Schneider Electric XPS-AXE5120P Safety Relay

Позиционирование продукта: Safety module for emergency stop & safety gate switch monitoring (Категория 0 останавливаться). Replacement for legacy XPSAX

Типовые модели: XPSAXE5120P / XPSAXE5120C

XPSAXE5120P: Removable screw terminals

XPSAXE5120C: Removable spring terminals

Источник питания: 24 В переменного/постоянного тока (переменного тока & DC универсальный)

Монтаж: 35 мм DIN-рейка, ширина 22.5 мм

Габаритные размеры (Ш×В×Г): 22.5 × 99 × 114 мм

✅ Safety Ratings

ПЛ е / Кат.4 (В ИСО 13849-1)｜SIL CL3 (МЭК 61508 / МЭК 62061)

Применимые стандарты: В ИСО 13850 (Аварийная остановка), В ИСО 14119 (Safety Interlock Switches)

2. Канал & Определение терминала (XPSAXE5120)

1) Источник питания

А1, А2: Питание модуля, 24 В переменного/постоянного тока

2) Safety Inputs (Dual-channel monitoring, dual NC emergency stop / safety switches recommended)

С11-С12: Канал 1

С21-С22: Канал 2

Detects short circuits and wire breaks between dual channels; synchronous response window between channels ＜0.5 s

3) Start Circuit (Перезагрузить)

S33, S34

Short S33 and S34 → Automatic Reset

Connect external NO pushbutton between S33 and S34 → Manual Reset

4) External Contactor Feedback Circuit (Обязательный!)

Y1, Y2

Wire auxiliary NC contacts of main circuit contactor in series to Y1-Y2;

Функция: Prevent unexpected machine startup if contactors weld closed (anti-bounce restart protection).

5) Выходы безопасности (3 sets of instantaneous NO safety contacts)

13-14, 23-24, 33-34

Three independent safety relay contacts for de-energizing power contactor coils.

Single contact rated current: 6 А; АС-15: 360 VA continuous load; DC-13: 24 V/1.5 A.

6) Auxiliary PLC Signal Output (Non-safety circuit!)

41-42: 1 set of NC signal contacts

Only used for status feedback to PLC. Strictly prohibited for safety cut-off circuits.

7) Светодиодные индикаторы

PWR: Power supply present

БЕГАТЬ: Safety circuit closed, outputs energized

3. Operating Logic
4. Включение питания; emergency stop reset & safety gate closed → S11-S12 / S21-S22 conductive
5. Y1-Y2 feedback circuit closed (main contactor de-energized)
6. Press reset button (or auto-reset active) → internal dual relays energize
7. 13-14 / 23-24 / 33-34 закрывать, machine operation permitted
8. Emergency stop triggered / gate opened / wiring fault detected → three safety outputs open instantaneously (≤80 ms)
9. Reset is blocked until all faults are cleared
10. Recommended Typical Wiring Schemes
11. Standard Scheme (Dual NC Emergency Stop + Ручной сброс + Обратная связь)

А1/А2: 24 В источник питания

Dual NC emergency stop: Common power feed, two channels routed separately to S11-S12 and S21-S22

NO start pushbutton wired across S33-S34

Auxiliary NC contacts of main power contactor wired in series to Y1-Y2

13/23/33 connected to power; 14/24/34 wired in parallel to drive main contactor coil

2. Prohibited Practices

Do NOT use 41-42 signal contacts for safety cut-off

Do NOT omit Y1-Y2 feedback circuit (losses anti-weld protection, cannot achieve Cat.4)

Single-channel wiring only achieves PL d/Cat.3, fails high-end machine requirements

5. Key Notes for Legacy XPSAX Replacement (Common Application)

Legacy model: XPSAX5120 → Replace with XPSAXE5120P

1. Terminal assignments not fully pin-to-pin compatible, direct plug replacement is impossible; terminal wiring must be rechecked
2. XPSAXE adopts removable terminals for easier cabinet wiring and maintenance
3. Height dimension increased; verify available installation space
4. Identical operating logic and safety rating
5. Series Selection Comparison Reference

XPS-AXE: Аварийная остановка / мониторинг ворот безопасности, 3 NO safety outputs, with feedback; Категория 0 останавливаться

XPS-AC: Компактный 22.5 ширина мм, similar functions with minor load capacity differences

XPS-AK: Supports safety light curtains, коврики безопасности; расширенные функции, более высокая стоимость

7. Распространенное устранение неполадок
8. RUN LED off after power-up

Verify S11/S21 both channels are conductive

Check continuity of Y1-Y2 (confirm contactor not welded)

2. Machine cannot restart after emergency stop release

Confirm reset mode: short S33 and S34 for automatic reset

Short circuit or wire break detected in dual input channels

3. Random tripping during operation

Total wiring resistance of input cables exceeds limit (≤50 Ω); use larger cross-section cables for long wiring runs

я могу предоставить:

✅ Text version of standard wiring schematic

✅ Full datasheet parameters of XPSAXE5120P

✅ Terminal comparison table: XPSAX vs XPSAXE

Application Scenarios of Schneider XPS-AXE (XPSAXE5120P/C) Реле безопасности

Core Position Recap

Only supports two safety input types: dual-channel dual NC emergency stop pushbuttons + safety gate interlock switches

Рейтинг безопасности: ПЛ е / Кат.4, Уровень безопасности CL3, Категория 0 instantaneous power cut-off

Not compatible with: Световые завесы безопасности, коврики безопасности, устройства двуручного управления;

Стандартная конфигурация: External contactor feedback circuit (Y1-Y2), 3 safety NO outputs, 1 PLC status signal output; supports Manual Reset / Автоматический сброс.

1. Supported Safety Functions
2. Emergency Stop Circuit Monitoring (ИСО 13850) : Monitoring machine main emergency stop and zone emergency stop via dual channels
3. Safety Guard Door Interlock Monitoring (ИСО 14119) : Mechanical fences, access doors, protective hood interlock switches

Applicable switches: Dual NC safety gate switches, magnetic safety interlock switches (НЗ контакты)

2. Industry Typical Applications

1) General Machine Tools & Metalworking Equipment

токарные станки с ЧПУ, обрабатывающие центры, фрезерные станки, шлифовальные машины

Small presses, hydraulic machines, press brakes, ножницы

Cutting machines, шлифовальные машины, deburring equipment

Использование: Machine panel emergency stop + electrical cabinet door / protective hood interlock

2) Упаковка, Печать & Rubber/Plastics Machinery

Vertical form fill seal machines, flow wrappers, case packers, auxiliary palletizing equipment

Blow molding machines, injection molding auxiliary equipment, small extrusion lines

Печатные машины, laminators, die-cutters

Функции: Risk of nipping between rollers and conveyors; immediate machine shutdown required upon guard door opening

3) Транспортировка & Logistics Automation Equipment

Ленточные конвейеры, роликовые конвейеры, transfer units, lifting transfer tables

Small automated storage systems, sorting workstations, single units on packaging lines

Guard fence interlock at roller conveyor corners

4) Small Robot Workcells

Compact 6-axis robots, SCARA robot single-unit safety fencing

⚠️ Limitation: Only for fence door + workstation emergency stop monitoring. Additional XPS-AK safety relay required if safety light curtains are deployed.

5) Еда & Pharmaceutical Packaging Equipment

Разливочные машины, укупорочные машины, этикетировочные машины, auxiliary sterilization equipment

Food cutting and material handling standalone machines

Преимущества: 24 V AC/DC wide range power supply, compact DIN rail mounting; meets CE requirements for export machinery

6) Деревообработка & Composite Processing Machinery

Edge banders, nesting CNC routers, гравировальные станки, sanders

Panel cutting, small composite hot-press equipment

7) Test Benches & Custom Automation Machinery

Component air-tightness test stations, press-fit custom machines, torque tightening equipment

Small lithium battery assembly equipment, inspection tooling

Widely adopted for safety circuit construction on custom machines to satisfy EU Machinery Directive & CE marking

3. Typical Wiring Application Schemes
4. Схема А: Single Machine with Emergency Stop + Ворота безопасности (Самый распространенный)

Two channels wired in series: Dual NC emergency stop + dual NC safety gate. Machine shuts down immediately upon activation of either device.

Suitable for standalone equipment fitted with protective hoods and safety fences.

2. Схема Б: Dual-channel Emergency Stop Monitoring Only

Both channels connected to dual NC emergency stop without safety gates; used for open-frame equipment only equipped with emergency stop protection.

3. Схема С: Safety Guard Door Monitoring Only

Two channels connected to safety gate switches, working with zone emergency stops to form the complete machine safety system.

4. Неподходящие приложения (Подводные камни выбора)
5. Required interface with safety light curtains, коврики безопасности, safety edges → Select XPS-AK / XPSUAK
6. Required time-delayed shutdown (Category1/2 stop) → XPS-ATE time-delay series
7. Required two-hand control function → XPS-AB
8. Mixed multiple safety signals (световая завеса + safety gate + аварийная остановка) → Universal XPSUAF safety module
9. Solid-state safety outputs required (no mechanical contacts) → Models with semiconductor outputs
10. Key Selection Reminders

Direct replacement for legacy XPSAX5120: XPSAXE5120P (винтовые клеммы) / XPSAXE5120C (spring terminals)

Compact cabinet alternative with equivalent functions: Compare XPSAC5121

To achieve Cat.4 safety rating, Y1-Y2 contactor feedback circuit cannot be omitted

I can organize:

✅ Text version of standard XPSAXE wiring diagram

✅ Safety function description text for CE risk assessment (directly usable in machine manuals)

Detailed Analysis of Y1-Y2 External Contactor Feedback Circuit for Schneider XPS-AXE (XPSAXE)

Terminals Y1, Y2

Connect auxiliary Normally Closed (Северная Каролина) contacts of main power contactors

⚠️ This circuit must not be omitted to achieve PL e / Кат.4

1. Four Core Functions

1) Anti-Weld Contactor Protection (Most Critical)

Сценарий: Main contactor main contacts weld closed due to high current ablation or mechanical jamming.

Normal shutdown: Contactor coil de-energized, основные контакты разомкнуты; auxiliary NC contacts restore closed state, Y1-Y2 conductive.

Weld fault condition: Safety relay cuts outputs, but main power circuit remains energized; auxiliary NC contacts stay open → Y1-Y2 circuit opens.

XPS-AXE detects open Y1-Y2 circuit, locks safety system and blocks reset, preventing unexpected machine startup and severe safety hazards.

2. Closed-loop safety monitoring to meet EN ISO 13849 Кат.4

Cat.4 safety standard requires the system to detect faults of its actuators (контакторы).

If Y1-Y2 feedback is omitted:

Safety rating downgrades to PL d / Кат.3, failing requirements for high-end machinery and CE export certification.

3. Prevent Recurring Start-Stop Oscillation

After machine trips without feedback monitoring:

The safety relay may repeatedly attempt to energize/de-energize contactors in certain conditions, accelerating contact arc erosion.

Feedback logic ensures: Reset is only permitted after the contactor is fully de-energized.

4. Logic Interlock to Verify Actuator Status

Reset conditions of safety relay add one prerequisite: Confirm all power contactors are in de-energized state.

Full reset sequence conditions:

1. Аварийная остановка / safety gate dual-channel inputs return to closed state
2. Y1-Y2 feedback circuit conductive (contactor confirmed open)
3. Execute manual or automatic reset
4. Стандартные правила подключения
5. Wire auxiliary NC contact of contactor in series. DO NOT use NO contacts!
6. Only contacts can be wired between Y1 and Y2; parallel components are prohibited.
7. Multiple contactor setup: Auxiliary NC contacts of all main contactors must be wired in series into Y1-Y2 (reset allowed only when all contactors open).
8. Common Wiring Mistakes & Consequences

❌ Mistake 1: Direct short-circuit Y1-Y2

Последствие: Feedback function disabled, loss of weld detection. Safety rating downgraded to PL d, Cat.4 claim invalid; non-compliant during CE audit. Risk of sudden machine startup if contactor welds.

❌ Mistake 2: Connect contactor NO contacts

Последствие: Y1-Y2 opens when contactor energizes → safety relay trips continuously during machine operation, equipment cannot run.

❌ Mistake 3: Only one contactor connected in feedback while multiple power contactors exist

Последствие: Weld failure of any unmonitored contactor cannot be detected, creating safety blind spot.

4. Plain-language Summary

The safety relay issues the shutdown command. Y1-Y2 feedback confirms whether the contactor actually opens as commanded.

If contactor sticks closed and fails to open, the safety relay locks the system and prevents machine restart.

Supplementary Notes for XPS-AXE

Feedback circuit belongs to safety-related wiring; separate routing from power cables is recommended.

For local machines without export requirements where only PL d is demanded, shorting Y1-Y2 is theoretically possible but not recommended by Schneider official manuals. All risks shall be borne by the machine manufacturer.