General notes 8
Test pulses, pulsing and power control 8
Behavior in case of faults 8
Automatic restart and start button 9
Safety in case of faults 9
Fuse protection for power supply 9
Voltage drop on cable and switch 10
Connection cables and plug connectors 11
Connector assignment 11
Connection example 12
Setup 13
LED indicators 13
Teach-in function for actuator 13
Functional check 14
System status table 15
Technical data 16
Technical data for safety switch CES-AH-C03-AH-SM 16
Technical data for actuator CES-A-BBA/CES-A-BCA 19
Technical data for actuator CES-A-BPA 21
Technical data for actuator CES-A-BRN 23
The Coded Electronic Safety switches series CES are safety devices for monitoring movable safety guards.
In combination with a safety guard, this safety component prevents dangerous
machine movements from being performed for as long as the safety guard is
opened. A stop command is triggered if the safety guard is opened during the
dangerous machine function.
Before safety switches are used, a risk assessment must be performed on the
machine, e.g., in accordance with:
Ì EN ISO 13849-1, Safety of machinery. Safety related parts of control systems.
General principles for design
Ì EN ISO 14121-1, Safety of machinery. Risk assessment. PrinciplesÌ IEC 62061, Safety of machinery. Functional safety of safety-related electrical,
electronic and programmable electronic control systems.
Devices in the system family CES-AH... have special safety outputs that are suitable
for the direct switching of large loads. In appropriate applications it is therefore
not necessary to connect power relays or contactors in between.
Important!
The device interrupts the supply of power to the load, if, e.g., the safety guard
is open.
Correct use includes compliance with the relevant requirements for installation
and operation, for example
Ì EN ISO 13849-1, Safety of machinery. Safety related parts of control systems.
General principles for design
Ì EN 1088, Safety of machinery. Interlocking devices associated with guards.
Principles for design and selection
Ì EN 60204-1, Safety of machinery. Electrical equipment of machines. General
requirements
Ì EN 60947-5-3, Specification for low-voltage switchgear and controlgear. Con-
trol circuit devices and switching elements. Requirements for proximity devices
with defined behaviour under fault conditions
The safety switch must be used only in conjunction with the designated CES actuators from EUCHNER. On the use of different actuators, EUCHNER provides no
warranty for safe function.
Ì The user is responsible for the integration of the device into a safe overall
system. For this purpose, the overall system must be validated, e.g. in accordance with EN ISO 13849-2.
Ì Correct use requires observing the permissible operating parameters (see
Technical data).
Ì If a product data sheet is included with the product, the information on the
data sheet applies in case of discrepancies with the operating instructions.
Ì It is only allowed to use components that are permissible in accordance with
15Combination possible, typ. switch-on distance 15 mm
Combination possible, guard locking for process protection
Combination possible, guard locking for personal protection
Combination not permissible
CES-A-BCA
088 786
CES-A-BPA
098 775
CES-A-BRN-100251
100 251
Exclusion of liability and warranty
In case of failure to comply with the conditions for correct use stated above, or
if the safety instructions are not followed, or if any servicing is not performed as
required, liability will be excluded and the warranty void.
Safety switches fulfill personal protection functions. Incorrect installation or tampering can lead to fatal injuries to personnel.
Check the safe function of the safety guard particularly
Ì after any setup workÌ after the replacement of a CES componentÌ after an extended period without useÌ after every fault
Independent of these checks, the safe function of the safety guard should be
checked at suitable intervals as part of the maintenance schedule.
Warning!
Danger of fatal injury in the event of incorrect connection or incorrect use.
Ì Safety switches must not be bypassed (bridging of contacts), turned away,
removed or otherwise rendered ineffective.
On this topic pay attention in particular to the measures for reducing the possibility of bypassing from EN 1088:1995+A2:2008, Section 5.7.
Important!
The device is only allowed to be installed and placed in operation by authorized
personnel
Ì who are familiar with the correct handling of safety components Ì who are familiar with the applicable EMC regulationsÌ who are familiar with the applicable regulations on health and safety and ac-
cident prevention
Ì who have read and understood the operating instructions.
Prior to use, read the operating instructions and keep it in a safe place. Ensure
the operating instructions is always available during mounting, setup and servicing. EUCHNER cannot provide any warranty in relation to the readability of the
CD for the storage period required. For this reason you should archive a printed
copy of the operating instructions. If you should lose the operating instructions,
you can download this documents from www. EUCHNER.de.
The safety switch CES-AH-C03-AH-SM complies with the following safety requirements:
Ì Category 3 according to DIN EN ISO 13849-1Ì Proximity device with self-monitoring type PDF-S according to EN 60947-5-3.Ì Redundant design of the circuit in the unit with self-monitoringÌ This means that the safety system still functions even if an internal component
fails
Ì The switch state of the semiconductor outputs is continuously monitored inter-
nally
The CES non-contact safety switch consists of three components: coded actuator,
evaluation unit and read head.
The evaluation unit is integrated into a housing with the read head.
Each actuator possesses a unique electronic coding and so is a unique element in
the system used. The code in an actuator cannot be reprogrammed.
The actuator must be assigned to the safety switch by a teach-in process so that
it is detected by the system. This unambiguous assignment ensures a particularly
high level of protection against tampering.
The safety switch with integrated evaluation unit and read head is fastened to the
fixed part of the safety guard.
Within the device, the operation of the two safety outputs is dual-channel.
The actuator attached to the movable part of the safety guard is moved towards
the read head fitted in the safety switch by closing the door. When the switch-on
distance is reached, power is supplied to the actuator by the inductive read head
and data can be transferred.
The bit pattern read is compared with the code saved in the safety switch, if the
data match the safety outputs are enabled.
Due to the combination of dynamic polling of the actuator and the redundant, diverse
design of the safety electronics with the two feedback switching elements for each
safety output, the safety switch will enter the safe state with every detectable fault.
The safety outputs shut down the safety circuits if the safety guard is opened.
The state of the safety outputs is monitored internally by two microprocessors.
For the safety outputs to switch on, there must be a voltage of U
input. This voltage can be supplied either using a jumper (automatic start) or using
a start button.
The safety switch has a redundant circuit design with self-monitoring. This means
that the safety system is still effective even if a component fails.
on the START
B
The system is designed so that a failure will not result in the loss of the safety
function. The occurrence of failures is detected by cyclic self-monitoring at the
latest on the next demand to close the safety contacts (e.g. on starting).
Risk of damage to equipment as a result of incorrect installation. Safety switches
must not be used as a mechanical end stop.
Ì Fit an additional end stop for the movable part of the safety guard.
Important!
Ì From the assured switch-off distance S
, the safety outputs are safely shut
ar
down.
Ì When mounting several safety switches, observe the stipulated minimum dis-
tance to avoid mutual interference.
min. 80mm
Ì If the actuator is installed flush, the switching distance changes as a function
of the installation depth and the safety guard material.
Flush mounting
Surface maounting
Operating
Actuator
distance
Actuator
Operating
distance
Note the following points:
Ì Actuator and safety switch must be easily accessible for inspection and re-
placement.
Ì Actuator and safety switch must be fitted so that
Ì the front faces are at the minimum switch-on distance 0.8 x S
when the safety guard is closed (see section Operating distances). For a side
approach direction for the actuator a minimum distance must be maintained
so that the operating distance of the side lobes is not entered (see operating
distance for the actuator).
Ì when the safety guard is open up to the distance S
tance), a hazard is excluded.
(assured switch-off dis-
ar
or closer
ao
Ì the actuator is positively mounted on the safety guard, e.g. by using the
Risk of damage to equipment or malfunctions as a result of incorrect connection.
Ì To avoid faults, the cable must be laid with protection.Ì The power for the operating voltage and for the inputs +LA and +LB must be
provided from a common power supply.
Ì All the electrical connections must either be isolated from the mains supply
by a safety transformer according IEC 61558-2-6 with limited output voltage
in the event of a fault, or by other equivalent isolation measures.
Ì With inductive loads there can be voltage spikes of up to -50 V lasting sev-
eral milliseconds on switching off the outputs.
Ì To prevent overvoltages on the inputs and outputs for the safety circuits,
inductive loads must be connected with free-wheeling diodes (see Connection examples page 12.
Ì Power devices which are a powerful source of interference must be installed
in a separate location away from the input and output circuits for signal processing. The cable routing for safety circuits should be as far away as possible from the cables of the power circuits.
Important!
Attention!
Important!
Test pulses, pulsing and power control
Ì In operation the device regularly switches off the safety outputs for approx.
6 ms to check the safe switching function. The loads connected must tolerate this behavior.
Ì A load connected is controlled using the safety paths +LA/LA and +LB/LB.
The control voltage can be pulsed for power control.
Ì Do not use a control system with pulsing to test the output cables or switch
off the pulsing function in your control system.
Behavior in case of faults
Ì In the event of a fault in the safety switch, the safety circuit is switched off
and the DIA LED illuminates red.
Ì After approx. 5 s. the device performs a re-start.
If the device does not appear to function when operating voltage is applied (e.g.
green STATE LED does not flash), the safety switch must be returned unopened
to the manufacturer.
Pay attention to the notes for the following applications:
Automatic start, with a jumper (+24 V are continuously present at the START
input)
¨ The device restarts automatically after faults.
Manual start (start via a start button)
¨ Prior to each restart the start button must be pressed
Ì A sticking start button (fault due to welding etc.) is not detected by the device
and results in an automatic restart.
Attention!
Danger due to automatic start / restart.
An automatic start / restart can occur:
Ì On closing the safety guardÌ On switching on the power supplyÌ On automatic restart after the detection of a fault
Ì Check carefully which start mode is suitable for your application.Ì Check whether additional measures are necessary to prevent an automatic
restart.
Safety in case of faults
Ì The operating voltage UÌ The contacts +LA/LA and +LB/LB are short circuit-proof and protected against
reverse polarization.
Ì To prevent switching on of the load connected in the case of a short circuit
between LA or LB and the operating voltage UB, the cables must be laid rigidly
and with protection.
is reverse polarity protected.
B
Fuse protection for power supply
The power supply must be provided with fuse protection depending on the current
required for the outputs. If both outputs (LA and LB) are used, protect with max.
10 A fuse.
Risk of damage to equipment or malfunctions as a result of incorrect connection cables.
Ì Use EUCHNER connectors. Ì If other connection components are used, the following recommendations
apply. EUCHNER provides no warranty for safe function in case of failure to
comply with these requirements.
Ì The maximum cable length should not exceed 50 m.
Recommended connection cable:
e.g. LiYY 7 x 1mm²,
Ölflex classic 400P 7 x 0.75
Mating connector for the evaluation unit:
EUCHNER M23, 9-pin, cable cross-section max. 1 mm² order no. 106 597
Important!
Alternative e.g.
Coninvers order no. RC-09S1N121600, cable cross-section max. 1 mm²
It is imperative you use the original tools from the connector manufacturer for
assembly and follow the assembly instructions from the connector manufacturer.
1NCNot used *
2StartStart input
3LASafety output, channel 1
4+LAInput for channel 1
5+LBInput for channel 2
6LBSafety output, channel 2
7UBPower supply, DC 24 V
80 VGround, DC 0 V
9NCNot used *
* The unused connection pins are not allowed to be connected by the user!
Within the device, the shutdown of the two outputs LA and LB is dual-channel. As
such, each of the outputs represents a separate safety output.
U
B
START
Attention!
UB
7
Internal
logic
0V
8
1) Load, e.g. valve coil, DC motor, Ohmic load etc.
2) In case of inductive loads, it is imperative free-wheeling diodes are used to protect the outputs on the safety switch.
+LB5+LA4START
2
NC1NC
9
LA
LB
3
Feedback
6
loop
1)2)1)2)
Feedback
loop
Figure 2: Connection example with start button and feedback loop
Ì A short circuit between the cables on the safety outputs LA and LB and an-
other cable must be prevented.
Ì In certain circumstances, a failure exclusion as per EN 13849-1, section 7.3
can be applied, see also EN 13849-2, section D.5.2.
Ì The CES-AH represents a subsystem as per EN 13849-1 and complies with
PL d. To integrate the switch in a category 3 structure, it is necessary to
monitor the downstream load (the feedback loop must be monitored).
Ì This example shows only an excerpt that is relevant for connection of the
CES-AH system. The example illustrated here does not show complete
system planning. The user is responsible for safe integration in the overall
system.
Teach-in operation or Power Up
(for further signal function see status table)
Important!
DIA
red
illuminated
- Internal electronics fault
- Fault at the inputs/outputs
Teach-in function for actuator
The actuator must be allocated to the safety switch using a teach-in function before
the system forms a functional unit.
During a teach-in operation, the safety outputs are in high-resistance state, i.e. the
system is in the safe state.
Ì The safety switch disables the code of the previous actuator if teach-in is
carried out for a new actuator. Teach-in is not possible again immediately for
this actuator if a new teach-in process is carried out. The disabled code is
deleted again in the safety switch only after a third code has been taught.
Ì The safety switch can only be operated with the last actuator taught.Ì If the switch detects an actuator which has already been taught when in
teach-in standby state, this state is ended immediately and the switch changes to normal state.
Ì The actuator being taught is not activated if it is within the operating dis-
tance for less than 60 s.
Carrying out teach-in for a new actuator
1. Apply operating voltage to the safety switch.
¨ The green LED flashes quickly (approx. 10 Hz)
A self-test is performed during this time (approx. 3 s). After this, the LED
flashes cyclically three times and signals that it is in standby state for teachin.
Standby-state for teach-in remains active for approx. 3 minutes.
2. Move new actuator to the read head (observe distance < S
¨ Teach-in operation starts, green LED flashes (approx. 1 Hz). During teach-in,
the safety switch checks whether the actuator is a disabled actuator. If this is
not the case, the teach-in operation is completed after approx. 60 seconds,
the green LED goes out. The new code has been saved, the old code disabled.
3. To activate the new actuator code from the teach-in operation in the safety
switch, the operating voltage to the safety switch must then be switched off
for min. 3 seconds.
3 xDoor open, unit is ready for teach-in for another actuator (only short time after power-up)
1 HzTeach-in operation
2 xOverload (e.g. short circuit on a safety output)
3 xOver-temperature
4 xOutput fault (e.g. fault on a switching element)
5 xInternal fault (e.g. component faulty, data fault)
DIA (red)
Self-test after power up
Normal operation, door closed
Positive acknowledgement after acknowledgement of teach-in operation
LED not illuminated
Key to symbols
Important!
LED illuminated
10 Hz (8 s)
3 x
XAny state
LED flashes for 8 seconds at 10 Hz
LED flashes three times
If you do not find the displayed device status in the System status table, this indicates an internal device fault. In this case, you should contact the manufacturer.
If a product data sheet is included with the product, the information on the data
sheet applies in case of discrepancies with the operating instructions.
Technical data for safety switch CES-AH-C03-AH-SM
Parameter
min.typ.max.
Housing materialPlastic
Dimensions40 x 40 x 171mm
Weight0.35kg
Ambient temperature at I(LA) / I(LB) > 3 A-20-+55
Storage temperature-25-+70
Degree of protectionIP67
Safety classIII
Degree of contamination3
Installation position
ConnectionM23 plug connector, 9-pin
Operating voltage U
Current consumption (no load on outputs)150mA
External fuse (operating voltage U
, +LA and +LB)0.25-10A
B
Power supply for load U(+LA)/U(+LB)U
Safety outputs LA/LBSemiconductor outputs, p-switching, short circuit-proof
- Output voltage U(LA/U(LB)
HIGH U(LA)
HIGH U(LB)V DC
1)
U
- 1.5-U
B
LOW U(LA)/U(LB)0-4
Testing of the outputs
- Test pulse length
- Test interval
-
10
Switching current per safety output30-4000mA
Utilization category according to EN 60947-5-2DC-13 24V 4A
Caution: outputs must be protected with a free-wheeling diode in case of inductive loads.
Classification acc. to EN 60947-5-3PDF-S
Start input START
LOW0-2
Rated insulation voltage U
i
Rated impulse withstand voltage U
imp
--75V
--1.5kV
Resilience to vibrationAccording to EN 60947-5-2
Switching delay from state change
Fault detection time
3)
2)
--260ms
-0.1215s
Difference time between the two safety outputs--50ms
Ready delay
Dwell time
4)
5)
--3s
0.5--s
Switching frequency--1Hz
Repeat accuracy R acc. to EN IEC 60947-5-3≤ 10%
Mounting distance between 2 switches or 2 actuators80--mm
EMC protection requirements In acc. with EN 60947-5-3
Reliability values according to EN ISO 13849-1
Category3
Performance Level (PL)d
PFH
d
Mission time20years
1) Values at a switching current of 4 A without taking into account the cable lengths.
2) Corresponds to the risk time according to EN 60947-5-3. This is the maximum switch-off delay for the safety outputs following removal of the actuator.
3) The fault detection time is the time for the detection of an internal fault in the device. At least one of the switching elements on each safety output is opened during this process.
4) After the operating voltage is switched on, the semiconductor outputs are switched off during the ready delay.
5) The dwell time of an actuator inside and outside the operating distance must be at least 0.5 s to ensure reliable detection of internal faults in the evaluation unit (self-monitoring).
Value
Any
-
-
1.03 x 10
Unit
°CAmbient temperature at I(LA) / I(LB) < 3 A-20-+70
Ready delay: After switching on, the unit carries out a self-test for 3 s. The system
is ready for operation only after this time.
Risk time according to EN 60947-5-3: If an actuator moves outside the oper-
ating distance, the safety outputs LA and LB on the corresponding safety switch
are deactivated after a maximum of 260 ms.
Difference time: The safety outputs LA and LB switch with a slight time offset.
They have the same signal state at the latest after a difference time of 50 ms.
System times for "restart after fault" and "normal operation"
Example application: UB = 24 V
+LA permanently connected to UB
+ LB switched by control system
Actuator
Start
+LA
LA
+LB
LB
DIA (LED red)
Detected
None
+24 V
0 V
+24 V
0 V
+24 V
0 V
+24 V
0 V
+24 V
0 V
On
Off
∆ t
1
∆ t
2
∆ t
3
∆ t
4
t
Start
Dt
= Fault detection time
1
= Fault time (5 s, switch spends this time in the fault state)
D t
2
= PowerUp time (3 s)
D t
3
= Risk time (≤ 260 ms, time from "no actuator" to "outputs switch off")
- CES-A-BCAPlastic PE-HD without reinforcement, fully encapsulated
Flat seal material (CES-A-BCA only)Fluororubber 75 FPM 4100
Dimensions42 x 25 x 12mm
Weight0.02kg
Ambient temperature
- CES-A-BCA- 25-+ 50
Degree of protection acc. to EN
IEC 60529
Installation positionActive face opposite read head
Power supplyInductive via read head
Regular inspection of the following is necessary to ensure trouble-free long-term
operation:
Ì Check the switching function (see section Functional check)Ì Check the secure fastening of the devices and the connections
Order
no.
Unicode106 300
Actuator BBA42 mm x 25 mm071 840
Actuator BCA42 mm x 25 mm088 786
Actuator BPA40 mm x 40 mm098 775
Actuator BRN80 mm x 40 mm100 251
Mating connector
for evaluation unit
M23 9-pin106 597
Loss of the safety function because of damage to the system.
In case of damage, the related safety component must be replaced. The replacement of individual parts in a safety component is not permitted.
Service
Ì Check for soiling
No servicing is required, repairs to the device are only allowed to be made by the
manufacturer.
Note!
The year of manufacture can be seen in the lower right corner of the rating plate.
If service support is required, please contact:
EUCHNER GmbH + Co. KG
Kohlhammerstrasse 16
D-70771 Leinfelden-Echterdingen