Phoenix PSR-SPP Series: Industrial Safety Relays - Comprehensive Application & Selection Guide

Product Positioning & Core Value

The Phoenix PSR-SPP Series represents a portfolio of high-performance industrial safety relays engineered to protect personnel and equipment in automation environments. Designed to monitor safety-related functions (e.g., emergency stops, safety gates, light curtains), these relays ensure compliance with global safety standards (EN ISO 13849-1, IEC 61508) and support SIL 1-3 safety integrity levels. With versatile power supply options (24DC, 60UC, 120UC, 230UC, 230AC), flexible contact configurations (NO/NC, relay/thyristor outputs), and integrated functions (time delay, diagnostic feedback, expansion capabilities), the series delivers reliable safety circuit monitoring for manufacturing, process control, robotics, and machinery applications. Its compact DIN rail design, robust construction, and easy configuration make it ideal for both simple and complex safety systems, minimizing downtime while ensuring maximum protection.

Product Family Overview

The PSR-SPP Series is categorized by power supply type and functional focus to meet diverse safety requirements:

1. DC Power Supply Models (24DC)

• Function: Safety relays for 24V DC industrial control systems (most common in automation).
• Key Variants:
  • General Purpose: URML4, URD3, URM4 (universal safety functions with multiple contact outputs).
  • Time-Delay (TS): Integrated time delay for safety functions requiring delayed shutdown/startup.
  • Expansion (ESD/ESP): Expandable safety relays for complex safety circuits (e.g., multiple safety gates).
  • Mixed Output (THY): Thyristor outputs for silent operation in noise-sensitive environments.
  • Specialized: MXF (mixed function), SDC (solid-state output), RSM (remote signal monitoring).
• Typical Models: PSR-SPP-24DC/URML4/3X1/1X2/B, PSR-SPP-24DC/TS/M, PSR-SPP-24DC/ESD/5X1/1X2/T5.

2. Universal Voltage (UC) Models (60UC, 120UC, 230UC)

• Function: Safety relays compatible with both AC and DC power supplies (flexible global deployment).
• Key Variants: ESAM (expandable with auxiliary functions, e.g., diagnostic feedback).
• Voltage Ranges:
  • 60UC: 24~60V AC/DC
  • 120UC: 85~132V AC/DC
  • 230UC: 170~264V AC/DC
• Typical Models: PSR-SPP-230UC/ESAM4/3X1/1X2/B, PSR-SPP-120UC/ESAM4/3X1/1X2/B.

3. AC Power Supply Model (230AC)

• Function: Safety relays for 230V AC power systems (traditional industrial installations).
• Key Variant: ESAM2 (2-channel expansion, diagnostic feedback).
• Typical Model: PSR-SPP-230AC/ESAM2/3X1/1X2/B.

Technical Specifications (Universal Parameters)

Detailed Function Module Introduction

1. DC Power Supply Models (24DC)

2. Universal Voltage (UC) & AC Models

Application Scenario Analysis

1. Emergency Stop (E-Stop) Systems

Recommended Configuration:

• DC Systems: PSR-SPP-24DC/URML4/3X1/1X2/B (2903584)
• Universal Voltage: PSR-SPP-230UC/ESAM4/3X1/1X2/B (2901429)
• AC Systems: PSR-SPP-230AC/ESAM2/3X1/1X2/B (2901431)

Implementation Advantages:

• 3 NO + 1 NC contacts support redundant E-Stop circuits (PL e/SIL 3 compliance).
• Diagnostic feedback (B suffix) enables remote fault alerts (e.g., broken E-Stop wiring).
• Universal voltage models adapt to global power standards.

2. Safety Gate & Light Curtain Monitoring

Recommended Configuration:

• Multiple Safety Gates: PSR-SPP-24DC/ESD/5X1/1X2/T5 (2981279)
• Time-Delay Requirements: PSR-SPP-24DC/TS/M (2986025)
• High-Density I/O: PSR-SPP-24DC/TS/SDI8/SDIO4 (2986041)

Implementation Advantages:

• Expandable ESD models support up to 8 safety inputs (ideal for multi-gate systems).
• Time-delay function allows machine coast-down before gate opening.
• Integrated digital I/O reduces need for additional control modules.

3. Robotics & Automated Machinery

Recommended Configuration:

• Silent Operation: PSR-SPP-24DC/MMS/1X1/THY (2981693)
• Remote Monitoring: PSR-SPP-24DC/URM4/5X1/2X2/B (1442342)
• Complex Safety Logic: PSR-SPP-24DC/ESD/4X1/30 (2981813)

Implementation Advantages:

• Thyristor outputs eliminate relay noise (critical for precision robotics).
• 5 NO + 2 NC contacts support redundant safety circuits.
• 30s time delay (ESD/4X1/30) accommodates long machine cycle times.

4. Global Manufacturing Facilities (Multi-Voltage)

Recommended Configuration:

• 230V AC/DC: PSR-SPP-230UC/ESAM4/3X1/1X2/B (2901429)
• 120V AC/DC: PSR-SPP-120UC/ESAM4/3X1/1X2/B (2901425)
• 60V AC/DC: PSR-SPP-60UC/ESAM4/3X1/1X2/B (2901427)

Implementation Advantages:

• Universal voltage (UC) models eliminate need for region-specific relays.
• ESAM expansion modules add diagnostic and auxiliary functions without rewiring.
• SIL 3/PL e compliance meets global safety standards (e.g., EU Machinery Directive, US OSHA).

Selection Guide

Step 1: Determine Power Supply

Step 2: Select Safety Function

Step 3: Confirm Contact Configuration

• NO Contacts (X1): Required for safety circuit activation (e.g., 3X1 = 3 NO contacts for redundant paths).
• NC Contacts (X2): For auxiliary safety functions (e.g., 1X2 = 1 NC contact for alarm signaling).
• Output Type: Relay (16A, for high-power loads) or Thyristor (2A, for silent operation).

Step 4: Special Features

• Diagnostic Feedback: Choose "B" suffix models for auxiliary diagnostic contacts (remote fault monitoring).
• Manual Reset: "M" suffix models (e.g., TS/M) require manual reset after safety circuit trip.
• Expansion: ESAM/ESD variants support additional safety inputs/outputs for complex systems.

Installation & Maintenance Guide

Installation Steps:

1. Mounting: Snap the relay onto a 35mm DIN rail, ensuring ≥10mm spacing for heat dissipation.
2. Wiring: Connect power supply, safety inputs (E-Stop, safety gate), and safety outputs (machine shutdown) per terminal markings. Use 0.5~2.5mm² conductors.
3. Torque: Tighten terminal screws to 0.5~0.8Nm (prevents vibration-induced loosening).
4. Configuration: Set time delay (if applicable) via DIP switches or potentiometer (TS variants).
5. Testing: Verify LED indicators (green = power-on, yellow = safety circuit active) and test safety function (trip E-Stop to confirm machine shutdown).

Maintenance Points:

• Status Monitoring: Regularly check LEDs (red = fault); resolve issues (e.g., broken wiring, short circuit) before resetting.
• Fault Diagnosis: Use diagnostic feedback contacts (B suffix) to integrate with PLC/HMI for remote fault alerts.
• Reset Procedure: For manual reset (M) models, reset only after identifying and resolving the safety hazard.
• Inspection: Conduct semi-annual checks for loose connections, damaged housing, and terminal corrosion.
• Replacement: Replace relays after 10 years of service or if they fail safety function tests (per EN ISO 13849-1).

PSR-SPP Series vs. Traditional Safety Relays

Summary & Next Steps

The Phoenix PSR-SPP Series delivers robust, compliant safety relay solutions for industrial automation, supporting diverse power supplies, safety functions, and global standards. Whether for simple E-Stop systems or complex multi-input safety circuits, these relays ensure personnel and equipment protection while enabling efficient system integration and maintenance. By selecting the appropriate power supply, safety function, and contact configuration, you can optimize safety performance, reduce downtime, and ensure compliance with regional and international safety regulations.