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CES-AZ-UES-xxx
User Manual
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EUCHNER CES-AZ-UES-xxx User Manual

Operating instructions Non-contact safety system CES-AZ-UES-... (Multicode)
More than safety.
Operating Instructions Safety System CES-AZ-UES-...
Contents
Correct Use 3
Exclusion of Liability and Warranty 4
General Safety Instructions 5
Function 6
Installation 9
Electrical Connection 11
Safety in case of faults 11 Fusing of the power supply and the safety contacts 12 Connection example CES-AZ-UES-01B 13 Connection example CES-AZ-UES-02B 14 Connection example CES-AZ-UES-04B 15
Commissioning 16
LED indicators 16 Parameter setting 16 Functional Check 18
System Status Table 20
Technical Data 22
Ordering Information and Accessories 49
Inspection and Service 51
Service 51
Declaration of Conformity 52
2
Operating Instructions Safety System CES-AZ-UES-...
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 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. Principles 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, in particular
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 (PDF)
The following components can be connected to the evaluation unit CES-AZ--UES...:
Ì CES read heads Ì CEM read heads Ì CET read headss
For further information, refer to the operating instructions of the corresponding component and to the following table Possible combinations for CES components.
Ì The devices permit a safety-related stop function, initiated by a safety guard
according to Table 8 - DIN EN ISO 13849-1: 2008-12.
Ì The safety-related function of the PDF is the opening of the output
contacts (13/14, 23/24) when the actuator is absent.
Ì The user is responsible for safe integration of the device in a safe overall
system. For this purpose, the overall system must be validated, e.g. in ac­cordance with EN ISO 13849-2.
Ì The permissible operating parameters must be observed for correct use
(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 Only components may be used that are permissible in accordance with the
table below.
3
Operating Instructions Safety System CES-AZ-UES-...
Possible combinations for CES components
Actuator
Evaluation unit
CES-AZ-UES-01B
105139
CES-AZ-UES-02B
105140
CES-AZ-UES-04B
105141
Read head/ safety switch
CES-A-BSP-104970
104970
CES-A-BBN-106600
106600
CES-A-BDN-06-104730
104730
CES-A-LSP-...
All items
CES-A-LNN-...
All items
CES-A-LCA-...
All items
CES-A-LNA-...
All items
CES-A-LQA-SC
095650
CES-A-LMN-SC
077790
CEM-A-LE05K-S2
094800
CEM-A-LE05R-S2
095792
CEM-A-LH10K-S3
095170
CEM-A-LH10R-S3
095793
CET1-AX-LRA-...
095735
CET1-AX-LDA-...
100399
15 Combination possible, typ. switch-on distance 15 mm
20
15 19
CES-A-BBA
071840
CES-A-BCA
088786
CES-A-BQA
098108
15 15 16
15 15 16
15 15 23
CES-A-BDA
084720
CES-A-BMB
077791
5
CEM-A-BE05
094805
CEM-A-BH10
095175
CET-A-BWK-50X
096327
Combination possible, guard locking for process protection
Key to symbols
Combination possible, guard locking for personal protection
Combination not permissible
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.
4
Operating Instructions Safety System CES-AZ-UES-...
General Safety Instructions
As the unique actuator codes are not evaluated, the CES-AZ-UES-... 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 severe injuries to personnel.
The number of teach-in and switching operations is saved in the internal memory in the evaluation unit. If necessary, this memory can be read by the manufacturer.
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 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.
Warning!
Important!
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 Ì who have read and understood the operating instructions.
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 System CES-AZ-UES-...
Function
The safety system CES-AZ-AES... complies with the following safety requirements:
Ì Category 4, PLe according to EN ISO 13849-1 Ì Proximity device with self-monitoring type PDF-M according to EN 60947-5-3. Ì Redundant design of the circuit in the evaluation unit with self-monitoring. As a
result, the safety system is still effective even if a component fails.
Ì When the safety guard is opened and closed, it is checked whether the safety
system relays open and close correctly.
The CES non-contact safety system consists of three components:
Ì Coded actuator Ì Read head Ì Evaluation unit
The number of read heads that can be connected depends on the evaluation unit:
CES-AZ-AES-01B
CES-AZ-AES-02B
CES-AZ-AES-04B ¨ 4 read heads
It is also possible to connect a start button (monitoring of the falling edge) and a feedback loop for monitoring external relays and contactors.
The individual configuration is defined by a setup procedure.
Each delivered actuator possesses a unique electronic coding and so is a unique element in the system used. The code in an actuator cannot be reprogrammed.
Unlike systems with unique code detection, on the CES-AZ-UES... 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 evaluation unit (unique code detection).
The read heads are fastened to the fixed part of the safety guard and are each connected to the evaluation unit via a two-core screened cable.
The actuator fastened to the movable part of the safety guard is moved towards the read head 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.
The bit pattern read is compared with the code saved in the evaluation unit. If the data match, the door monitoring output O1 or O1...O2 or O1...O4 (semiconductor output) on the related read head is set HIGH. If all data for all read heads activated match, the safety outputs (relay outputs) are then enabled. The OUT LED illuminates.
¨ 1 read head
¨ 2 read heads
Optionally, a feedback loop can be connected to the evaluation unit. The evaluation unit can then only be started with the feedback loop closed. A welded contactor contact in the release path will thus be detected the next time the machine is started.
Due to the combination of dynamic polling of the actuators and the redundant, diverse design of the safety electronics with two safety outputs, the evaluation unit will enter the safe state with every detectable fault.
When a safety guard is opened, the safety outputs switch off the safety circuit and the OUT LED goes out. The state of the safety outputs is monitored internally by positively driven NC contacts (relay output).
6
Operating Instructions Safety System CES-AZ-UES-...
Independent of the switching state of the safety circuit, the position of all safety doors can be polled via the outputs O1 or O1...O2 or O1...O4.
If an internal fault occurs in the evaluation unit, the safety circuit is switched off, the diagnostic output (DIA) is set HIGH and the DIA LED illuminates red.
7
Operating Instructions Safety System CES-AZ-UES-...
Block diagram CES-AZ-UES-...
CES-AZ-UES-01B
UB, 0V Power supply J, 0V Jumper for teach-in operation H11/H12 Connection for read head 1 SH1 Screen read head 1 TST Test input (see „Self-test with test
O1 Semiconductor monitoring output DIA Diagnostics output 13, 14 Connection for relay contact A,
23, 24 Connection for relay contact B,
Y1, Y2 Feedback loop S Connection for start button
input TST“ page 18)
safety relay enable
safety relay enable
(monitoring of the falling edge)
Activation of the
teach-in operation
with jumper
on J, 0V.
0V
UB
J
CES-AZ-UES-01B 105139
TST
SH1
O1
Trans­ponder
Read­head
H11
1
H12
EUCHNER
+
K2
K1
DIA
+
23 24
13 14
Y1 Y2 S
UB, 0V Power supply J1, J2 Jumper for teach-in operation H11/H12, H21/H22 Connection for read heads 1 and 2 SH1, SH2 Screen read heads 1 and 2 TST Test input (see „Self-test with test
O1, O2 Semiconductor monitoring outputs DIA Diagnostics output 13, 14 Connection for relay contact A,
23, 24 Connection for relay contact B,
Y1, Y2 Feedback loop S Connection for start button
input TST“ page 18)
safety relay enable
safety relay enable
(monitoring of the falling edge)
CES-AZ-UES-02B
Activation of the
teach-in operation
with jumper
on J1, J2.
0V
UB
J1 J2 SH1
H11
CES-AZ-UES-02B 105140
TST
O1
CES-AZ-UES-04B
Activation of the
teach-in operation
with jumper
on J1, J2.
Trans­ponder
Read­head
H12
O2
Trans­ponder
Read­head
1
EUCHNER
1
K2
SH2
+
K1
Trans­ponder
Read­head
H21
DIA
Trans­ponder
Read­head
2
H22
+
23 24 13 14
2
Trans­ponder
Read­head
3
Y1 Y2 S
Trans­ponder
Read­head
4
UB, 0V Power supply J1, J2 Jumper for teach-in operation H11/H12...H41/H42 Connection for read heads 1..0.4 SH1...SH4 Screen read heads 1...4 TST Test input (see „Self-test with test
O1...O4 Semiconductor monitoring outputs DIA Diagnostics output 13, 14 Connection for relay contact A,
23, 24 Connection for relay contact B,
Y1, Y2 Feedback loop S Connection for start button
input TST“ page 18)
safety relay enable
safety relay enable
(monitoring of the falling edge)
0V
UB
CES-AZ-UES-04B 105141
TST
J1 J2
SH1
O1
H11
O2
H12
8
EUCHNER
K2
O3
SH2
O4
H21
+
K1
DIA
H2223SH3
+
24
H31
13
H3214SH4
Y1
H41
Y2
H42
S
Operating Instructions Safety System CES-AZ-UES-...
Installation
Caution!
Safety switches must not be bypassed (bridging of contacts), turned away, removed or otherwise rendered ineffective.
Ì On this topic pay attention in particular to the measures for reducing the pos-
sibility of bypassing according to EN 1088:1995.A2:2008, sec. 5.7.
Ì The evaluation unit must be mounted in a control cabinet with a minimum
degree of protection of IP 54. A snap-in element on the rear of the device is used for fastening to standard rails.
Ì If several evaluation units are mounted side by side in a control cabinet with-
out air circulation (e.g. fan), a minimum distance of 10 mm must be main­tained between the evaluation units. The distance enables heat from the evaluation unit to dissipate.
Caution!
Risk of damage to equipment as a result of incorrect installation. Read heads or actuators 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 read heads, observe the stipulated minimum dis-
tance to avoid mutual interference.
- For CES-A-LNA/-LCA s
- For CES-A-LMN s
- For CES-A-LQA s
= 50 mm
min
= 20 mm
min
= 80 mm
min
s
min
Ì If the actuator is installed fl ush, the switching distance changes as a function
of the installation depth and the safety guard material.
Flush mounting Surface mounting
Operating
Actuator
distance
Actuator
Operating
distance
9
Operating Instructions Safety System CES-AZ-UES-...
Note the following points:
Ì Actuator and read head must be easily accessible for inspection and replace-
ment.
Ì The switching operation must only be triggered by the specific actuator desig-
nated for this purpose.
Ì Actuator and read head must be fitted so that
Ì the front faces are at the minimum switch-on distance 0.8 x S
(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.
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.
or closer
ao
(assured switch-off dis-
ar
10
Operating Instructions Safety System CES-AZ-UES-...
Electrical Connection
Warning!
In case of an error, loss of the safety function through incorrect connection.
Ì The monitoring output OUT 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 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 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 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.
Ì Use cable material made of copper with a temperature resistance of at least
75 °C.
Ì The tightening torque for the screws on the connection terminals must be
0.6 ... 0.8 Nm.
Ì The connection cable for the read heads must only be extended using EUCHNER
plug connectors and adequate consideration must be given to EMC. Intermedi­ate terminals must not be used.
Ì The screen on the connection cable for the read head must be connected
to the appropriate terminal SH1 ... 4 on the evaluation unit. The portion of cable from which insulation is stripped should be kept as short as possible (max. 3 cm).
Safety in case of faults
Ì The operating voltage U Ì The connections for the read heads are not short circuit-proof. Ì A short circuit between 13/14 and 23/24 can be detected only by means of
external pulsing.
Ì A short circuit in the cable can be excluded by laying the cable with protection.
is reverse polarity protected.
B
11
Operating Instructions Safety System CES-AZ-UES-...
Fusing of the power supply and the safety contacts
Ì Provide external contact fuses (6 A gG fuse or 6 A circuit breaker, characteris-
tic B or C) for relay outputs.
Ì The power supply must be protected with a max. 8 A fuse before terminal U
.
B
12
Operating Instructions Safety System CES-AZ-UES-...
Connection example CES-AZ-UES-01B
24 VDC
Trans­ponder
-F1
-F2
0V
UB
CES-AZ-UES-01B 105139
TST
J SH1
O1
Read-
head
H11
1
H12
EUCHNER
K2
+
K1
DIA
+
23 24
13 14
Y1
Y2
L2
L1
-K3
L3
13
23
33
14
24
34
Start
13
23
-K4
14
S
-M1
33
24
34
M
~
3
GND
Important!
21
-K4
22 21
-K3
22
-V1
-K3
A1
-V2
A2
-K4
A1
A2
feedback loop
To achieve category 4 according to EN ISO 13849-1, it is necessary to monitor the downstream contactors (here contacts of -K3 and -K4 in the feedback loop). This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
If only one enable path is to be used for control (e. g. of downstream contactors), failures involving a short circuit between the contacts on the enable path and, for example, the power supply must be excluded.
With reference to EN ISO 13849-2 Table D.5, this exclusion can be provided if
Ì the cables are inside an electrical installation space and Ì the enclosure meets the related requirements (see EN 60204-1 or IEC 60204-1).
This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
13
Operating Instructions Safety System CES-AZ-UES-...
Connection example CES-AZ-UES-02B
24 VDC
-F1
-F2
0V
UB
CES-AZ-UES-02B 105140
TST
J1 J2 SH1
O1
Trans­ponder
Read-
head
H11
O2
1
H12
EUCHNER
SH2
K2
+
H21
K1
Trans­ponder
Read­head
DIA
2
H22
+
23 24
13 14
Y1
Y2
L2
L1
-K3
L3
13
23
33
14
24
34
Start
13
23
-K4
14
S
-M1
33
24
34
M
~
3
GND
Important!
21
-K4
22 21
-K3
22
-V1
-K3
A1
-V2
A2
-K4
A1
A2
feedback loop
To achieve category 4 according to EN ISO 13849-1, it is necessary to monitor the downstream contactors (here contacts of -K3 and -K4 in the feedback loop). This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
If only one enable path is to be used for control (e. g. of downstream contactors), failures involving a short circuit between the contacts on the enable path and, for example, the power supply must be excluded.
With reference to EN ISO 13849-2 Table D.5, this exclusion can be provided if
Ì the cables are inside an electrical installation space and Ì the enclosure meets the related requirements (see EN 60204-1 or IEC 60204-1).
This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
14
Operating Instructions Safety System CES-AZ-UES-...
Connection example CES-AZ-UES-04B
24 VDC
-F1
-F2
0V
UB
CES-AZ-UES-04B 105141
TST
J1 J2 SH1
O1
Trans­ponder
Read-
head
H11
O2
1
H12
EUCHNER
SH2
K2
O3
O4
+
H21
K1
Trans­ponder
Read­head
DIA
2
H22
+
23
SH3
24
Trans­ponder
Read­head
H31
13
3
H32
14
SH4
Y1
Trans­ponder
Read­head
H41
Y2
4
H42
S
Start
-K3
-K4
-M1
L2
L1
L3
13
23
33
14
24
34
13
23
33
14
24
34
M
~
3
GND
Important!
21
-K4
22 21
-K3
22
-V1
-K3
A1
-V2
A2
-K4
A1
A2
feedback loop
To achieve category 4 according to EN ISO 13849-1, it is necessary to monitor the downstream contactors (here contacts of -K3 and -K4 in the feedback loop). This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
If only one enable path is to be used for control (e. g. of downstream contactors), failures involving a short circuit between the contacts on the enable path and, for example, the power supply must be excluded.
With reference to EN ISO 13849-2 Table D.5, this exclusion can be provided if
Ì the cables are inside an electrical installation space and Ì the enclosure meets the related requirements (see EN 60204-1 or IEC 60204-1).
This example shows only an excerpt that is relevant for connection of the CES system. The example illustrated here does not show complete system planning. The user is responsible for safe integration in the overall system.
15
Operating Instructions Safety System CES-AZ-UES-...
Commissioning
LED indicators
STATE LED green State display (multifunction display using flashing modes)
OUT LED yellow Safety circuit closed
DIA LED red - Operating error or
- External fault (fault in the feedback loop) or
- Internal device fault or
- TST input activated (function test active)
Parameter setting
Before the system forms a function unit, the parameters are set in the evaluation unit by the user (number of connected read heads, with or without automatic start, with or without feedback loop). During this process the read heads are activated.
These configuration parameters are saved in the non-volatile memory in the evalu­ation unit.
Important!
The safety outputs are open during the parameter assignment. The system is in a safe state.
Ì During the parameter setting the following conditions must be met:
Ì There must be no state change, e.g. opening a safety guard or closing a
further safety guard or a change in the signal on the terminals for the start button and the feedback circuit.
Ì The power supply must not be switched off.
Ì If these conditions are not met, the evaluation unit switches to the safe fault
state (diagnostics LED illuminates) and signals this operating fault with the STATE LED by 3 short flashes that are repeated every second. The param­eter setting operation must be repeated.
Ì The number of parameter setting operations is unlimited. The evaluation unit
can be re-configured as often as required.
Ì Do not change DIP switches during operation.
To trigger a parameter setting operation, the user must perform the following actions in the stipulated order:
1. Prepare for parameter setting operation
Ì Switch off power supply U
B
Ì Fit a jumper between terminals J1 and J2
(for CES-AZ-AES-01B between J and 0V)
16
Operating Instructions Safety System CES-AZ-UES-...
2. Set required configuration on DIP switches
Switch designation Switch position left (OFF) Switch position right (ON)
1 No read head connected to terminals
2 No read head connected to terminals
3 No read head connected to terminals
4 No read head connected to terminals
5 Automatic start
6 No feedback loop connected Feedback loop connected
3. Set required configuration on machine
Ì Close all doors to be monitored (the actuators must be in the operating
distance of the related read head)
Ì For Manual start operating mode: Keep start button closed Ì For With feedback loop operating mode: keep feedback loop closed
4. Start parameter-setting operation
Ì Switch on operating voltage Ì Wait for self-test (STATE LED flashes for approx. 10 seconds at 15 Hz) Ì Parameter setting operation starts (STATE LED flashes at approx. 1 Hz) Ì Wait for acknowledgement of the parameter setting operation (STATE LED
goes out after approx. 10 seconds)
H11, H12, SH1 connected
H21, H22, SH2 connected
H31, H32, SH3 connected
H41, H42, SH4 connected
(No start button connected)
Read head connected to terminals
H11, H12, SH1 connected
Read head connected to terminals
H21, H22, SH2 connected
Read head connected to terminals
H31, H32, SH3 connected
Read head connected to terminals
H41, H42, SH4 connected
Manual start
(Start button connected)
5. End parameter-setting operation
Ì Remove jumper between J1 and J2
(for CES-AZ-AES-01B between J and 0V)
Ì For Manual start operating mode: Start button must be connected Ì For With feedback loop operating mode: Feedback loop must be con-
nected
Ì Press reset button or interrupt operating voltage for at least 10 seconds Ì Wait for self-test (STATE LED flashes for approx. 10 seconds at 15 Hz)
6. Check all safety guards for effectiveness
Changing the configuration
The evaluation unit can be re-configured as often as required. For this purpose you must proceed as per the first parameter setting operation according to the section Setup.
17
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