Leuze S200 Operating Instructions

S200
Safety Switches
EN 2011/09 - 607270
We reserve the right to
make technical changes
SAFE IMPLEMENTATION AND OPERATION
Original operating instructions
© 2011 Leuze electronic GmbH + Co. KG In der Braike 1 D-73277 Owen - Teck / Germany Phone: +49 7021 573-0 Fax: +49 7021 573-199 http://www.leuze.com info@leuze.de
1 About this document............................................................................................5
1.1 Other applicable documents ................................................................................................5
1.2 Used symbols and signal words ..........................................................................................6
2 Safety................................................................................................................... 7
2.1 Approved purpose and foreseeable improper operation......................................................8
2.1.1 Proper use .....................................................................................................................................8
2.1.2 Foreseeable misuse ......................................................................................................................9
2.2 Competent personnel.........................................................................................................10
2.3 Responsibility for safety.................................................... ........................... ......................10
2.4 Exemption of liability..........................................................................................................10
3 Device description.............................................................................................11
4 Functions........................................................................................................... 14
5 Applications .......................................................................................................15
6 Mounting............................................................................................................16
6.1 Adjusting the deflection head.................................................................................. .... .. .... .16
6.2 Mounting the Safety Switch ............................... .... ....... .... .. .... .. ......... .. .... .. .... ....... .... .. .... ...17
6.3 Mounting the actuator ................................................................. ..... .. .. .... .. .. .. .. ....... .. .. .. .. ...18
7 Electrical connection..........................................................................................20
7.1 Connecting the contact block................................................................... .. .... .. ..... .... .. .. .... .20
8 Setting the device into service...........................................................................24
9 Testing...............................................................................................................25
9.1 To be performed prior to the initial start-up by competent personnel................................. 25
9.2 To be performed periodically by competent personnel......................................................25
9.3 To be performed daily by the operating personnel ............................................................26
10 Cleaning............................................................................................................. 27
11 Disposing...........................................................................................................28
12 Service and support........................................................................................... 29
13 Accessories .......................................................................................................30
13.1 Accessory dimensional drawings.......................................................................................31
14 Technical data ...................................................................................................34
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15 EC Declaration of Conformity............................................................................37
4 S200 Leuze electronic

1 About this document

1.1 Other applicable documents

The information on the S200 Safety Switch is divided into two documents. Docu­ment "S200 Application information" contains only the most important safety notices.
ª For the safe implementation, testing and operation, down load document S200
Safe implementation and operation from http://www.leuze.com/s200/ or request it from service.schuetzen@leuze.de or tel. +49 8141 5350-111.
Table 1.1: Documents on the S200 Safety Switch
Purpose and target group Title Source
Detailed information for all users
S200 Safe implementation and operation (this docu­ment)
About this document
On the Internet, download from: http :/ /www.leuze.com/ s200/
Basic information for techni­cians and operating company
S200 Application information Print document part
no. 607236 included in the delivery contents of the product
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About this document

1.2 Used symbols and signal words

Table 1.2: Warning symbols and signal words
Symbol for dangers
NOTICE Signal word for property damage
CAUTION Signal word for minor injury
WARNING Signal word for severe injury
DANGER Signal word for life-threatening danger
Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.
Indicates dangers that may result in minor injury if the measures for dan­ger avoidance are not followed.
Indicates dangers that may result in severe or fatal injury if the measures for danger avoidance are not followed.
Indicates dangers that will result in severe or fatal injury if the measures for danger avoidance are not followed.
Table 1.3: Other symbols
Symbol for tips Text passages with this symbol provide you with further information.
Symbols for action steps
ª
Text passages with this symbol instruct you to perform actions.
xxx Placeholder in the product description for all variants
6 S200 Leuze electronic

2 Safety

Before using the Safety Switch, a risk evaluation must be performed according to valid standards (e.g. EN mounting, operating and testing, document S200 Safe implementation and oper ation, application information as well as all applicable national and international standards, regulations , rul es and directives must be obs erv ed. Ob se rve and print out relevant and supplied documents and distribute to the affected personnel.
The following sta nda rds a pply for the risk e val ua tion a t the protective dev ice prior to using the Safety Switch:
• EN ISO 14121, Safety of machinery, risk evaluation
• EN ISO 12100-1, Safety of machinery
• EN ISO 13849-1, Safety-related parts of control systems
The realizable category of integratio n in control circuits acc. to EN ISO 13849 -1 is dependent on the used contact block, wiring and mechanical conditions.
In particular, the fo llowin g nationa l and i nternationa l legal regulatio ns apply for the start-up, technical inspections and work with Safety Switch:
• Machinery directive 2006/42/EC
• Low voltage directive 2006/95/EC
• Use of work equipment directive 89/655 EEC
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and Labor Protection Act
• Device Safety Act
Safety
ISO 12100-1, EN ISO 13849-1, EN ISO 14121). For
-
For safety-related information you may also contact the local authorities (e.g., industrial inspectorate, employer's liability insurance association, labor inspec­torate, labor protection and health authority).
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Safety

2.1 Approved purpose and foreseeable improper operation

2.1.1 Proper use

• The Safety Switch must only be used after it has been selected in accor­dance with the respectively applicable instructions and relevant standards, rules and regulations regarding labor protection and safety at work, and after it has been installed on the machine, connected, commissioned, and checked by a competent person.
• When selecting the Safety Switch it must be ensured that its safety-related capability meets or exceeds the req uire d pe rformance level PLr ascertained in the risk assessment.
• It must be in perfect condition and inspected regularly.
• The switching process must only be triggered by an actuator approved for this Safety Switch that is connected to the moveable guard in a non-detach­able and tamperproof manner.
WARNING
A running machine can cause severe injuries!
ª Make certain that, during all conversi ons, maintenan ce work and inspec tions,
the system is securely shut down and protected against being restarted again.
S200 Safety Switches must be connected in such a way that a dangerous state can only be activated while the protective device is closed and so that the dangerous state s tops up on ope ning of the protective d ev ice . It mus t not be used if the point of o peration c an be a ccessed d uring the lag t ime befor e the dan gerous state has ended.
Connection conditions:
• the dangerous state can only be activated while the protective device is closed
• opening the protective device while the machine is running triggers a stop command and ends the dangerous state
8 S200 Leuze electronic
Safety
Furthermore, the S2 00 Safety Sw itch mus t not be used under the follow ing condi­tions:
• high concentration of dust particles in the surrounding area
• rapidly changing ambient temperature (leads to condensation)
• in the event of strong physical shoc ks
• in explosive or easily flammable atmospheres
• the mounting locations are not sufficiently stab le
• the safety of multiple persons is dependent on the function of this Safety Switch (e.g. nuclear power plants, trains, aircraft, motor vehicles, incinera­tors, medical device s)
For machines with longer slowdowns, a Safety Locking Device must be used.
Handling the Safety Switch: ª Observe the permissible environmental conditions for storage and operation
(see chapter 14).
ª Immediately replace damaged Safety Switch according to these instructions. ª Use cable gland, insulation materials and connecting wires of the appropriate
protection rating.
ª Protect the Safety Switch from penetrating foreign bo dies (e.g. sha vings, sand
and blasting agent).
ª Before performing painting work, cover the actuation slot, actuator and name
plate.
ª Immediately clean any contaminati on from the Safe ty Switch tha t impacts fu nc-
tion according to these instructions.
ª Make no structural changes to the Safety Switch. ª The Safety Switch must be exchanged after a maximum of 20 years.
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2.1.2 Foreseeable misuse

Any use other than that defined under the "approved purpose" or which goes beyond that use of the Safety Switch is considered improper use!
E.g. - using without non-detachably mounted actuator
• looping into the safety circuit parts that are not relevant to safety
• using the switch as a limit stop
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Safety

2.2 Competent personnel

Prerequisites for competent personnel:
• suitable technical training
• knows the rules and re gulations for labor protect ion, safety at work and safety technology and can assess the safety of the machine
• knows the instructions for the Safety Switch and the machine
• was instructed by the respons ible i ndividua ls on the mountin g and opera tion of the machine and of the Safety Switch

2.3 Responsibility for safety

Manufacturer and operating company must ensure that the machine and imple­mented Safety Switch function properly and that all affected persons are adequately informed and trained.
The type and content of all imparted information must not lead to unsafe actions by users.
The manufacturer of the machine is responsible for:
• safe machine cons truc tion
• safe implementation of the Safety Switch
• imparting all relevant information to the operating company
• adhering to all regulations and directives for the safe starting-up of the machine
The operating company is responsible for:
• instructing the operating personnel
• maintaining the safe operation of the machine
• adhering to all regulations and directives for labor protection and safety at work
• regular testing by competent personnel

2.4 Exemption of liability

Leuze electronic GmbH + Co. KG is not liable in the following cases:
• Safety Switch is not used as intended
• safety notices are not adhered to
• mounting and electrical connection are not properly performed
• reasonably foreseeable misuse is not taken into account
10 S200 Leuze electronic

3 Device description

1
3
2
4
5
The Safety Switch of the S20 0 series is an electro- mechani cal switch ing devic e in a housing made of metal; the d evice satisfi es protection ra ting IP design facilitates easy replacement. By means of the funnel-shaped insertion opening, the actuator self-centers, even if the door is slightly misadjusted.
Models with diffe rent contact set s with screw t erminals or M12 p lug connect ion are available.
Device description
67. The standard
1 Deflection head 2 Dust cover 3 Insertion opening for actuator 4 Housing cove r 5 Name plate (connection data, production code and year of manufacture)
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Device description
60
43
35
109.5
8
30 40
6.5
30
38
8
32
15
53x7.3
5.3
15
M12x1
23
13.3
Table 3.1: S200 Safety Switch
Article Part No. Description
S200-M3C1-M20 63000200 2NC, 1 cable entry S200-M1C1-M20 63000201 1NC + 1NO, 1 cable entry S200-M4C1-M20 63000202 2NC + 1NO, 1 cable entry S200-M4C1-M12 63000203 2NC + 1NO, 1 cable entry / M12 plug
Figure 3.1: Dimensions of S200-M1C1 -M20, S200-M3C1-M20 an d S200-M4C1-
M20 in mm
Figure 3.2: Dimensions of S200-M4C1-M12 in mm (M12 plug dimensions) The deflection head ca n be turne d in 90° inc rement s and set to 5 app roach direc -
tions. A selection of different actuators ensures that the Safety Switch can be mounted in any position.
12 S200 Leuze electronic
Figure 3.3: Approach directions
Device description
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Functions

4 Functions

The Safety Switch signals to the safety switching device whether the protective device is closed. Moving the actuator in closes the safety contacts; moving the actuator out forces the safety conta cts to open (e.g . upon opening o f the protective device). As a result, the machine can only be switched on if the protective device is closed.
14 S200 Leuze electronic

5 Applications

The Safety Switch can be used for e.g. the following protective devices:
• turning or swiveling moveable guards
• laterally moveable protective gratings or sliding gates
• heavy doors or rolling gates
Applications
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Mounting

6 Mounting

WARNING
Severe accidents may result if the Safety Switch is not mounted properly!
The protective function of the Safety Switch is only ensured if appropriately and professionally mounted for the respective, intended area of application.
ª Mounting may only be performed by competent personnel. ª Observe standards, regulations and these instructions. ª Protect the housing and deflection head from material s penetrating th e enclo-
sure (environmental conditions (see chapter 14)).
ª Test to ensure proper function.

6.1 Adjusting the deflection head

ª Loosen the 2 screws on the deflection head.
16 S200 Leuze electronic
ª Lift the deflection head and turn in the desired approach direction.
ª Tighten the 2 screws on the deflection head with 0.8–1.2 Nm. ª Close unused opening with the dust cover.

6.2 Mounting the Safety Switch

Prerequisites for mounting:
• deflection head has been set
• fully assembled
ª Select the mounting location so that the following conditions are satisfied:
• Safety Switch and actuator can be well matched to one another mechani­cally and can be permanently mounted
• accessible to qualified personnel for testing and replacement
• difficult to access by operating personnel while the protective device is open
Mounting
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Mounting
ª Position washers and screw down Safety Switch with 2–3 Nm.

6.3 Mounting the actuator

NOTICE
The Safety Switch may be damaged if mounted improperly!
ª Use separate mechanical limit stop for the moving part of the protective
device.
ª Align actuator so that it does not hit or rub against the edges of the inse rtio n
opening.
Prerequisites for proper functio n:
• actuator is not deformed or damaged
• actuator is suitable for the Safety Switch Proper function is ensured only with original accessories (see chapter 13).
18 S200 Leuze electronic
Wrong Correct
0,5 ... 5 mm
ª Align actuator.
Play for the actuator in the closed state: 0.5–5 mm.
Mounting
ª Secure actu ator with rivets or tamperproof screws so that it cannot be
detached.
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Electrical connection
222112
11
222112
11
222114
13
222114
13

7 Electrical connection

WARNING
Serious accidents may result if the electrical connection is faulty!
ª Electrical connection may only be performed by competent personnel.

7.1 Connecting the contact bloc k

DANGER
Risk of death by electric shock!
ª Interrupt the voltage supply to the Safety Switch.
Prerequisites for the electrical connection:
• temperature stability of the cable insulation material must be greater than the maximum temperature of the housing (see chapter 14)
• cable gland with appropriate protection rating
• maximum current load is observed (see chapter 14)
Figure 7.1: Contact block 2NC (S200-M3C1-M20)
Figure 7.2: Contact block 1NC + 1NO (S200-M1C1-M20)
20 S200 Leuze electronic
Electrical connection
222112
11
222112
11
34
33
34
33
3
4
5
6
7
8
1
1
7
6
5
4
3
2
8
Figure 7.3: Contact block 2NC + 1NO (S200-M4C1-M20, S200-M4C1-M12)
Figure 7.4: Pin assignment of the 8-pin M12 plug (S200-xxx-M12-xxx)
ª Unscrew the housing cover. ª Connect the contact block according to the appli cation-spec ific circu it diagram .
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Electrical connection
Var. B
Var. A
-K3
-K4
14 24 42
13 23 41
-K4-K3
1
2
0V 0V PE PE
L+
-S1
-K3
-K4
+24V
0V
MSI-SR4
A1
-A2
A2
S22 S12 S31 S33 S34 S35
2 AOPD-
1 AOPD+
33
34
2 AOPD+
IV-0
RES-0
RES-I
x1
x2
L-
S200-M3C1-M20
1
2
1
2
L+ L+
1
2
+24V +24V
A1
A2
-K3
L- L-
A1
A2
-K4
*
*
1
2
1
2
211211 22
* Spark extinction circuit, suitable spark extinction provided
Figure 7.5: Connection example S200-M3C1-M20 ª Tighten cable terminal screws with 0.6–0.8 Nm.
22 S200 Leuze electronic
ª Tighten the housing cover with 0.8–1.2 Nm.
Electrical connection
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Setting the device into service

8 Setting the device into service

Prerequisites:
• Safety Switch is mounted and connected according to these instructions
• operating personnel have been trained in the correct use
ª Test the function of the Safety Switch (see chapter 9). The Safety Switch is then ready for use.
24 S200 Leuze electronic
Testing

9 Testing

S200 Safety Switches are maintenance-free. Nevertheless, they must be replaced after maximum 1,000,000
ª Always replace the entire Safety Switch including actuator. ª For the testing intervals, observe nationally applicable regulations. ª Document all tests in a comprehensible manner.

9.1 To be performed prior to the initial start-up by competent personnel

ª Check whether the Safety Switch is operated according to its spe cified environ-
mental conditions (see chapter 14).
ª Test to ensure proper mechanical and electrical function (see chapter 9.2).

9.2 To be performed periodically by competent personnel

Mechanical function
ª Stop the dangerous state and open the protective device. ª Check that the components are securely fastened. ª Test the cable entry for leaks. ª Check Safety Switch and actuator for damage, deposits, deformation and
wear.
ª Test several times whether the actuator can be easily moved into the Safety
Switch.
switching cycles.
Electrical function
WARNING
Severe accidents may result if tests are not performed properly!
ª Make certain that there are no persons in the danger zone.
ª Stop the dangerous state and open the protective device. ª Make certain that the machine cannot be st arted whi le the pr otecti ve dev ice is
open.
ª Close the protective device and start the machine. ª Test several times whether the machine stops upon opening of the protective
device.
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Testing
ª Test whether the dangerous state ends before the point of operation can be
reached.

9.3 To be performed daily by the operating personnel

WARNING
Severe accidents may result if tests are not performed properly!
ª Make certain that there are no persons in the danger zone.
ª Stop the dangerous state and open the protective device. ª Check the Safety Switch and actuator for damage or tampering. ª Make certain that the machine cannot be st arted whi le the pr otecti ve dev ice is
open.
ª Close the protective device and start the machine. ª Test whether the machine stops upon opening of the protective device.
26 S200 Leuze electronic

10 Cleaning

There must be no soilin g (e.g. shavings a nd dust) present, espe cially in the deflec ­tion head of the Safety Switch.
Prerequisites for cleaning:
• protective device is opened and machine is switched off
• voltage supply to the Safety Switch is interrupted
ª Periodically clean the Safety Switch while the prot ective devic e is opened (e.g.
with vacuum cleaner).
Cleaning
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Disposing

11 Disposing

ª The nationally valid regulations for electro-mechanical components are to be
observed when disposing.
28 S200 Leuze electronic

12 Service and support

Telephone number for 24-hour standby service: +49 (0) 7021/ 573-0
Service hotline: +49 (0) 8141/ 5350-111 Monday to Thursday, 8.00 a.m. to 5.00 p.m. (UTC+1) Friday, 8.00 a.m. to 16.00 p.m. (UTC +1)
E-mail: service.protect@leuze.de Return address for repairs: Service Center Leuze electronic GmbH + Co. KG In der Braike 1 D-73277 Owen - Teck / Germany
Leuze electronic offers a regular safety inspection by a competent person.
Service and support
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Accessories

13 Accessories

Table 13.1: Actuators of the AC-AH series for the S200 Safety Switch
Article Part No. Description
AC-AH-S 63000720 Straight AC-AH-A 63000721 Angled AC-AH-F4 63000722 Straight, flexible, 4 directions AC-AH-F2J2 63000723 Straight, flexible, 2 directions, alignable 2 direc-
AC-AH-F1J2 63000724 Straight, flexible, 1 direction, alignable 2 directions AC-AH-F4J2-TK 63000725 Straight, flexible, 4 directions, alignable 2 direc-
tions
tions, rotatable head
Table 13.2: Accessories for the S200 Safety Switch
Article Part No. Description
AC-A-M20-12NPT 63000843 Adapter, M20 x 1.5 on 1/2 NPT AC-PLM-8 63000845 Built-in plug, M12, metal, with internal 8-pin con-
AC-KL-AH 63000846 Actuator interlock, for locking the actuator intro-
CB-M12-5000E-5GF 678055 PUR, 5-pin, 5 m, shielded, M12 coupling, straight,
CB-M12-10000E-5GF 678056 PUR, 5-pin, 10 m, shielded, M12 coupling,
CB-M12-15000E-5GF 678057 PUR, 5-pin, 15 m, shielded, M12 coupling,
CB-M12-25000E-5GF 678058 PUR, 5-pin, 25 m, shielded, M12 coupling,
nection cable
duction
prefabricated on one end
straight, prefabricated on one end
straight, prefabricated on one end
straight, prefabricated on one end
CB-M12-5000E-8GF 678060 PUR, 8-pin, 5 m, shielded, M12 coupling, straight,
30 S200 Leuze electronic
prefabricated on one end
Accessories
32
15
30
26 15.3
R>300
R>500
R>500
Ø 5.5
6
15
10
16.2
2.5
Article Part No. Description
CB-M12-10000E-8GF 678061 PUR, 8-pin, 10 m, shielded, M12 coupling,
CB-M12-15000E-8GF 678062 PUR, 8-pin, 15 m, shielded, M12 coupling,
straight, prefabricated on one end
straight, prefabricated on one end
CB-M12-25000E-8GF 678063 PUR, 8-pin, 25 m, shielded, M12 coupling,
straight, prefabricated on one end

13.1 Accessory dimensional drawings

15
6152226
Figure 13.1: AC-AH-S actuator
5.5
R>300
10
30
16.2
32
R>500
2.5
R>500
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Figure 13.2: AC-AH-A actuator
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Accessories
32
30
13
20
11
4.5
16
2426
R>300
R>500
R>500
2.5
16.2
7
4.2
32
13
20
7
4.5
30
12°
12°
20
22
26
11
R>100
R>100
R>100
2.5
7
16.2
4
Figure 13.3: AC-AH-F4 actuator
Figure 13.4: AC-AH-F2J2 actuator
32 S200 Leuze electronic
1126
R
80
12°
12°
12°
12°
R
80
R 80
2.5
20
4.8
Ø 4.2
6.5
28
12°
12°
8.5
39
5.2
1310.826
16.2
30
16.2
11°
5.2
16
Figure 13.5: AC-AH-F1J2 actuator
R>100
5.5
40 56
37
8.6
2.4
32
Accessories
R>500
2.5
R>500
Figure 13.6: AC-AH-F4J2-TK actuator
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Technical data

14 Technical data

Table 14.1: General
Switch type Interlock device without guard interlocking
Actuator, external AC-AH series: straight, angled, resilient,
Approach actuation directions 1 x above, 4 x side (90°) Approach speed min. 1 mm/s, max. 0.5 m/s Actuation force (pull-out) 10 N Actuating path with forced separation S200-M1C1-M20: min. 8.6 mm
Mechanical life time according to IEC 60947-5-1
Actuation frequency according to IEC 60947-5-1
Service life (T EN ISO 13849-1
Number of cycles before dangerous failure (B10d) according to EN 61810-2
) in accordance with
M
in accordance with EN 1088
alignable
S200-M3C1-M20: min. 10.2 mm S200-M4C1-M20: min. 8.8 mm S200-M4C1-M12: min. 8.8 mm
1,000,000 switching cycles
max. 3600 per hour
20 years
2,000,000
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Technical data
Usage category in accordance with EN 60947-5-1 with screw terminal connection
Maximum load when using 5-pin cables: Maximum load when using 8-pin cables:
Usage category in accordance with EN 60947-5-1 with M12 plug connection
Dimensions (dimensional drawings) see chapter 3
AC 15 (Ue / Ie): 250 V / 6 A 400 V / 4 A 500 V / 1 A
DC 13 (Ue / Ie): 24 V / 6 A 125 V / 1.1 A 250 V / 0.4 A
24 V / 4 A(see chapter 13) 24 V / 2 A(see chapter 13)
AC 15: (Ue / Ie) 24 V / 2 A
DC 13: (Ue / Ie) 24 V / 2 A
Table 14.2: Safety
Protection rating IP 67 Contact protection grounding Recoil tolerance 5 mm Contact allocation S200-M1xxx: 1NC + 1NO
Contact material silver alloy Switching principle slow-action contact Opening of contact positive-forced Rated insulation voltage with screw terminal
connection Rated insulation voltage with M12 plug con-
nection Conventional thermal current with screw ter-
minal connection
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S200-M3xxx: 2NC S200-M4xxx: 2NC + 1NO
400 V AC, 600 V DC
30 V AC, 36 V DC
max. 10 A
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Technical data
Conventional thermal current with M12 plug connection
Short circuit protection in accordance with IEC 60269-1 with screw terminal connection
Short circuit protection in accordance with IEC 60269-1 with M12 plug connection
max. 2 A
10 A, 500 V , type aM
2 A, 500 V , type gG
Table 14.3: Housing
Housing material metal
Table 14.4: Connection
Number of cable entries 1 Type of cable entry M20 x 1.5 Conductor cross-section (stranded) with
screw terminal connection
1 x 0.5 mm
Table 14.5: Environment
Temperature range, operation –25 ... +80 °C Dirt levels, external, in accordance with
EN 60947-1
3
2
to 2 x 2.5 mm
2
These tables do not apply in comb ination w ith additio nal M12 plug or con necting cable except where these components are explicitly mentioned.
36 S200 Leuze electronic

15 EC Declaration of Conformity

EC Declaration of Conformity
You can download this EC Declaration of Conformity as a PDF from: http://www.leuze.com/s200/
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