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Operating Instructions
Non-Contact Safety Switch
CES-I-AR-U-C04 (Unicode)
More than safety.
Operating Instructions Safety Switch CES-I-AR-U-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 |
Teach-in function for actuator |
20 |
Functional check |
22 |
System status table |
23 |
Technical data |
24 |
Technical data for safety switch CES-I-AR-U-C04 |
24 |
Technical data for actuator CES-A-BBN-C04 |
28 |
Technical data for actuator CES-A-BDN-06 |
30 |
Ordering information and accessories |
31 |
Inspection and service |
31 |
Service |
32 |
Declaration of conformity |
33 |
2
Operating Instructions Safety Switch CES-I-AR-U-C04
About this document
This document is valid for all safety switches CES-I-AR-U-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:
ÌÌEN ISO 13849-1, Safety of machinery. Safety related parts of control systems. General principles for design
ÌÌEN ISO 12100, Safety of machinery - General principles for design - Risk assessment and risk reduction
ÌÌIEC 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
ÌÌEN ISO 13849-1, Safety of machinery. Safety related parts of control systems. General principles for design
ÌÌEN 1088, Safety of machinery. Interlocking devices associated with guards. Principles for design and selection
ÌÌEN 60204-1, Safety of machinery. Electrical equipment of machines. General requirements
ÌÌEN 60947-5-3, Specification for low-voltage switchgear and controlgear. Control 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!
ÌÌThe 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.
ÌÌCorrect use requires observing the permissible operating parameters (see Technical data).
ÌÌIf 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-U-C04
Important!
ÌÌIn 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.
ÌÌWhen 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.
ÌÌIn the case of series connection of more than 11 devices, the PFHd can be calculated according to one of the stated methods in EN ISO 13849-1:2008, section 4.5.1.
ÌÌIf 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.
ÌÌIt is only allowed to use components that are permissible in accordance with the table below.
Possible combinations for CES components
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Actuator |
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Safety switch |
CES-A-BBN-C04-115271 |
CES-A-BDN-06-104730 |
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CES-I-AR-U-C04-... |
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Key to symbols |
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Combination possible |
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Note! |
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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-U-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 ÌÌafter any setup work
ÌÌafter the replacement of a CES component ÌÌafter an extended period without use ÌÌafter 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. ÌÌSafety 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
ÌÌwho are familiar with the correct handling of safety components ÌÌwho are familiar with the applicable EMC regulations
ÌÌwho are familiar with the applicable regulations on health and safety and accident prevention
ÌÌwho have read and understood the operating instructions
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. 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-U-C04
Function
The device complies with the following safety requirements: ÌÌSafety category 4, PLe according to EN ISO 13849-1 ÌÌRedundant design of the circuit in the unit with self-monitoring
ÌÌThis means that the safety system still functions even if an internal component fails
ÌÌThe switch state of the semiconductor outputs is continuously monitored internally
ÌÌShort 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 state table and section Typical system times):
ÌÌSafety guard closed
ÌÌBoth 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.
The actuator must be assigned to the safety switch by a teach-in operation so that it is detected by the system. This unambiguous assignment ensures a particularly high level of protection against tampering.
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.
The bit pattern read is compared with the code saved in the safety switch. If the data match, the safety outputs are enabled. 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.
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).
6
Operating Instructions Safety Switch CES-I-AR-U-C04
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-U-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.
ÌÌFit an additional end stop for the movable part of the safety guard.
Important!
ÌÌFrom the assured switch-off distance Sar, the safety outputs are safely shut down.
ÌÌWhen mounting several safety switches and actuators, observe the stipulated minimum distance to avoid mutual interference.
Installation options |
min. 140 mm |
|
ÌÌThe 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 |
C |
D |
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A |
B |
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Note the following points:
ÌÌActuator and safety switch must be easily accessible for inspection and replacement.
ÌÌThe switching operation must only be triggered by the specific actuator designated for this purpose. For permissible combinations please see the table of possible combinations on page 4.
ÌÌActuator and safety switch must be fitted so that
ÌÌthe front faces are at the minimum switch-on distance 0.8 x Sao or closer 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 |
ÌÌwhen the safety guard is open up to the distance Sar (assured switch-off distance), a hazard is excluded.
ÌÌthe actuator is positively mounted on the safety guard, e.g. by using the safety screws included.
ÌÌPay 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-U-C04
Electrical connection
The following connection options are available: ÌÌSeparate operation
ÌÌSeries connection with Y-distributors from EUCHNER (only with M12 plug connector)
ÌÌSeries connection, e.g. with wiring in the control cabinet
ÌÌOperation on an AR evaluation unit.
Warning!
In case of an error, loss of the safety function through incorrect connection. ÌÌTo ensure safety, both safety outputs (FO1A and FO1B) must always be
evaluated.
ÌÌThe monitoring output OD must not be used as a safety output.
ÌÌLay the connection cables with protection to prevent the risk of short circuits.
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connection. ÌÌDo 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.
ÌÌThe 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.
ÌÌAll 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).
ÌÌFor 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.
ÌÌFor 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.
ÌÌAll 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.
ÌÌPower 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-U-C04
Caution!
ÌÌIn 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
ÌÌThe operating voltage UB is reverse polarity protected. ÌÌThe contacts FO1A/FO1B are short circuit-proof.
ÌÌA short circuit between FO1A and FO1B is detected by the switch.
ÌÌA 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 Imax
Imax |
= IUB + IOD + IFO1A+FO1B |
IUB |
= Switch operating current (35 mA) |
IOD |
= Monitoring output load current (max. 50 mA) |
IFO1A+FO1B = Load current of safety outputs FO1A + FO1B (2 x max. 200 mA)
Requirements for connection cables
Caution!
Risk of damage to equipment or malfunctions as a result of incorrect connection cables.
ÌÌUse connection components and connection cables from EUCHNER
ÌÌOn the usage of other connection components, the requirements in the following table apply. EUCHNER provides no warranty for safe function in case of failure to comply with these requirements.
ÌÌThe 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-U-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).
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lmax =200 m |
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l1 |
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l2 |
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ln |
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umin = 24 V -10% |
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un = 24 V -20% |
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SPS |
iout |
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PLC |
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5 x 0,34 mm2 |
5 x 0,34 mm2 |
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5 x 0,34 mm2 |
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oder |
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5 x 0,14 mm2 |
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CES-I-AR # n |
CES-I-AR # n-1 |
CES-I-AR # 1 |
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n |
Iout (mA) |
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l1 (m) |
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Max. cable length from |
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Max. number of |
Possible output current per channel |
last switch to control system |
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switches |
FO1A/FO1B |
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with conductor cross-section |
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0.14 mm² |
0.34 mm² |
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10 |
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70 |
140 |
|
25 |
|
50 |
110 |
5 |
50 |
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35 |
80 |
|
100 |
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25 |
50 |
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200 |
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13 |
25 |
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10 |
|
60 |
120 |
|
25 |
|
50 |
90 |
6 |
50 |
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35 |
70 |
|
100 |
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20 |
50 |
|
200 |
|
13 |
25 |
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10 |
|
35 |
70 |
|
25 |
|
30 |
60 |
10 |
50 |
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25 |
50 |
|
100 |
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15 |
35 |
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200 |
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10 |
20 |
Important!
The cables between the Y-distributors must have a conductor cross-section of 0.34 mm².
11
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