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AES 1145
Operating Instruction
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schmersal AES 1135, AES 1136, AES 1145, AES 1146 Operating Instruction

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AES 1135 / 1136 AES 1145 / 1146
Operating instructions Safety-monitoring module
EN
1
1. About this document
1.1 Function
1.2 Target group: authorised qualified personnel
All operations described in this operating instructions manual must be carried out by trained specialist personnel, authorised by the plant operator only.
Please make sure that you have read and understood these operating instructions and that you know all applicable legislations regarding occupational safety and accident prevention prior to installation and putting the component into operation.
The machine builder must carefully select the harmonised standards to be complied with as well as other technical specifications for the selection, mounting and integration of the components.
1.3 Explanation of the symbols used
Information, hint, note:
This symbol is used for identifying useful additional information.
Caution:Failure to comply with this warning notice could lead to failures or malfunctions. Warning:Failure to comply with this warning notice could lead to physical injury and/or damage to the machine.
1.4 Appropriate use
The products described in these operating instructions are developed to execute safety-related functions as part of an entire plant or machine. It is the responsibility of the manufacturer of a machine or plant to ensure the correct functionality of the entire machinery or plant.
The safety-monitoring module must be exclusively used in accordance with the versions listed below or for the applications authorised by the manufacturer. Detailed information regarding the range of applications can be found in the chapter "Product description".
1.5 General safety instructions
The user must observe the safety instructions in this operating instruc­tions manual, the country-specific installation standards as well as all prevailing safety regulations and accident prevention rules.
Further technical information can be found in the Schmersal catalogues or in the online catalogue on the Internet: www.schmersal.net.
The information contained in this operating instructions manual is provided without liability and is subject to technical modifications.
The entire concept of the control system, in which the safety component is integrated, must be validated to EN ISO 13849-2.
There are no residual risks, provided that the safety instructions as well as the instructions regarding mounting, commissioning, operation and maintenance are observed.
Content
1 About this document
1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Target group: authorised qualied personnel. . . . . . . . . . . . . . . . . .1
1.3 Explanation of the symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.4 Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.5 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.6 Warning about misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.7 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Product description
2.1 Ordering code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.2 Special versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Destination and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.5 Safety classication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
3 Mounting
3.1 General mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
3.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
4 Electrical connection
4.1 General information for electrical connection. . . . . . . . . . . . . . . . . . 3
5 Operating principle and settings
5.1 Operating principle after the operating voltage is switched on . . . .3
6 Set-up and maintenance
6.1 Functional testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
6.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
7 Disassembly and disposal
7.1 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
8 Appendix
8.1 Wiring examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
8.2 Integral System Diagnostics (ISD) . . . . . . . . . . . . . . . . . . . . . . . . . .4
9 Declaration of conformity
9.1 EC Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
x.000 / v.A. / 12.20 11 / BZ-N r. 5013 7-17V900 / Teile -Nr. 1172884-EN / Ausgab e E
EN
Operating instructions. . . . . . . . . . . . .pages 1 to 6
Translation of the original operating instructions
2
Operating instructions Safety-monitoring module
AES 1135 / 1136 AES 1145 / 1146
EN
1.6 Warning about misuse
In case of inadequate or improper use or manipulations of the safety-monitoring module, personal hazards or damages to machinery or plant components cannot be excluded. The relevant requirements of the standard EN 1088 must be observed.
1.7 Exclusion of liability
We shall accept no liability for damages and malfunctions resulting from defective mounting or failure to comply with this operating instructions manual. The manufacturer shall accept no liability for damages result­ing from the use of unauthorised spare parts or accessories.
For safety reasons, invasive work on the device as well as arbitrary re­pairs, conversions and modifications to the device are strictly forbidden; the manufacturer shall accept no liability for damages resulting from such invasive work, arbitrary repairs, conversions and/or modifications to the device.
2. Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
AES 113
➀
No. Option Description
➀
5 without start-up test 6 with start-up test
AES 114
➀
No. Option Description
➀
5 without start-up test 6 with start-up test
Only if the information described in this operating instruc­tions manual are realised correctly, the safety function and therefore the compliance with the Machinery Directive is maintained.
2.2 Special versions
For special versions, which are not listed in the order code below 2.1, these specifications apply accordingly, provided that they correspond to the standard version.
2.3 Destination and use
The safety-monitoring modules for integration in safety circuits are designed for fitting in control cabinets. They are used for the safe evaluation of the signals of positive break position switches for safety functions or magnetic safety sensors on sliding, hinged and removable safety guards as well as emergency stop control devices.
Design
The safety-monitoring modules have a dual-channel structure. They include two safety relays with monitored positive action contacts. The NO contacts of the relays, which are wired in series, build the enabling contacts.
2.4 Technical data
Standards: EN 60204-1; EN 60947-5-3;
EN ISO 13849-1; IEC 61508;
BG-GS-ET-14; BG-GS-ET-20
Start conditions: Automatic Feedback circuit available: no Start-up test: AES ...5: no; AES ...6: yes Pull-in delay for automatic start: adjustable 0.1 / 1.0 second Drop-out delay in case of emergency stop: < 50 ms Rated operating voltage Ue: 24 VDC Rated operating current Ie: 0.2 A Rated insulation voltage Ui: 250 V Rated impulse withstand voltage U
imp
: 4 kV
Thermal test current I
the
: 6 A Internal electronic fuse: no Power consumption: < 5 W
Inputs monitoring:
Cross-wire short detection: yes Wire breakage detection: yes Earth connection detection: yes Number of NC contacts: convertible 1NC → 2NC Number of NO contacts: convertible 1NO → 0NO
Outputs:
Stop category 0: 1 Stop category 1: 0 Number of safety contacts: 1 Number of auxiliary contacts: 0 Number of signalling outputs: 2 Switching capacity of the safety contacts: max. 6 A Switching capacity of the signalling outputs: Y1, Y2 = 100 mA Utilisation category to EN 60947-5-1: AC-15: 230 V / 3 A
DC-13: 24 V / 2 A
Max. fuse rating of the safety contacts: 6 A gG D-fuse Fuse rating of the signalling outputs:
- AES 1135/1136: short-circuit proof;
- AES 1145/1146: short-circuit proof, p-type Mechanical life: 20 million operations LED display: ISD
Ambient conditions:
Operating temperature: 0 °C ... +55 °C Storage and transport temperature: −25 °C ... +70 °C Protection class: Enclosure: IP40
Terminals: IP20
Clearance: IP54
Degree of pollution: 2 Mounting: Snaps onto standard DIN rail to EN 60715 Connection type: Screw connection Min. cable section: 0.25 mm² Max. Cable section: 2.5 mm², solid strand or multi-strand
lead (including conductor ferrules)
Tightening torque: 0,6 Nm Max. cable length: 1000 m of 0.75 mm² conductor Weight: 190 g Dimensions (H x W x D): 100 x 22.5 x 121 mm
2.5 Safety classification
Standards: EN ISO 13849-1; IEC 61508 PL: up to d Control category: up to 3 PFH-value: 1.0 x 10-7 / h; Applicable for applications with up
to max. 50,000 switching cycles / year and
max. 80 % contact load. Diverging
applications upon request.
SIL: up to 2 Service life: 20 years
3
AES 1135 / 1136 AES 1145 / 1146
Operating instructions Safety-monitoring module
EN
3. Mounting
3.1 General mounting instructions
Mounting: snaps onto standard DIN rails to EN 60715.
3.2 Dimensions
Device dimensions (H/W/D): 100 x 22.5 x 121 mm
4. Electrical connection
4.1 General information for electrical connection
The electrical connection may only be carried out by authorised personnel in a de-energised condition.
Wiring examples: see appendix
To avoid EMC disturbances, the physical ambient and operational conditions at the place where the product is installed, must meet the provisions laid down in the paragraph "Electromagnetic Compatibility (EMC)" of DIN EN 60204-1.
5. Operating principle and settings
5.1 Operating principle after the operating voltage is switched on Without start-up test AES 1135 / AES 1145:
1. The functionality of the safety-monitoring module is tested.
2. If the safety guard is closed or the emergency stop button released, the enabling paths of the safety-monitoring module will close. The LED is green.
3. The cable and the connected safety switch are only tested when the safety guard is opened or the emergency stop button when actuated
With start-up test AES 1136 / AES 1146:
1. The functionality of the safety-monitoring module is tested.
2. The safety guard or the emergency stop button must be actuated, in order to check the cables and the connected safety switch (start-up test).
3. If the safety guard is closed or the emergency stop button released, the enabling paths of the safety-monitoring module will close. The LED is green.
If the safety guard is opened or the emergency-stop button is actuated, the enabling paths of the safety-monitoring module will open. The machine is stopped and the LED flashes yellow.
Inputs: S14/S22
Connect a safety switch with one NC and one NO contact or two safety switches with one contact each or an emergency-stop button at input S14/S22.
Safety switch with two NC contacts: X1
For an operation with two NC contacts, input X1 must be supplied with 24 VDC.
Outputs
Enabling paths 13-14: NO contacts for safety functions
Additional outputs Y1/Y2:
AES 1135/1136 Y1: Authorized operation (release output closed)
Y2: No authorized operation (release output opened)
AES 1145/1146 Y1: Safety guard opened (release output opened)
Y2: Failure (release output opened)
The additional outputs Y1 and Y2 must not be integrated in the safety circuit; they may only be used for signalling purposes.
Enable delay time
The enable delay time can be increased from 0.1 s to 1 s by changing the position of a jumper link connection. Remove the enclosure cover carefully by means of a screwdriver. Change the position of the jumper link connection B1.
Jumper link connection closed = 1 s
6. Set-up and maintenance
6.1 Functional testing
The safety function of the safety-monitoring module must be tested. The following conditions must be previously checked and met:
1. Correct fitting of the safety-monitoring module
2. Fitting and integrity of the power cable
6.2 Maintenance
In the case of correct installation and adequate use, the safety­monitoring module features maintenance-free functionality. We recommend a regular visual inspection and functional test, including the following steps:
• Check the correct fixing of the safety monitoring module
• Check the cable for damage.
Damaged or defective components must be replaced.
7. Disassembly and disposal
7.1 Disassembly
The safety monitoring module must be disassembled in the de­energised condition only.
7.2 Disposal
The safety monitoring module must be disposed of in an appropriate manner in accordance with the national prescriptions and legislations.
4
Operating instructions Safety-monitoring module
AES 1135 / 1136 AES 1145 / 1146
EN
8. Appendix
8.1 Wiring examples
The application examples shown are suggestions. They however do not release the user from carefully checking whether the switchgear and its set-up are suitable for the individual application.
The wiring example refers to a closed safety guard and a voltage-free state. Inductive loads (e.g. contactors, relays, etc.) are to be provided with suitable interference suppression circuitry. Do not connect ad­ditional loads to terminal S..
AES 1135/1136
L1
A1
100mA
S13
K1
K3
14
A2
max.
Y1 Y2 X1
K4
3
K2
S14 S21
S22
13
+24 VDC
0 V
N
M
A1
A2
A
A
AES 1145/1146
A
AES 1145/1146
AES 1135/1136
L1
A1
100mA
S13
K1
K3
14
A2
max.
Y1 Y2 X1
K4
3
K2
S14 S21
S22
13
+24 VDC
0 V
N
M
A1
A2
Legend
A
Positive break A S Non-contact safety sensor A Safety switch
8.2 Integral System Diagnostics (ISD)
The safety monitoring modules LED display to show the different switching conditions and faults. The following tables show the different switching conditions.
Tables switching condition indication
Diagnostic LED System condition
The LED is green. Enabling paths closed LED flashes yellow (0.5 Hz)
Enabling paths open
LED flashes yellow (2 Hz)
Safety guard closed, however no release; possible causes: incorrect operation (only one contact actuated upon opening) or voltage drop → perform start-up test
In case of error messages, the LED lights orange intermittently. During these intermissions, the LED flashes one up to seven times with short pulses.
Table error indications
Indication (orange) LED
Error Cause
1 impulse
Inputs S1 Defective supply
voltage lead, defective switch, erroneous fitting of the switch; switch only partially ac­tuated* for at least 5 s
4 impulses
Interference signals at the inputs (no safe evaluation as­sured)
Too high capacitive or inductive interference at the switch's cables or the supply voltage lead
5 impulses One or both relays
did not close within the monitoring time
Too low operating voltage Ue; defective relay
6 impulses
Relay not disabled upon the actuation of the switch
May be due to contact welding
7 impulses Dynamic monitoring
of both channels (cross-monitoring) failure
Fault in one channel; internal data transmis­sion interrupted
* Partial actuation: position of the switch, in which only one contact was actuated.
Deleting the error message
The fault message is deleted once the fault has been rectified and after the connected switch has been actuated to check the various functions.
5
AES 1135 / 1136 AES 1145 / 1146
Operating instructions Safety-monitoring module
EN
AES 1135-C-EN
9. Declaration of conformity
The currently valid declaration of conformity can be downloaded from the internet at www.schmersal.net.
9.1 EC Declaration of conformity
Name of the safety component: AES 1135 / AES 1136 /
AES 1145 / AES 1146
Description of the safety component: Safety-monitoring module for non-contact
safety switches and safety relay combination in connection with the BNS series magnetic safety switches
Harmonised EC-Directives: 2006/42/EC-EC-Machinery Directive
2004/108/EC EMC-Directive
Person authorized for the compilation of the technical documentation:
Ulrich Loss Möddinghofe 30 42279 Wuppertal
Notied body, which approved the full quality assurance system, referred to in Appendix X, 2006/42/EC:
TÜV Rheinland Industrie Service GmbH Alboinstraße 56 12103 Berlin ID n°: 0035
Place and date of issue: Wuppertal, October 7, 2009
Authorised signature
Heinz Schmersal
Managing Director
EC Declaration of conformity
Translation of the original declaration of conformity
valid as of December 29, 2009
K.A. Schmersal GmbH Industrielle Sicherheitsschaltsysteme Möddinghofe 30, 42279 Wuppertal Germany Internet: www.schmersal.com
We hereby certify that the hereafter described safety components both in its basic design and construction conform to the applicable European Directives.
K. A. Schmersal GmbH Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, D - 42279 Wuppertal Postfach 24 02 63, D - 42232 Wuppertal
Phone: +49 - (0)2 02 - 64 74 - 0 Telefax +49 - (0)2 02 - 64 74 - 1 00 E-Mail: info@schmersal.com Internet: http://www.schmersal.com
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