** on 1 contact path: max. 5 A see current limit curve 

To alter the functions automatic start - manual start and with or without cross fault monitoring, the switches S1 and S2 are used. These are located behind the front cover (see unit programming). 

The setting with or without cross fault monitoring on E-stop buttons is made with S1. S2 is used to change between automatic an manual restart. On automatic start also the terminals S33 - S34 have to be linked. For connection please see application examples. 

## **ATTENTION - AUTOMATIC START!** 

According to IEC/EN 60 204-1 part 9.2.5.4.2 and 10.8.3 it is not allowed to restart automatically after emergency stop. Therefore the machine control has to disable the automatic start after emergency stop. 

**Switching capacity** to AC 15: NO contacts: 3 A / AC 230 V IEC/EN 60 947-5-1 NC contacts: 2 A / AC 230 V IEC/EN 60 947-5-1 to DC 13: NO contacts: 1 A / DC 24 V IEC/EN 60 947-5-1 NC contacts: 1 A / DC 24 V IEC/EN 60 947-5-1 **Electrical contact life** to AC 15 at 2 A, AC 230 V: 10[5] switching cycles IEC/EN 60 947-5-1 to DC 13 at 1 A, DC 24 V: > 1.5 x 10[5] switching cycles **Permissible operating frequency:** max. 1 200 operating cycles / h **Short circuit strength** max. fuse rating: 6 A general-purpose IEC/EN 60 947-5-1 line circuit breaker: C 8 A **Mechanical life:** 10 x 10[6] switching cycles 

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## **Technical Data** 

## **General Data** 

**Operating mode:** Continuous operation **Temperature range** operation: - 15 ... + 55 °C storage : - 25 ... + 85 °C **altitude:** < 2.000 m **Clearance and creepage distances** rated impuls voltage / pollution degree: 4 kV / 2 (basis insulation) IEC 60 664-1 **EMC** Electrostatic discharge: 8 kV (air) IEC/EN 61 000-4-2 HF irradiation: 10 V / m IEC/EN 61 000-4-3 Fast transients: 2 kV IEC/EN 61 000-4-4 Surge voltages between wires for power supply: 1 kV IEC/EN 61 000-4-5 between wire and ground: 2 kV IEC/EN 61 000-4-5 Interference suppression: Limit value class B EN 55 011 **Degree of protection** Housing: IP 40 IEC/EN 60 529 Terminals: IP 20 IEC/EN 60 529 **Housing:** Thermoplastic with V0 behaviour according to UL subject 94 **Vibration resistance:** Amplitude 0.35 mm IEC/EN 60 068-2-6 frequency 10 ... 55 Hz **Climate resistance:** 15 / 055 / 04 IEC/EN 60 068-1 **Terminal designation:** EN 50 005 **Wire connection:** 1 x 4 mm[2] solid or 1 x 2.5 mm[2] stranded ferruled (isolated) or 2 x 1.5 mm[2] stranded ferruled (isolated) DIN 46 228-1/-2/-3/-4 or 2 x 2.5 mm[2] stranded ferruled DIN 46 228-1/-2/-3 **Wire fixing:** Box terminal with wire protection, removable terminal strips **Mounting:** DIN rail IEC/EN 60 715 **Weight:** 220 g 

## **Dimensions** 

**Width x height x depth:** 

22.5 x 84 x 121 mm 

## **Safety Related Data** 

**Values according to EN ISO 13849-1:** Category: 4 PL: e MTTFd: 236.3 a (year) DC / DC : 99.0 % avg dop: 365 d/a (days/year) hop: 24 h/d (hours/day) tZyklus: 3600 s/Zyklus = 1 /h (hour) 

## **Values according to IEC/EN 62061 / IEC/EN 61508:** 

|SIL CL:<br>SIL:<br>HFT:<br>DC / DCavg:<br>SFF:|3<br>3<br>1<br>99.0<br>99.7|IEC/EN<br>IEC/EN<br>%<br>%|62061<br>61508|
|---|---|---|---|
|PFHD:<br>T1:|1.97E-10<br>20|h-1<br>a (year)||



*) HFT = Hardware-Failure Tolerance 

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

## **UL-Data** 

**The safety functions were not evaluated by UL. Listing is accomplished according to requirements of Standard UL 508, “general use applications”** 

## **Nominal voltage UN:** 

BG 5925, /101, /102, /103, /104: DC 24 V AC/DC 24 V 

**Ambient temperature:** -15 … +55°C 

**Switching capacity:** Ambient temperature 45°C Pilot duty B300 5A 250Vac Resistive 5A 24Vdc Resistive or G.P. Ambient temperature 55°C: Pilot duty B300 4A 250Vac Resistive 4A 24Vdc Resistive or G.P. **Wire connection:** 60°C / 75°C copper conductors only AWG 20 - 12 Sol Torque 0.8 Nm AWG 20 - 14 Str Torque 0.8 Nm 

**Technical data that is not stated in the UL-Data, can be found in the technical data section.** 

## nfo 

## **CSA-Data** 

**Nominal voltage UN:** BG 5925/113, /114: DC 24 V AC/DC 24 V **Ambient temperature:** -15 … +55°C **Switching capacity:** 5A 230Vac **Wire connection:** 60°C / 75°C copper conductors only AWG 20 - 12 Sol Torque 0.8 Nm AWG 20 - 14 Str Torque 0.8 Nm 

**Technical data that is not stated in the UL-Data, can be found in the technical data section.** 

## nfo 

## **Standard Type** 

BG 5925.03/61  AC/DC 24 V Article number: 0049169 • Output: 3 NO contacts • Nominal voltage UN: AC / DC 24 V • Width: 22.5 mm 

## **Variants** 

BG 5925._ _/60: CSA-approval BG 5925._ _/61: UL-approval BG 5925._ _ /101: 

E-stop with fast automatic start without line fault detection on the ON-button 

BG 5925._ _ /102: BG 5925.02/103: 

Automatic-restart, without crossfault monitoring Manual restart, with crossfault monitoring for DC 24 V Switching capacity to AC 15: 5 A / 230 V Contact fuse 6 A fast / 4 A slow 

without internal switches S1 and S2 

BG 5925.02/104: Automatic restart, with cross fault monitoring for DC 24 V 

Switching capacity to AC 15: 5 A / 230 V Contact fuse 6 A fast / 4 A slow 

without internal switches S1 and S2 

BG 5925._ _/105: With switch S1 and without crossfault monitoring for AC 230 V 

BG 5925._ _/106: With switch S2 and with crossfault monitoring for AC 230 V 

## **Ordering example for variants** 

BG 5925 ._ _ /_ _ _   /61 DC 24 V Nominal voltage with UL-approval Variant, if required Contacts Type 

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 Characteristics<br>250<br>200<br>150<br>100<br>50<br>0<br>1 2 3 4 5 6 7 8<br>switching current I [ A ]<br>safe breaking, no continuous arcing,<br>max. 1 switching cycle/s<br>M5834_a<br>[ VDC ]<br>U<br>switching voltage<br>**----- End of picture text -----**<br>


Arc limit curve under resistive load 

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Quadratic total current limit curve 

electric life DC13 24V DC / ton 0,4s; toff 9,6s 2 contacts in series 

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0,9<br>0,8<br>0,7<br>0,6<br>0,5<br>0,4<br>0,3<br>0,2<br>0,1<br>0<br>0 1 2 3 4 5 6 7 8<br>M5783<br>6x10<br>switching cycles<br>**----- End of picture text -----**<br>


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Contact service life 

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**Application Examples** 

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Single channel emergency stop circuit. This circuit does not have any redundancy in the emergency-stop control circuit. **Note: Refer to „Unit programming“!** Switches in pos.: S1 no cross fault detection S2 manual start 

2-channel emergency stop circuit without cross fault monitoring. **Note: Refer to „Unit programming“!** Switches in pos.: S1 no cross fault detection S2 manual start 

Suited up to SIL3, Performance Level e, Cat. 4 

Suited up to SIL2, Performance Level d, Cat. 3 

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L1<br>E-stop<br>On K4<br>K5<br>A1(+) S11 S33 S34 S12 S22 13 .. ..<br>BG5925<br>A2(-) S21 14 .. ..<br>K4 K5<br>N<br>M7119_a<br>**----- End of picture text -----**<br>


Contact reinforcement by external contactors controlled by one contact path. **Note: Refer to „Unit programming“!** Switches in pos.: S1 no cross fault detection S2 manual start 

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2-channel safety gate monitoring. 

**Note: Refer to „Unit programming“!** Switches in pos.: S1 no cross fault detection S2 manual start 

Suited up to SIL3, Performance Level e, Cat. 4 

Suited up to SIL3, Performance Level e, Cat. 4 

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L1<br>On K4 E-stop<br>K5<br>A1(+) S11 S33 S34 S12 S22 13 23 ..<br>BG5925<br>A2(-) S21 14 24 ..<br>K4 K5<br>N<br>M7120_a<br>**----- End of picture text -----**<br>


Contact reinforcement by external contactors, 2-channel controlled. The output contacts can be reinforced by external contactors with forcibly guided contacts for switching currents > 8 A. Functioning of the external contactors is monitored by looping the NC contacts into the closing circuit (terminals S33-S34). **Note: Refer to „Unit programming“!** Switches in pos.: S1 no cross fault detection S2 manual start 

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2-channel emergency stop circuit with cross fault detection **Note: Refer to „Unit programming“!** Switches in pos.: S1 cross fault detection S2 manual start 

Suited up to SIL3, Performance Level e, Cat. 4 

Suited up to SIL3, Performance Level e, Cat. 4 

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**E. DOLD & SÖHNE KG • D-78114 Furtwangen** • PO Box 1251 • Telephone (+49) 77 23 / 654-0 • Telefax (+49) 77 23 / 654-356 

e-mail: dold-relays@dold.com • internet: http://www.dold.com 

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