Schneider Electric XPS-AXE5120P Safety Relay

การวางตำแหน่งผลิตภัณฑ์: Safety module for emergency stop & safety gate switch monitoring (หมวดหมู่ 0 หยุด). Replacement for legacy XPSAX

โมเดลทั่วไป: XPSAXE5120P / XPSAXE5120C

XPSAXE5120P: ขั้วต่อสกรูแบบถอดได้

XPSAXE5120C: Removable spring terminals

พาวเวอร์ซัพพลาย: 24 วี เอซี/ดีซี (เครื่องปรับอากาศ & ดีซี ยูนิเวอร์แซล)

การติดตั้ง: 35 ราง DIN มม, ความกว้าง 22.5 มม

ขนาดโดยรวม (กว้าง×สูง×ลึก): 22.5 × 99 × 114 มม

✅ Safety Ratings

พีแอล อี / แมว.4 (ใน ISO 13849-1)｜SIL CL3 (ไออีซี 61508 / ไออีซี 62061)

มาตรฐานที่ใช้บังคับ: ใน ISO 13850 (หยุดฉุกเฉิน), ใน ISO 14119 (Safety Interlock Switches)

2. ช่อง & นิยามเทอร์มินัล (XPSAXE5120)

1) พาวเวอร์ซัพพลาย

A1, A2: แหล่งจ่ายไฟของโมดูล, 24 วี เอซี/ดีซี

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

S11-S12: ช่อง 1

S21-S22: ช่อง 2

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

3) Start Circuit (รีเซ็ต)

ส33, ส34

Short S33 and S34 → Automatic Reset

Connect external NO pushbutton between S33 and S34 → Manual Reset

4) External Contactor Feedback Circuit (บังคับ!)

Y1, ย2

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

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

5) ผลลัพธ์ด้านความปลอดภัย (3 sets of instantaneous NO safety contacts)

13-14, 23-24, 33-34

Three independent รีเลย์ความปลอดภัย contacts for de-energizing power contactor coils.

Single contact rated current: 6 ก; เอซี-15: 360 VA continuous load; ดีซี-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) ไฟ LED แสดงสถานะ

PWR: Power supply present

วิ่ง: Safety circuit closed, outputs energized

3. ตรรกะปฏิบัติการ
4. เปิดเครื่อง; emergency stop reset & safety gate closed → S11-S12 / S21-S22 conductive
5. Y1-Y2 feedback circuit closed (main contactor de-energized)
6. กดปุ่มรีเซ็ต (or auto-reset active) → internal dual relays energize
7. 13-14 / 23-24 / 33-34 ปิด, 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 + รีเซ็ตด้วยตนเอง + ข้อเสนอแนะ)

A1/A2: 24 แหล่งจ่ายไฟวี

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: หยุดฉุกเฉิน / การตรวจสอบประตูนิรภัย, 3 NO safety outputs, with feedback; หมวดหมู่ 0 หยุด

XPS-AC: กะทัดรัด 22.5 ความกว้างมม, similar functions with minor load capacity differences

XPS-AK: Supports safety light curtains, เสื่อนิรภัย; ฟังก์ชั่นที่ได้รับการปรับปรุง, ต้นทุนที่สูงขึ้น

7. การแก้ไขปัญหาทั่วไป
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

I can provide:

✅ 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) รีเลย์ความปลอดภัย

Core Position Recap

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

ระดับความปลอดภัย: พีแอล อี / แมว.4, SIL CL3, หมวดหมู่ 0 instantaneous power cut-off

Not compatible with: Safety light curtains, เสื่อนิรภัย, อุปกรณ์ควบคุมสองมือ;

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

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

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

2. Industry Typical Applications

1) เครื่องมือกลทั่วไป & Metalworking Equipment

CNC lathes, ศูนย์เครื่องจักรกล, เครื่องกัด, เครื่องบด

Small presses, hydraulic machines, กดเบรก, shears

Cutting machines, เครื่องบด, deburring equipment

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

2) บรรจุภัณฑ์, การพิมพ์ & Rubber/Plastics Machinery

Vertical form fill seal machines, เครื่องห่อไหล, case packers, อุปกรณ์เสริมการจัดเรียงบนพาเลท

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

เครื่องพิมพ์, laminators, die-cutters

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

3) กำลังลำเลียง & Logistics Automation Equipment

สายพานลำเลียง, สายพานลำเลียงแบบลูกกลิ้ง, 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

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

5) อาหาร & Pharmaceutical Packaging Equipment

เครื่องบรรจุ, capping machines, เครื่องติดฉลาก, auxiliary sterilization equipment

Food cutting and material handling standalone machines

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

6) งานไม้ & Composite Processing Machinery

Edge banders, nesting CNC routers, engraving machines, แซนเดอร์

การตัดแผง, 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. Scheme A: Single Machine with Emergency Stop + ประตูนิรภัย (ที่พบบ่อยที่สุด)

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. Scheme B: 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. Scheme C: 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. การใช้งานที่ไม่เหมาะสม (Selection Pitfalls)
5. Required interface with safety light curtains, เสื่อนิรภัย, 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 (ม่านแสง + ประตูนิรภัย + หยุดฉุกเฉิน) → Universal XPSUAF safety module
9. Solid-state safety outputs required (ไม่มีการสัมผัสทางกล) → Models with semiconductor outputs
10. Key Selection Reminders

Direct replacement for legacy XPSAX5120: XPSAXE5120P (ขั้วต่อสกรู) / XPSAXE5120C (ขั้วต่อสปริง)

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, ย2

Connect auxiliary Normally Closed (เอ็นซี) contacts of main power contactors

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

1. Four Core Functions

1) Anti-Weld Contactor Protection (สำคัญที่สุด)

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

Normal shutdown: Contactor coil de-energized, ผู้ติดต่อหลักเปิดอยู่; 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 แมว.4

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

If Y1-Y2 feedback is omitted:

Safety rating downgrades to PL d / แมว.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. หยุดฉุกเฉิน / 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. Standard Wiring Rules
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

ผลที่ตามมา: 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

ผลที่ตามมา: 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

ผลที่ตามมา: 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.