EUCHNER CES-AR-C01-CH-SA User Manual
Operating Instructions
Non-Contact Safety Switch
CES-AR-C01-CH-SA (Multicode)
More than safety.
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Contents
Correct use 3
Possible combinations for CES components 4
Exclusion of liability and warranty 5
General safety instructions 5
Function 6
Changing the approach direction 7
Mounting 8
Electrical connection 9
Safety in case of faults 10
Fuse protection for power supply 10
Requirements for connection cables 11
Maximum cable lengths 11
Connector assignment of safety switch CES-AR 13
Connection of a single CES-AR-C 14
Connection of several CES-AR-C in a switch chain 16
Notes on operation with safe control systems 18
Setup 20
LED indicators 20
Initial setup 20
Functional check 20
System status table 21
Technical data 22
Technical data for safety switch CES-AR-C01-CH-SA 22
Technical data for actuator CES-A-BBA 25
Technical data for actuator CES-A-BPA 27
Technical data for actuator CES-A-BRN 29
Ordering information and accessories 31
Inspection and service 31
Service 32
Declaration of conformity 33
2
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Correct use
The Coded Electronic Safety switches series CES are safety devices for monitoring movable safety guards.
In combination with a separating safety guard and the machine control, this safety
component prevents dangerous machine movements from occurring while the
safety guard is open. 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 12100, Safety of machinery – General principles for design – Risk as-
sessment and risk reduction
Ì IEC 62061, Safety of machinery. Functional safety of safety-related electrical,
electronic and programmable electronic control systems.
Correct use includes compliance with the relevant requirements for installation
and operation, for example
Important!
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 behavior 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.
Several devices are only allowed to be connected in series using devices intended
for series connection with the CES-AR. Check the operating instructions for the
related device. A combination of other CES devices or devices from other manufacturers is not allowed.
A maximum of 20 safety switches are allowed to be operated in a switch chain.
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 In the estimation of the PL for the overall system, a maximum value of
100 years can be assumed for the MTTFd according to the limit value in
EN ISO 13849-1:2008, section 4.5.2. This corresponds to a minimum value
for the PFHd of 2.47x10-8/h.
Ì When up to 11 devices are connected in series, these limit values can be
assumed for the entire switch chain as a subsystem. As a subsystem, this
switch chain achieves PL e.
3
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Important!
CES-AR-C01-CH-SA
Key to symbols
Safety switches
098942
Ì In the case of series connection of more than 11 devices, the PFH
calculated according to one of the stated methods in EN ISO 13849-1:2008,
section 4.5.1.
Ì If the simplified method according to section 6.3 of EN ISO 13849:2008-12
is used for validation, the Performance Level (PL) might be reduced when
more than 11 devices are connected in series.
Ì It is only allowed to use components that are permissible in accordance with
the table below.
Possible combinations for CES components
Actuator
CES-A-BBA
071840
Combination possible
CES-A-BPA
098775
CES-A-BRN
100251
can be
d
Note:
Devices with version number V 1.1.2 or higher can be operated on an AR evaluation unit. Please refer to the operating instructions for the relevant AR evaluation
unit for more information.
4
Operating Instructions Safety Switch CES-AR-C01-CH-SA
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.
General safety instructions
As the unique actuator codes are not evaluated, the CES-AR-C01-CH-SA version
can only be used for applications in which a hazard cannot result from possible
tampering with the system.
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 work
Ì after the replacement of a CES component
Ì after an extended period without use
Warning!
Caution!
Ì 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.
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.
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 regulations
Ì who are familiar with the applicable regulations on health and safety and ac-
cident prevention
Ì who have read and understood the operating instructions.
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!
Prior to use, read the operating instructions and keep these in a safe place.
Ensure that the operating instructions are always available during mounting,
setup and servicing work. 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. You can download
the operating instructions from www.EUCHNER.de.
5
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Function
The device complies with the following safety requirements:
Ì Category 4, PLe according to EN ISO 13849-1
Ì Redundant design of the circuit in the unit with self-monitoring
Ì 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
Ì Short circuit detection at the safety outputs by pulse signals
The following switch-on condition applies to safety outputs OA and OB (see also
System status table and the section Typical system times):
Ì Safety guard closed
Ì Both safety outputs (IA and IB) must be on
The system consists of the following components: coded actuator (transponder)
and switch.
Every EUCHNER actuator supplied has an electronic coding (unique coding) that is
read by the read head. Only if a correct coding is detected does the system accept
the actuator. The code in an actuator cannot be reprogrammed.
Unlike systems with unique code detection, on the CES-AR-C01-CH-SA a specific
code is not polled but instead it is only checked whether the actuator is of a type
that can be detected by the system (multicode detection). There is no exact comparison of the actuator code with the code defined in the safety switch (unique
code detection).
The safety switch is fastened to the fixed part of the safety guard.
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 read head by induction and data can be transferred.
If a permissible code is detected, the safety outputs are released.
Due to the combination of dynamic polling of the actuator and the redundant,
diverse design of the safety electronics with the two feedback safety outputs, the
safety switch will enter the safe state with every detectable fault.
When the safety guard is opened, the safety outputs switch off the safety circuit
and the monitoring output (OUT) is switched off. The state of the safety outputs is
monitored internally by two microprocessors.
If faults are detected, the safety circuit is switched off and the DIA LED illuminates.
In case of devices with a DIA monitoring output, the output is switched on.
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.
The system is designed so that failures 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).
If the safety door with the actuator should settle over time, the actuator can drift
out of the read head operating distance. The device recognizes this and indicates
that the actuator is in the limit range (function available for V 1.1.2 and higher).
This allows the safety door to be readjusted in time.
6
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Changing the approach direction
Caution!
Risk of damage to equipment as a result of trapped cables.
Ì Make sure that the cables are not trapped or torn off when the approach
direction is changed.
The active face of the read head can be adjusted in 5 directions. It is marked by
the red face.
The plug connector can be realigned in 45° steps to change the direction of the
cable outlet (when using elbow connectors).
1. Remove the top part of the mounting base and push the bottom part of the
mounting base off the read head.
2. Unscrew the screws on the fastening bracket.
3. Undo the read head from the fastening bracket and tilt the read head forward
by 90°.
¨ The active face is now pointing downward.
4. Hold the fastening bracket tight and turn the read head by 180°.
5. Re-tighten the screws for the read head on the fastening bracket. Tightening
torque 0.6 Nm.
6. Turn the read head in 90° steps until the desired approach direction is
reached.
Change the alignment of the plug connector if necessary.
7. Push the read head onto the bottom part of the mounting base and reassemble the mounting base.
7
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Mounting
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
distance 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
Actuator
Operating
distance
Surface mounting
Actuator
Operating
distance
Note the following points:
Ì Actuator and safety switch must be easily accessible for inspection and re-
placement.
Ì The switching operation must only be triggered by the specific actuator desig-
nated for this purpose.
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). To avoid
entering the area of possible side lobes, a minimum distance is to be maintained in case of a side approach direction. See section Typical operating
distance for the related 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
safety screws included.
Ì they cannot be removed or tampered with using simple means.
Ì Pay attention to the maximum tightening torque for the read head or safety
switch and actuator mountings of 1 Nm. For read heads/actuators made of
PE-HD, the maximum tightening torque is only 0.5 Nm.
8
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Electrical connection
The following connection options are available:
Ì Separate operation
Ì Series connection with Y-distributors from EUCHNER (only with M12 plug con-
nector)
Ì Series connection, e.g. with wiring in the control cabinet.
Ì Operation on an AR evaluation unit
Warning!
In the event of a fault: Loss of the safety function due to incorrect connection.
Ì To ensure safety, both safety outputs (OA and OB) must always be evaluated.
Ì The monitoring output OUT or DIA must not be used as a safety output.
Ì Lay the connection cables with protection to prevent the risk of short cir-
cuits.
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connection.
Ì Do not use a control system with pulsing or switch off the pulsing function in
your control system. The device generates its own clock signal on the output lines OA/OB. A downstream control system must tolerate these pulses,
which may have a length of up to 1 ms.
The pulses are also output when the safety outputs are switched off.
Depending on the inertia of the connected device (control system, relay,
etc.), this can lead to short switching processes.
Ì The inputs on an evaluation unit connected must be positive-switching, as the
two outputs on the safety switch deliver a level of +24 V in the switched-on
state.
Ì All the electrical connections must either be isolated from the mains supply by
a safety transformer according to IEC 61558-2-6 with limited output voltage in
the event of a fault, or by other equivalent isolation measures (PELV).
Ì For use and operation as per the requirements, a power supply with the
feature "for use in class 2 circuits" must be used. The same requirement applies to the safety outputs.
Alternative solutions must comply with the following requirements:
a) Electrically isolated power supply unit with a max. open-circuit voltage of 30
V/DC and a limited current of max. 8 A.
b) Electrically isolated power supply unit in combination with fuse as per UL248.
This fuse should be designed for max. 3.3 A and should be integrated into
the 30 V/DC voltage section.
Ì For use and applications as per the requirements of , a connection cable
listed under the UL category code CYJV2 or CYJV must be used. The connection cables from EUCHNER meet these requirements. The same requirement applies to the safety outputs.
Ì All electrical outputs must have an adequate protective circuit for inductive
loads. The outputs must be protected with a free-wheeling diode for this purpose. RC interference suppression units must not be used.
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.
9
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Caution!
Ì In order to avoid EMC interference, the physical environmental and operating
conditions at the installation site of the device must comply with the requirements according to the standard EN 60204-1:2006, section 4.4.2 (EMC).
Ì Please pay attention to any interference fields in case of devices such as
frequency converters or induction heating systems. Observe the EMC instructions in the manuals from the respective manufacturer.
Important!
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.
Safety in case of faults
Ì The operating voltage U
is reverse polarity protected.
B
Ì The contacts OA/OB are short circuit proof.
Ì A short circuit between OA and OB is detected by the switch.
Ì A short circuit in the cable can be excluded by laying the cable with protection.
Fuse protection for power supply
The power supply must be provided with fuse protection depending on the number
of switches and current required for the outputs. The following rules apply:
Max. current consumption of an individual switch I
I
= IUB + I
max
= Switch operating current (50 mA)
I
UB
= Monitoring output load current (max. 200 mA)
I
OUT
= Load current of safety outputs OA + OB (2 x max. 400 mA)
I
OA+OB
OUT
+ I
OA+OB
Max. current consumption of a switch chain Σ I
Σ I
max
= I
+ n x (IUB + I
OA+OB
OUT
)
n = Number of connected switches
max
max
10
Operating Instructions Safety Switch CES-AR-C01-CH-SA
Requirements for connection cables
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connection cables.
Ì Use connection components and connection cables from EUCHNER
Ì On the usage of other connection components, the requirements in the fol-
lowing table apply. EUCHNER provides no warranty for safe function in case
of failure to comply with these requirements.
Observe the following requirements with respect to the connection cables:
Parameter Value Unit
Conductor cross-section 0.34 mm²
R max. 60 W/km
C max. 120 nF/km
L max. 0.65 mH/km
Recommended cable type LIYY 8x or 5x 0.34 mm²
Maximum cable lengths
Switch chains are permitted up to a maximum overall cable length of 200 m taking
into account the voltage drop as a result of the cable resistance (see table below
with example data and case example).
l
=200 m
max
l
2
u
= 24 V -10%
min
l
1
l
n
un = 24 V -20%
SPS
PLC
Max. number of
5 x 0,34 mm
n
switches
5
6
10
i
out
2
CES-AR # n CES-AR # n-1 CES-AR # 1
I
(mA)
out
Possible output current per channel
OA/OB
10 150
25 100
50 80
100 50
200 25
10 120
25 90
50 70
100 50
200 25
10 70
25 60
50 50
100 40
200 25
Max. cable length from the last switch
l1 (m)
to the control system
11
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