SHGV/RD1/x1x/x2x+x3x Multi-Channel Redundant Safety Relay Industrial Automation EN 61508

​1. Product Overview

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The Schmersal SHGV/RD1/x1x/x2x+x3x series represents an advanced modular rope-operated emergency stop (E-stop) system designed for critical safety applications demanding rapid intervention and secure reset control. This sophisticated solution integrates three core components: the ​SHGV/RD1/x1x reset module​ (containing the control unit and reset mechanism), the ​​/x2x selector block​ (for specifying reset mode and actuator type), and the ​SHGV...x3x rope tensioner unit. Unlike basic pull-wire systems, this architecture features a dedicated remote reset module allowing authorized personnel to perform controlled machine restarts at a central location after an E-stop activation. The system utilizes a high-strength stainless steel wire rope installed along hazardous machine perimeters. A robust aluminum alloy or durable plastic housing (typically rated IP65) protects internal components from dust, moisture, and mechanical impact common in demanding industrial environments like heavy manufacturing or material handling.

​2. Key Technical Parameters

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Operating control voltage typically ranges from ​24V DC to 230V AC (50/60 Hz)​, ensuring compatibility with diverse industrial power systems. The reset module ​​(/x1x)​​ incorporates ​safety-rated, force-guided contacts​ configured as dual-channel Normally Closed (NC), meeting stringent requirements for ​PL e (ISO 13849-1)​​ and ​SIL 3 (IEC 62061)​. Contact ratings commonly reach ​6A @ 250V AC / 10A @ 24V DC. The ​​/x2x​ suffix defines critical options: ​actuator type​ (e.g., key-operated reset, mushroom pushbutton) and ​reset mode​ (manual or monitored). The ​x3x​ tensioner unit provides essential rope monitoring signals indicating "Rope Tensioned" or "Rope Slack/Pulled" via dedicated contacts. Customizable rope lengths often exceed ​100 meters. Components feature ​high mechanical durability (>1 million operations)​​ and offer versatile ​cable entry options​ (M20 or M25 conduits via suffix variants). Environmental specifications include operation from ​​-30°C to +70°C​ and resistance to oils and common industrial chemicals.

​3. Primary Applications and Use Cases

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This system is vital for safeguarding extensive linear machinery where immediate emergency stop activation and controlled restart are paramount. Key deployments include ​long conveyor systems​ in mining, ports, parcel sorting centers, and automotive production lines, enabling personnel to halt operations from any point along the hazard. It's equally crucial for ​large press lines, ​robotic assembly cells, ​bulk material processing plants, and ​automated warehouse systems​ (AS/RS) spanning significant areas. The remote reset functionality (/RD1) addresses scenarios where restart authorization must be centralized – preventing unauthorized or unsafe restarts. By providing continuous E-stop access along the entire hazard perimeter, it ensures compliance with machinery safety directives (e.g., EU Machinery Directive 2006/42/EC) while protecting workers near high-risk zones such as rotating equipment, pinch points, or moving transfers. The rope condition monitoring (x3x) is essential for critical infrastructure where undetected rope slackness or damage could compromise safety.

​4. Product Advantages and Functional Benefits

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The SHGV/RD1/x1x/x2x+x3x delivers significant operational and safety advantages:

• ​Comprehensive Hazard Coverage:​​ Continuous rope access ensures emergency stops can be activated instantly from any location along the protected zone.
• ​Secure Remote Reset:​​ The dedicated reset module (/RD1) mandates authorized intervention (key/monitored) at a designated point, preventing untimely or unsafe restarts.
• ​Enhanced Diagnostics:​​ Integrated rope tension monitoring (via x3x) provides immediate feedback on system integrity (rope taut, slack, or broken), reducing maintenance time.
• ​Modular Flexibility:​​ Component separation (reset unit, selector, tensioner) simplifies installation, maintenance, and customization for complex layouts.
• ​High Safety Integrity:​​ Dual-channel force-guided contacts achieve top-tier Performance Levels (PL e) and SIL 3, enabling use in Category 4 safety circuits.
• ​Reduced Downtime:​​ Proactive diagnostics and robust construction minimize unplanned outages in harsh environments.
• ​Compliance Assurance:​​ Design inherently meets IEC/EN 60947-5-1, ISO 13849-1, and IEC 62061 requirements for emergency stop devices.

​5. Core Functionality and Safety Integration

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The system operates as a failsafe chain reaction. Pulling the wire rope or causing slack (e.g., rope breakage) displaces the ​x3x tensioner unit. This displacement mechanically forces the tensioner's internal safety contacts to change state. These signals are hardwired to the ​SHGV/RD1/x1x reset module. Within this module, force-guided relay contacts immediately open the main dual-channel E-stop circuit upon receiving the signal, demanding an uncontrolled stop (Category 0 per EN 60204-1) by cutting power to hazardous machine movements. Crucially, restart is blocked until an authorized operator uses the ​integrated reset actuator (as configured in /x2x – e.g., key turn or twist release)​​ physically at the reset module after rectifying the emergency condition. This mechanical linkage ensures direct-positive opening action for safety contacts. The dual-channel design allows continuous monitoring for dangerous faults like contact welding via the safety controller. The tensioner's rope condition signal provides additional diagnostic feedback to the PLC or HMI for operational awareness.

Packaging & Shipping

Company Information
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