EUCHNER CES-I-AR-M-C04 User Manual
Operating Instructions
Non-Contact Safety Switch
CES-I-AR-M-C04 (Multicode)
More than safety.
Operating Instructions Safety Switch CES-I-AR-M-C04
Contents
About this document 3
Correct use 3
Possible combinations for CES components 4
Exclusion of liability and warranty 4
General safety instructions 5
Function 6
Mounting 8
Electrical connection 9
Safety in case of faults 10
Fuse protection for power supply 10
Requirements for connection cables 10
Maximum cable lengths 11
Connector assignment, safety switch CES-I-AR 13
Connection of a single CES-I-AR 14
Connection of several CES-I-AR 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-I-AR-M-C04 22
Technical data for actuator CES-A-BBN-C04 26
Technical data for actuator CES-A-BDN-06 28
Ordering information and accessories 29
Inspection and service 29
Service 30
Declaration of conformity 31
2
Operating Instructions Safety Switch CES-I-AR-M-C04
About this document
This document is valid for all safety switches CES-I-AR-M-C04.
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
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.
Connection of several devices in an AR switch chain is permitted only using devices
intended for series connection in an AR switch chain. Check this in the instructions
of the device in question.
A maximum of 20 safety switches are allowed to be operated in a switch chain.
Important!
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.
3
Operating Instructions Safety Switch CES-I-AR-M-C04
Important!
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.
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.
can be
d
Possible combinations for CES components
Actuator
CES-I-AR-M-C04-...
Key to symbols
Safety switch
Combination possible
CES-A-BBN-C04-115271 CES-A-BDN-06-104730
Note!
The devices can be operated on an AR evaluation unit. Please refer to the operating
instructions for the relevant AR evaluation unit for more information.
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 Switch CES-I-AR-M-C04
General safety instructions
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
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!
Loss of safety function 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 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
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. 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-I-AR-M-C04
Function
The device complies with the following safety requirements:
Ì Safety 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 pulsed signals
The following switch-on condition applies for the safety outputs FO1A and FO1B
(see also System status table and section Typical system times):
Ì Safety guard closed
Ì Both safety inputs FI1A and FI1B must be switched on.
The CES 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-I-AP-M-C04 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. Independent of
the safety outputs, monitoring output OD switches on as soon as the actuator is
in the operating distance.
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 OD 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 monitoring output OI, 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.
6
Operating Instructions Safety Switch CES-I-AR-M-C04
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 switch the safety outputs (e.g. on starting).
If the safety door with the actuator should settle over time, the actuator can drift
out of the switch operating distance. The device recognizes this situation and
indicates that the actuator is in the limit range. This allows the safety door to be
readjusted in time.
7
Operating Instructions Safety Switch CES-I-AR-M-C04
Mounting
Caution!
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
down.
, the safety outputs are safely shut
ar
Ì When mounting several safety switches and actuators, observe the stipu-
lated minimum distance to avoid mutual interference.
Installation options
min. 140 mm
Ì The operating distance changes during the mounting of the actuator as a
function of the material used for the safety guard. Observe direction of arrow
on the device (see figure below).
Permissible approach directions
A B
C D
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. For permissible combinations please see the table of
possible combinations on page 4.
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). A minimum distance dependent on the actuator and the approach direction must be
maintained for a side approach direction:
- for CES-A-BBN-C04-115271 6 mm (A + B) / 2 mm (C + D)
- for CES-A-BDN-06-104730 10 mm
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 Pay attention to the maximum tightening torque of 0.8 Nm for the safety
switch and actuator mountings.
8
Operating Instructions Safety Switch CES-I-AR-M-C04
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 case of an error, loss of the safety function through incorrect connection.
Ì To ensure safety, both safety outputs (FO1A and FO1B) must always be
evaluated.
Ì The monitoring output OD 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 FO1A/FO1B. A downstream control system must tolerate these test
pulses, which may last up to 1 ms.
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 operation as per the requirements*, a connection cable
listed under the UL category code CYJV2 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.
* Note on the scope of the UL approval: Only for applications as per NFPA 79 (Industrial Machinery)
The devices have been tested as per the requirements of UL508 (protection against electric shock and fire).
9
Operating Instructions Safety Switch CES-I-AR-M-C04
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).
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
Caution!
Ì The operating voltage U
is reverse polarity protected.
B
Ì The contacts FO1A/FO1B are short circuit-proof.
Ì A short circuit between FO1A and FO1B 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 current
required for the outputs. The following rules apply:
Max. current consumption of a switch I
I
= IUB + IOD + I
max
= Switch operating current (35 mA)
I
UB
= Monitoring output load current (max. 50 mA)
I
OD
I
FO1A+FO1B
= Load current of safety outputs FO1A + FO1B (2 x max. 200 mA)
FO1A+FO1B
max
Requirements for connection cables
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.
Ì The connection cable must not be longer than 200 m in total.
Observe the following requirements with respect to the connection cables:
Parameter Value Unit
Conductor cross-section 0.14 ... 0.34 mm²
R max. 150 W/km
C max. 120 nF/km
L max. 0.65 mH/km
Recommended cable type LIYY 8x0.34 mm²
10
Operating Instructions Safety Switch CES-I-AR-M-C04
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
1
l
n
u
= 24 V -10%
min
i
SPS
PLC
out
l
2
un = 24 V -20%
5 x 0,34 mm
oder
5 x 0,14 mm
n
Max. number of
switches
5
6
10
2
2
5 x 0,34 mm
2
5 x 0,34 mm
CES-I-AR # n CES-I-AR # n-1 CES-I-AR # 1
l1 (m)
I
(mA)
out
Possible output current per channel
FO1A/FO1B
10 70 140
25 50 110
50 35 80
100 25 50
200 13 25
10 60 120
25 50 90
50 35 70
100 20 50
200 13 25
10 35 70
25 30 60
50 25 50
100 15 35
200 10 20
Max. cable length from the last switch
to the control system with conductor
cross-section
0.14 mm² 0.34 mm²
2
Important!
The cables between the Y-distributors must have a conductor cross-section of
0.34 mm².
11
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