RIELLO ELETTRONICA

CONTROL
DEVICES

GAMMA SYSTEM s.r.l 10044 PIANEZZA (TO) Italy - Via Torino, 24/I
Tel. +39.011.968.24.66 r.a. - Fax +39.011.967.42.11
e-mail: [email protected] Sito Web: www.gammasystem.com
 SENSORS
Or CONTROL DEVICES

Emergency stop circuit specifically designed to manage a sensor with reed contacts. The
contact, sketched in the description, is a set of NO contacts connected in series/parallel
which make when a mass is placed over them.
Contact making of the sensor causes the output contact of the device unit to break.
The control device is indispensable to check in a continuous way proper working of the
sensort, that is to be sure that when the sensor is stepped on, it generates the desired electric
signal.

A control device is capable of controlling several sensors (see technical specifications) but
it cannot perform the self-diagnostic function indicating which edge is faulty.

For zones with several sensors installed side by side, it is recommended that a self-control
device is used every 3 - 4 sensors.

Maximum surface of sensors which can be controlled through a single control device:
GP02/E GP02/E-S2 5m2 GP03 GP03/S2 10 m2.

MODELS

Type GP02 / GP02/S2

Type GP02/E - GP02/E-S2

Type GP03

Type GP03/S2

01
 ELECTRONIC CONTROL DEVICE
Type GP02 and GP02/S2

The purpose of the control unit is to continually check the operation of the sensor.
Two channels detect voltage at the sensor terminal leads (or bumper assembly) and
each channel switches a safety relay equipped with forced trip contacts (generally,
the relay is energized). When voltage drops by +/-10%, relays are de-energized and
drop out. On the point of view of safety, the two units are identical; the only
difference is that Model GP02/S2 is fitted with more contacts and is provided with
terminals (3-4) for the feedback contacts input for interface contactors. Each time the
sensor is activated, the control unit runs a self-control. This is also done each time
the equipment is started up. Also provided are 2 terminals for the input of a "TEST"
signal which switches On/Off the self-control circuits of the device simulating the
activation of the bumper sensor and checking the system efficiency.

Connections: - Standard power supply: 110VAC or 24Vdc

- 24VAC upon request
- Tolerance: ±10%
- Frequency: 40-60Hz
- Power consumption: 5 VA
- Operating ambient temperature: -10° +60°C

LIGHT INDICATORS (LEDs)

Sensor contacts pressed
Illuminated: "Power ON" Led L1 (green)
"Contact activated" Led L4 (yellow)
When releasing contacts, the device automatically
resets (only the "Power On" Led L1 - green - stays On)

Sensor cables/sensor broken:

Illuminated: "Power ON" Led L1 (green)
"Circuit broken" Led L3 (red)
"Controller failed" Led L2 (red)

Device fault:
Illuminated: "Power OFF" Led L1 (green)
"Controller failed" Led L2 (red)

02
 ELECTRONIC CONTROL DEVICE
Type GP02

TECHNICAL DATA
RL2-RL3 - NC-NC terminals
RELAY OUTPUT - Breaking voltage 380Vac
- Contact capacity 220VAC/4A/AC1
7
- Mechanical life of contact: 10 cycles
5
- Electrical life of contact: 10 cycles

CASING - Mounting on Omega 35 cm profile

or wall mounting with 2 M4 screws.
- Degree of protection of casing: IP30
- Degree of protection of terminals: IP2X
- Size: 75x100xh110 mm

LIGHT INDICATORS - L1 Led, green - Power On

- L2 Led, red - Controller failed
- L3 Led, red - Sensor or connection circuit broken
- L4 Led, yellow - Sensor activated

Connection TERMINALS V1-V2 - Power supply 110VAC 24DC,

24VAC upon request
A-B - Sensor power supply
C-C1 - Sensor feedback
NC-NC - The contact is made with sensor
powered but not activated. If the sensor
is activated or in case of sensor
and/orcontrollerfailure,the contact breaks.
16-17 - Terminals for TEST connection via no-
voltage "NO" contact.

03
 ELECTRONIC CONTROL DEVICE
Type GP02

Wiring diagram for 2 sensor

Sensor
Bordo 1 Bordo 2
Sensor
C A

C1 B

A B C C1

V1 V2 3 4 A B C C1 9 10 NC NC 13 14 15
+ -
RL4 RL1

L1 L2 L3 L4 RL2 RL3

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

TEST

L1: Live RL1 - energized with RL4 relay energized and RL2-RL3 de-
energized
L2: Controller failed RL2 - energized with bumper OK and not activated
L3: bumper failed RL3 - energized with bumber OK and not activated
L4: bumper activated RL4 - energized with bumper activated

04
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E GP02/E-S2

The objective of the control device is to continually control the functionality of the sensors.
Two sensors relays with forced trip contacts detect voltage at the ends of the sensor (or set of
sensors).
The relays, normally energized, drop out when one of the following conditions occurs:
Power failure
Activation of the sensor
Faults internal to the control device
Interruption of the inner circuit of the sensor or of connecting cables
between sensor and control device.

The supply voltage applied to the sensor is limited via a current limiting device with relevant
pilot circuit in order to prevent high short circuit currents to take place during the making stage
of the sensors.
At each making cycle of the contact the device performs a self-control function as it does each
time the equipment is started.
Input terminals are provided for TEST signals that turn on and off the circuits of the control
device thus simulating the sensor activation and verifying the proper operation of the system.
In the event a device without reset is used, the reset function shall be supplied by the machine
control system (see 594-1 1996 Standard).

07
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E

TECHNICAL SPECIFICATIONS

Safety category 3
Operating mode with and without reset

Electrical data
Power supply 24 Vdc
Power supply tolerance + 10%
With 24 Vdc power supply
Current draw with edge activated 15 mA
Current draw with reset module 90 mA
Operating temperature 0/+55°C
Delay to energizing (reset) 25 msec (typical)
Delay to de-energizing (switching) 8 msec (typical)
Answering time < 8 msec
Contacts at output Ag/Cd
Operating voltage of contacts 220 V
Max. commutable current (*) 4A
Max. continuous current (*) 2A
Power commutable from contact 1000 VA (4 at 250 V)
Contact protection on outlet 4 A fast – 2 A delay

Signaling led
Operating voltage of contact 125 Vac 30 Vdc
Max. current 110 Vac 0.2 A
Max. current 24 Vac 0.5 A
Mechanical life 10,000,000
(*) limited up to 100.000 operations

Connection to sensor
Voltage applied 24 Vdc
Max current in the contact 200 mA (pulse)
Max. length of connections 100 mt
Max. resistance of sensor 40 Ohm (20 Ohm each channel)
Max. controllable surface 5 m2
Section of connection cables min. 0.35 mm
For cables L>20 mt min. 1 mm 2

Casing Fastening onto 35 mm Omega sect

Degree of protection of casing IP30
Degree of protection of terminals IP 2X
Dimensions: 35x90xh 70 mm

08
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E

Technical data of output contacts

Safety contacts Terminals 1 -2
RL1 - RL2 relay output Trip voltage: 380Vac - 60Vdc
AgCd contacts
Contact working voltage: 220V
Max. commutable current (*) 4A
Max. continuous current (*) 2A
Commut. power from contact: 1000VA (4A 250V)
Protection of output contacts: 4A Quick-acting, 2A
Delayed
Breaking capacity 100VA (Area 4A 250V)
Mechanical life of contact: 107 cycles
Electrical life of contact: 105 cycles
(*) limited to 100.000 operations

Signalling contacts Terminals 5-6

RL3 relay output Trip voltage: 125Vac - 30Vdc
Tripping current 0.2A (110Vac) - 0.5A (24Vdc)
Breaking capacity: 50Vac
Mechanical life of the contact: 107 cycles
Electrical life of the contact: 105 cycles

Indications Supply- Green Led Indicator - "Voltage On”

Alarm- Red Led Indicator - "Faulty or activated sensor”
Ready- Green Led Indicator - sensor OK and not
activated

Connecting terminals 3-4 24Vdc supply voltage

7-8 Sensor power supply
9 - 10 Sensor return signal/Test
1 -2 Closed contact with powered, not activated
sensor. In case of sensor activation and/or sensor
fault or control device fault, the contact breaks.
5 -6 Signalling contact. Made with sensor OK and
not activated.
11-12 Input terminals for feedback contacts (make
the contact breaks jumper if not used).

09
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E

WIRING DIAGRAM FOR 2 SENSORS CONNECTION

C1 B

Sensor
Sensor
C A

RESET
Test

E2
B A C
C1

E1

7 8 9 10 11 12
A B C C1
Supply

Alarm

Ready
RL1

RL2

RL3

1 2 3 4 5 6
E1 E2
Fs1
-
+
- +

E-E1 – External emergency contactors (for Customer’s care)

direct stop stop with 2 contactors motor stop with 3 contactors

1
E1
2 E1

E
E

M
J

10
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E
ATTACHED RESET/RETRO-ACTION

Automatic Reset
Without retro-action
11 12
- Jumper 11 -12
- Insert jumper j1-j2-j3-j4 (see attached drawing fig. A)

With retro-action

- Insert jumper j1 - j2 - j3 - j4 (see attached drawing fig. A)

- Connect retro-action ring to terminals 11 - 12

11 12

Manual reset

Without retro-action

- Insert jumper j1 - j2 - j3 - j4 - j34 (see attached drawing fig. B)

- Connect reset button, NO contact without potential to
terminals 11 - 12 11 12

With retro-action

- Inserirt jumper j1 - j2 - j3 - j4 - j34 (see attached drawing fig. B)

- Connect reset button, NO contact without potential to
terminals 11 - 12
- Connect retro-action ring in series to reset button
11 12

N.B. the device is supplied in the configuration required by the customer. If the
configuration must be changed, pay attention to the above instructions. In a case of
dopubt, contact the manufacturer.

11
 JUMPER POSITIONING LAYOUT
FOR SELECTION OF MANUAL OR AUTOMATIC RESET

Manual
reset
J4
J34
J3

J1

J1

Figura B

DL2

DL3
DL1
J4 R1

R4

R3
J3 R12
J1 R24 C5

R26 R27
Q4
J2 R23
C4 C1
R22
R2

Automatic Q3 U2
reset
R25
R28

R30

R9
J4
DZ2
C6
J3 R20
D8

D7

U1
U3 O5
R6
R16

DZ3

D5
J1 R13 R29

J1

C3 C2
K4
R16

Figura A

12
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E-S2

TECHNICAL SPECIFICATIONS

Safety category 3
Operating mode with and without reset

Electrical data
Power supply 24 VCC
Power suppli tolerance +10%
With 24 Vdc power supply
Current draw with edge activated 15 mA
Current draw with reset module 90 mA
Operating temperature 0/+55°C
Delay to energizing (reset) 25 msec. (typical)
Delay to de-energizing (switching)) 8 msec. (typical)
Answering time < 15 msec
Contact at output Ag/Cd
Operating voltage of contcts 220 V
Max. commutable current (*) 6A
Max. continuous current (*) 4A
Power commutable from contact 1500 VA
Contact protection on outlet 6 A fast - 4 A delay

Signaling led
Operating voltage of contact 125 Vac 30 Vcc
Max. current 110 Vac 0.2 A
Max. current 24 Vcc 0.5 A
Mechancal life 10,000,000
(*) limited up to 100.000 operations

Connections to sensor
Voltage applied 24 Vdc
Max. current in the contact 200 m A (pulse)
Max. lenght of connections 100 mt
Max. resistance of sensore 40 Ohm (20 Ohm each channel)
Max controllable surface 5 m2
Section of connection cables min. 0.35 mmq
For cables L>20 mt min. 1 mm2

13
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E-S2

Technical data of outlet contacts

Relay outlet - Terminals 9-10 11-12

RL1 - RL2 - Opening voltage 220 Vac - 60 Vdc
Safety - Opening current 6 A
- Opening capacity 1500 VA
- Mechanical duration of contact 107 operations
- Electrical durations of contact 105 operationsi

Relay outlet - Terminals 1-2

RL3 - Opening voltage125 Vac - 30 Vdc
Signal - Opening current 0.2 A (110 Vac) - 0.5 A (24Vdc)
- Opening capacity 50 Vac
- Mechanical duration of contact 107 operations
- Electrical durations of contact 105 operations

CASING -Fastening on omega profile 70 mm

- Casing protection IP 30
- Terminal protection IP 2X
- Dimensions : 72 x 90 x h 70 mm

SIGNAL LED - L1) Red - Voltage ON

- L2) Red - Sensor faulty or running
- L3) Green - Sensor OK and not running

TERMINALS 14-15 Supply 24 Vdc

21-22 Sensor supply
23-24 Sensor return
9-10 11-12 Safety contacts closed with sensor
supplied and not running.

21-23 If the sensor is operated and/or faulty,

or control, the contact opens

1-2 Signal contact.

Closed with signal OK and not running
5-6 Inlet terminals for reset and retroaction
contact
18-19 Test

14
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E-S2
Connection layout for 2 sensors

- +
Sensor 1
B C1 B
Sensor 2
C1

C A
A C

Test

14 15 16 17 18 19 20 21 22 23 24 25
A B C C1
Supply Alarm Ready

RL1

RL1
RL2

RL2
RL3

1 2 3 4 5 6 7 8 9 10 11 12 13
E1
E1 E2
RESET

E2
Fs1

-
+

Example of connection::
E-E1 - external emergengy contactor (for the customer’s care)

direct stop stop with 2 contactors motor stop with 2 contactors

9-11
E1
10-12 E1

E
E

M
J

15
 ELECTRONIC CONTROL DEVICE
TYPE GP02/E-S2
INCLUDED RESET/RETROACTION

Automatic reset
Without retro-action
5 6
-Jumper 5-6
- Insert jumper j1 - j 2 - j3 - j4 (see attached drawing fig. A)

With retro-action

- Insert jumper j1 - j2 - j3 - j4 (see attached drawing fig. A)

- Connect retro-action ring to terminals 5-6
5 6

Manual reset

Without retro-action

- Insert jumper j1 - j2 - j3 - j4- j34 (see attached drawing fig. B)

- Connect reset button, NO contact without potential to terminals 5-6 5 6

With retro-action

- Insert jumper j1 - j2 - j3 - j4-j34 (see attached drawing fig. B)

-Connect reset button, NO contact without potential to terminals 5-6
- Connect retro-action ringin series to reset button

5 6

N.B. the device is supplied in the configuration required by the customer. If the
configuration must be changed, pay attention to the above instructions. In a case of
dopubt, contact the manufacturer.

16
 LAYOUT OF JUMPER POSITIONING
FOR MANUAL OR AUTOMATIC RESET SELECTION

Manual
reset
J4
J34
J3

J1

J1

Figure B

DL2

DL3
DL1
J4 R1

R4

R3
J3 R12
J1 R24 C5

R26 R27
Q4
J2 R23
C4 C1
R22
R2

Automatic Q3 U2
reset
R25
R28

R9 R30
J4
DZ2
C6
J3 R20
D8

D7

U1
U3 O5
R6
R16

DZ3

D5
J1 R13 R29

J1

C3 C2
K4
R16

Figure A

17
 ELECTRONIC CONTROL DEVICE
TYPE GP03 AND GP03/S2

The purpose of the control device is to continually control the functionality of the sensors.
Two sensors relays with forced trip contacts detect voltage at the ends of the sensor terminals
(or of a set of sensors).
The relays, normally energized, drop out in case one of the following conditions occurs:
Power failure
Activation of the sensor
Faults internal to the control device
Interruption of the inner circuit of the sensor or of connection cables between
the sensor and control device.
Diminishing of insulation resistances between the two sensors.

The electronic circuit built-into the device is capable of detecting when a given contact
resistive threshold is exceeded. This causes the system to shut off.
This characteristic is of paramount importance in that it permits controlling the degree of
deterioration of sensors due to inner or outer reasons.
The safety level offered by the two devices is identical; the only difference is that type
GP03/S2 has a higher amount of output contacts.
At each Up/Down cycle of an operator on the sensor, the device controls itself, as it does each
time the equipment is started.
Terminals are also provided for the input of a "TEST" signal that turns on and off the circuits of
the control device thus simulating the sensor activation and verifying the proper operation of
the system. For the input of feedback contacts, it is also used to verify the good operation of
relays or remote control switches used as interface for the emergency stop.
Control devices are supplied with an automatic reset function but they can be easily
converted into manual reset types.
In the event a device with automatic reset is used, the reset function shall be supplied by the
machine control system (see 594-1 1996 Standard).

18
 ELECTRONIC CONTROL DEVICE
TYPE GP03 AND GP03/S2
TECHNICAL SPECIFICATIONS
Safety category 3
Operating mode Automatic/manual reset
Supply voltage 24Vdc - 24Vac - 110Vac
Supply voltage tolerance ± 10%
Vac frequency range 42-60Hz
Vdc residual cripple 160%
with ac 24V - 110V
Power consumption (24Vdc supply) 3VA
Current with safety mat activated 30 mA
Current with reset module 100 mA
Operating temperature 0+55°C
Delay to energizing (reset) 25 msec
Delay to de-energizing (switching) 25 msec
Safety mat
Voltage applied 24Vdc
Max. current in the contact 25 mA
Max. length of connections 100 m
2
Max. controllable surface 10m
Casing Fastening onto 35 mm Omega section
Degree of protection: casing IP30
Degree of protection: terminals IP 2X
Dimensions: 75x90xh105 mm
Weight: 350 gr

LED INDICATORS
Carpet contacts pressed
Lighted: “Voltage ON" Led indicator (green), L1
“Contact activated" Led indicator (yellow), L4
when the mat contacts are released, the device
is automatically reset.
(only the green L1 "Voltage ON" Led stays On)

Cables or mat
Sensor interrupted Lighted: "Voltage ON" Led indicator (green), L1
“Circuit interrupted" Led indicator (red),
L3"Control device malfunction" Led indicator (red), L2
Device malfunction:
Lighted: "Power failure" Led indicator (green),
L1 "Control device malfunction" Led indicator (red), L2
19
 ELECTRONIC CONTROL DEVICE
Type GP03
Technical data of output contacts
Safety contacts NC - NC Terminals
RL1 - RL2 relay output AgCd contacts
Contact working voltage: 220V
Max. commutable current (*) 4A
Max. continuous current (*) 2A
Comm. power from contact: 1000VA (4A 250V)
Protection of output contacts: 6A Quick-acting, 2A
Delayed
Breaking capacity 100VA (Area 4A 250V)
Mechanical life of contact: 107 cycles
Electrical life of contact: 105 cycles
(*) limited to 100.000 operations

Indications L1) Green= "Voltage ON" Led indicator,

L2) Red= "Control device malfunction" Led
indicator,
L3) Red= "Sensor or connection circuit
interrupted" Led indicator
L4) Yellow= "Edge activated" Led indicator

Terminals V1-V2 -Power supply , upon request 110Vac or

24Vdc or 24Vac
A-B -Sensor power supply
C - C1 -Sensor return signal
NC - NC -Made contact with sensor powered
and not activated - if someone steps on
the sensor or in case of sensor and/or
control device fault,
Te-Te1 -Test connection terminals via "NO"
contact breaks. the no-voltage contact.
CR - Re -Input terminals for feedback contacts
(makejumper if not used)
CR - Rm -Terminals for manual reset connection
through "NO" no-voltage contact.

Operating modes:
Automatic reset: Make jumpers (CR-RM), connect JP1-JP2 inside the card.
Manual reset: Connect the external NO contact to CR-RM, remove
JP1-JP2 from the inside of the card.

20
 ELECTRONIC CONTROL DEVICE
Type GP03
Wiring diagram

24VDC Manual reset

24VAC E1
110VAC
TEST

E E1 E
E1E1
E1

V1 V2 Te Te1 A B C C1 Re CR Rm 12 13 NC NC 16 17
+ -
RL1

L1 L2 L3 L4 RL2

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Wiring diagram for 2 sensors connection

Sensor 1 Sensor 2
C A

C1 B

A B C C1

V1 V2 Te Te1 A B C C1 Re CR Rm 12 13 NC NC 16 17
+ -

E-E1 - Emergency external contactors (at User's care)

Example of direct shut off

21
 ELECTRONIC CONTROL DEVICE
Type GP03/S2

Technical data of output contacts

Safety contacts Terminals NC-NC/NC1-NC1/NO-NO

RL1 - RL2 relay output AgCd+Au contacts in sealed, tight relay
Contact working voltage: 250V - 30Vdc
Max. commutable current (*) 6A power factor 1
Max. continuous current (*) 4A
Commut. Power from contact: 1500VA
Protection of output contacts: 6A Quick-acting, 2A
Delayed
Mechanical life 10.000.000 operations
(*) limited to 100.000 operations 6A power factor 1
1500 VA

Indications L1) Green = "Voltage ON" Led indicator,

L2) Red = "Control device malfunction" Led
indicator,
L3) Red = "Sensor or connection circuit
interrupted Led indicator
L4) Yellow= "Sensor activated" Led indicator
Terminals V1 -V2 - Power supply , upon request 110Vac or
24Vdc or 24Vac
A - B - Sensor power supply
C - C1 - Sensor return signal
NC-NC - Contact made with sensor
powered and not NC1-NC1
activated - if someone steps on the sensor
or in case of sensor and/or control device
fault, the NC - NC and NC1-NC1 contacts
open.
NO-NO -Contact open with sensor
powered and not activated - if someone
steps on the sensor or in case of sensor
and/orcontrol device fault, the NO-NO
contact makes.

Te-Te1 -Test connection terminals through

"NO" no- voltage contact.
CR - Re -Input terminals for feedback contacts
(make jumper if not used)
CR-Rm -Terminals for manual reset
connection through "NO" no-voltage
contact.
Operating modes:
Automatic reset: Make jumpers (CR-RM), connect JP1-JP2 inside the card.
Manual reset: Connect the external NO contact to CR-RM,remove JP1-JP2
from the inside of the card.

22
 ELECTRONIC CONTROL DEVICE
Type GP03/S2
Wiring diagram

Manual reset
24VDC
24VAC E1
110VAC
TEST

E E1 E
E1E1
E1

V1 V2 Te Te1 A B C C1 Re CR Rm 12 13 NC NC 16 17
+ -
RL1 RL1

RL1
L1 L2 L3 L4 RL2 RL2

RL2

18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Wiring diagram for 2 sensors connection

Sensor 1 Sensor 2
C A

C1 B

A B C C1

V1 V2 Te Te1 A B C C1 Re CR Rm 12 13 NC NC 16 17
+ -

E-E1 - Emergency external contactors (at User's care)

Direct shut off motor stop with 2 contactors
Shut off with 2 contactors

NC
E1
NC E1

E
E

M
J

23
 ELECTRONIC CONTROLDEVICE
TYPE GP03/S2
INCLUDED RESET/RETROACTION

Automatic reset
Without retro-action Re CR Rm

- Jumper Re - Rm
- Insert jumper jp1 - jp2 (see attached drawing)

E1
With retro-action

E
- Jumper Cr - Rm
- Insert jumper jp1 - jp2 (see attached drawing)
- Connect retro-action ring to terminalsi Re- Cr
Re CR Rm

Manual reset
Without retro-action

- Jumper Re - Rm
Re CR Rm
- Remove jumper jp1 - jp2 (see attached drawing)
- Connect reset button, NO contact without potential
to terminals Cr - Rm

With retro-action
E1

- Remove jumper jp1 - jp2 (see attached drawing)

E
- Connect reset button, NO contact without potential
to terminals Cr - Rm
- Connect retro-action ring to terminals Re - Cr
Re CR Rm

N.B. the device is supplied in the configuration required by the customer. If the
configuration must be changed, pay attention to the above instructions. In a case of
dopubt, contact the manufacturer.

24
Insert JX1 and JX2 for automatic reset
Remove JX1 and JX2 for manual reset

25