Leuze electronic ERS200-M4C1-M20-HLR, ERS200 Series, ERS200-M1C3-M20-HLR, ERS200-M4C3-M20-HLR, ERS200-M4C1-M12-HLR Operating Instructions Manual

ERS200

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Safety Command Devices

Original operating instructions

EN 2011/07 - 607330

We reserve the right to

make technical changes

1 About this document................................ ..... ........................................ ..... .......... 5

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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 Fores eeable misuse..................... ...................................... .................. ................... .. .................. 10

2.2 Competent personnel ........................................................ .. .. .. .... .. .. ....... .. .. .... .. .. .. ....... .. .. ...10

2.3 Responsibility for safe ty............... ............... ........................................................................10

2.4 Exemption of liability....................................... ............... .......................................... ...........11

3 Device description ............................................................................................. 12

4 Functions........................................................................................................... 17

5 Applications .......................................................................................................18

6 Mounting............................................................................................................19

6.1 Setting the actuator head ...................................................................................................23

6.2 Mounting the E-STOP Rope Switch...................................................................................24

6.3 Mounting the rope.................. .............. ............................ .............. ............................ .........25

7 Electrical connection........................................... ..... ...... ...... ..............................30

7.1 Connecting the contact block .............................................................................................30

8 Setting the device into service...........................................................................33

9 Testing...............................................................................................................34

9.1 To be performed prior to the initial start-up by competent personnel.................................34

9.2 To be performed periodically by competent personnel.......................................................34

9.3 To be performed daily by the operating personnel.............................................................35

10 Cleaning.............................................................................................................36

11 Disposing...........................................................................................................37

12 Service and support....................................................... ....................................38

13 Accessories .......................................................................................................39

14 Technical data ...................................................................................................41

15 EC Declaration of Conformity ............................................................................44

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4 ERS200 Leuze electronic

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1 About this document

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1.1 Other applicable documents

The information on the ERS200 E-Stop Rope Switch is divided into two docu­ments. Document "ERS200 Application information" contains only the most
important safety notices.

ª For the safe implementation, testing and operation, download document

ERS200 Safe implementation and operation from Lueze website.

Table 1.1: Documents on the ERS200 E-Stop Rope Switch

Purpose and target group Title Source

Detailed information for all users ERS200 Safe imple-

mentation and opera­tion

About this document

On the Internet, download
from Leuze website.

Basic information for technicians
and operating company

Leuze electronic ERS200 5

ERS200 Application
information

Print document part
no. 607248 included in the
delivery contents of the product

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About this document

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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 ERS200 Leuze electronic

2 Safety

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Before using the E-Stop Rope Switch, a risk evaluation must be performed
according to valid standards (e.g. EN ISO 12100-1, EN ISO 13849-1,
EN ISO 14121). For mounting, operating and testing, document ERS200 Safe
implementation and operation, application information as well as all applicable
national and international standards, regulations, rules and directives must be
observed. Observe and print out relevant and supplied documents and distribute
to the affected personnel.

The following sta nda rds a pply for the risk e valua tion at the protectiv e d ev ice prior
to using the E-Stop Rope 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 the integration in control circuits according to
EN ISO 13849-1 is dependent on the used contact block and wiring.

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

For safety-related information you may also contact the local authorities (e.g.,
industrial inspectorate, employer's liability insurance association, labor inspec­torate, occupational safety and health authority).

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Safety

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2.1 Approved purpose and foreseeable improper operation

2.1.1 Proper use

• The E-Stop Rope 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 occupational
safety, and after it has been installed on the machine, connected, commis­sioned, and checked by a competent person.

• When selecting the E-Stop Rope Switch it must be ensured that its safety­related capability meets or exceeds the required performance 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 E-Stop Rope Switch that is connected to the moveable guard in a non­detachable and tamperproof manner.

WARNING

A running machine can cause severe injuries!

ª Make certain that, du ring all conversi ons, maintenan ce work and inspec tions,

the system is securely shut down and protected against being restarted
again.

WARNING

Severe accidents may result if an E-Stop command device is not used
properly!

ª Do not use as a replacement for other protective devices.
ª Investigate the cause of each release of an E-Stop Rope Switch along the

entire length of the rope.

An E-Stop Rope Switch is a supplementary protective measure f or shutting down
in the event of an emergency and must not be used as a replacement for other
protective devices.

ERS200 E-Stop Rope Switches are actua ted via a rope. They mu st be connected
so that the switching function is actuated by moving the rope in any direction and
the dangerous state is stopped immediately.

8 ERS200 Leuze electronic

Safety

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Connection conditions:

• rope is easily accessible

• E-Stop is possible at any time while the machine is running

• dangerous state is ended immediately, taking into consideration the appro­priate Stop category

• danger zone and occupied area along the entire length of the rope are visi­ble from the E-Stop Rope Switch

• start commands that result in dangerous states are only possible if the
Reset button is manually unlocked

• can be easily accessed by qualified personnel for testing and replacement

Furthermore, the ERS200 E-Stop Rope Switch must not be used under the
following conditions:

• rapidly changing ambient temperature (leads to condensation)

• in the event of strong physical shoc ks

• in explosive or easily flammable atmospheres

• the mounting locations for E-Stop Rope Switches, stud bolts and deflection
rollers are sufficiently stable

• 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)

Handling the E-Stop Rope S witch:

ª Observe mounting conditions (see chapter 6).
ª The maximum permissible rope length must no t be exceeded.
ª Observe the permissible environmental conditions for storage and operation

(see chapter 14).

ª Immediately replace damaged E-Stop Rope Switches according to these

instructions.

ª Use cable gland, insulation materials and connecting wires of the appropriate

protection rating.

ª Protect E-Stop Rope Switches from strong physical shocks and vibrations.
ª Protect E-Stop Rope Switc hes from pe netrati ng forei gn bod ies (e.g . shavin gs,

sand and blasting agent).

ª Before performing painting work, cover all moving parts, indicators and the

name plate.

ª Immediately clean any contaminatio n from the E-Stop Rope Switc h and deflec -

tion rollers that impacts the function according to these instructions.

ª Use only suitable original accessories (see chapter 13).

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Safety

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ª Make no structural changes to the E-Stop Rope Swit ch.
ª The E-Stop Rope Switch must be exchanged after a maximum of 20 years.

2.1.2 Foreseeable misuse

Any use other than that defined under the "approved purpose" or which goes
beyond that use of the E-Stop Rope 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

2.2 Competent personnel

Prerequisites for competent personnel:

• suitable technical training

• knows the rules and regulations for occupa tional safety, safety at work and
safety technology and can assess the safety of the machine

• knows the instructions for the E-Stop command device and the machine

• has been instructed by the responsible individuals on the mounting and
operation of the machine and of the E-Stop command device

2.3 Responsibility for safety

Manufacturer and operating company must ensure that the machine and imple­mented E-Stop Rope 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 E-Stop command device

• imparting all relevant information to the operating company

• adhering to all regulations and directives for the safe starting-up of the
machine

10 ERS200 Leuze electronic

The operating company is responsible for:

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• instructing the operating personnel

• maintaining the safe operation of the machine

• adhering to all regulations and directives for occupational safety 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:

• E-Stop Rope 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

Safety

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Device description

1

2

3

4

5
6

1

2

3

4

6

5

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3 Device description

The E-Stop Rope Switch of the ERS200 series is an E-Stop command device in
accordance with E N 60947-5 a nd satisfies protection rating IP 67. The hou si ng is
made of metal, and the actuator head is made of glass-fiber-reinforced, non­combustible plastic or metal. An adjustment indicator aids in correctly setting the
rope tension. The act uator head, which can b e tu rned in 90 ° in crements, ensures
that the Reset button— the p osi tio n of w hi ch is li ke w is e dis pl ay ed by me ans of an
indicator—is easily accessible. With deflection rollers, the course of the rope can
be adjusted to many dang er z one s. Various contact sets, hous ing siz es and rope
exit directions fulfill the most diverse requirements.

12 ERS200 Leuze electronic

1 Actuator head
2 Adjustment indicator
3 Fastening for rope
4 Reset button
5 Housing cover
6 Name plate (connection data, production code and year of manufacture)

Device description

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Table 3.1: ERS200 E-Stop Rope Switch

Article Part No. Description

ERS200-M0C3-M20-HLR 63000500 1NC + 1NO, 3 cable entries, exit lengthwise
ERS200-M1C3-M20-HLR 63000501 2NC, 3 cable entries, exit lengthwise
ERS200-M4C3-M20-HLR 63000502 2NC+1NO, 3 cable entries, exit lengthwise
ERS200-M4C1-M20-HLR 63000503 2NC+1NO, 1 cable entry, exit lengthwise
ERS200-M4C1-M12-HLR 63000504 2NC+1NO, 1 cable entry, exit lengthwise, M12 plug
ERS200-M4C3-M20-HAR 63000520 2NC+1NO, 3 cable entries, exit to the right
ERS200-M0C3-M20-HAR 63000522 2NC+1NO, 3 cable entries, exit to the right
ERS200-M1C1-M20-HAR 63000523 2NC, 1 cable entry, exit to the right
ERS200-M4C3-M20-HAL 63000521 2NC+1NO, 3 cable entries, exit to the left
ERS200-M0C3-M20-HAL 63000524 1NC+1NO, 3 cable entries, exit to the left
ERS200-M1C1-M20-HAL 63000525 2NC, 1 cable entry, exit to the left

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Device description

E

E

T

R

S

P

U

L

L

T

O

28

28

56

57

18

40

33

72

129

6

14.5

14.5

19.5

5.2x6.2

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Figure 3.1: Dimensions ERS-MxC3x-HLR in mm

84

20

32

22

E

T

S

E

R

O

T

P

U

L

L

5.2x6.2

89

40

57

18

56

47.8

14.5

6

14.5
33

Figure 3.2: Dimensions ERS200-MxC3x-HAR in mm

14 ERS200 Leuze electronic