Safety Relays

Part Number	Description / PDF	Quantity
1105097 Phoenix Contact	SAFE EXTENSION MODULE FOR LOCAL	5
1104974 Phoenix Contact	CONFIGURABLE SAFETY MODULE (BASI	9
1105011 Phoenix Contact	SAFE EXTENSION MODULE FOR MONITO	23
1104985 Phoenix Contact	SAFE EXTENSION MODULE WITH 4 SAF	7
1104972 Phoenix Contact	CONFIGURABLE SAFETY MODULE (BASI	5
2700524 Phoenix Contact	RELAY SAFETY 3PST 6A 24V	0
2981402 Phoenix Contact	RELAY SAFETY 7PST 6A 120V	1
1104986 Phoenix Contact	SAFE EXTENSION MODULE WITH 4 SAF	23
1104989 Phoenix Contact	SAFE EXTENSION MODULE FOR MONITO	23
2981813 Phoenix Contact	RELAY SAFETY DPST 6A 24V	625
2961574 Phoenix Contact	RELAY GEN PURPOSE	2
2986575 Phoenix Contact	RELAY SAFETY DPST 5A 24V	1213
2981499 Phoenix Contact	RELAY SAFETY DPST 6A 24V	0
2981538 Phoenix Contact	RELAY SAFETY SPST X 4 5A 24V	0
2963912 Phoenix Contact	RELAY SAFETY 8PST 6A 24V	262
1104889 Phoenix Contact	SAFE EXTENSION MODULE WITH 8 SAF	0
2963747 Phoenix Contact	RELAY SAFETY 7PST 6A 24V	4
2901422 Phoenix Contact	RELAY SAFETY	246
1105098 Phoenix Contact	SAFE EXTENSION MODULE FOR LOCAL	5
2963734 Phoenix Contact	RELAY SAFETY 6PST 6A 24V	178

Safety Relays

1. Overview

Safety relays are specialized control devices designed to ensure fail-safe operation in industrial systems. They monitor safety-related inputs (e.g., emergency stops, light curtains) and trigger protective actions by cutting power to machinery. Compliant with international standards like IEC 61508 and ISO 13849-1, these relays form the backbone of safety instrumented systems (SIS) across automation sectors.

2. Major Types and Functional Classification

Type	Functional Characteristics	Application Examples
Electromagnetic Safety Relays	Mechanical contact-based design with physical separation	Machinery emergency stops, simple safety circuits
Solid-State Safety Relays	Zero-contact semiconductor switching with vibration resistance	Precision equipment, explosive atmosphere environments
Programmable Safety Relays	Configurable logic with diagnostic capabilities	Robotic cells, complex safety interlocking systems
Monitoring Safety Relays	Continuous circuit integrity verification	Safety door interlocks, two-hand control systems

3. Structure and Components

Typical safety relay construction includes:

Enclosure: Flame-retardant polymer housing (UL94 V-0 rated)
Coil System: 24V DC/AC operating with bifilar winding for failure detection
Contact Arrangement: Gold-plated contacts with positive-guided mechanism
Diagnostic Circuitry: Built-in semiconductor for contact state monitoring
Mounting Options: DIN rail or PCB mount with screw/clamp terminal connections

4. Key Technical Parameters

Parameter	Typical Value	Importance
Safety Integrity Level (SIL)	SIL 3 (IEC 61508)	Determines risk reduction factor
Response Time	5-50 ms	Affects machine safe stop performance
Contact Rating	6A @ 250V AC	Dictates load switching capability
MTBF	500,000 hours	System uptime prediction
Environmental Temp	-20 C to +55 C	Operational reliability factor

5. Application Areas

Primary industries include:

Industrial Automation: CNC machines, assembly lines
Energy Systems: Wind turbine safety circuits
Transportation: Rail vehicle door control systems
Medical Equipment: MRI machine emergency cutoffs

Case Study: Automotive Press Line Safety

A major automotive manufacturer implemented safety relays in 1200-ton press machines, achieving PLc (EN ISO 13849-1) compliance through dual-channel emergency stop circuits with 35ms response time.

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Siemens	3SK1 Safety Relay	Modular design, PROFINET integration
Schneider Electric	XPSM Safety Relay	Multi-sensor monitoring, SIL3 capable
Omron	G9SP-N Safety Controller	Programmable with 30 pre-defined safety functions
Phoenix Contact	PSR-SCP-24DC-PO Safety Relay	Plug-in module with status visualization

7. Selection Guidelines

Critical selection factors:

Safety Category: Match to application risk assessment (Cat. 2/3/4)
Environmental Conditions: Consider temperature, vibration, and EMC
Certifications: Required standards (CE, UL, T V)
Expansion Capability: Future system scalability
Diagnostic Coverage: Minimum 90% recommended

8. Industry Trends

Emerging developments include:

Integration with Industry 4.0 through IO-Link interfaces
Functional safety for collaborative robots (cobots)
Wireless safety communication protocols
Miniaturization while maintaining IP67 ratings
AI-enhanced predictive maintenance capabilities