Operating instructions
Safety-monitoring module
EN
Operating instructions...................... pages 1 to 6
Translation of the original operating instructions
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AES 2155/2156
AES 2165/2166
1 About this document
1.1 Function
This operating instructions manual provides all the information you need
for the mounting, set-up and commissioning for the safe operation and
disassembly of the safety-monitoring module. The operating instructions
must be available in a legible condition and a complete version in the
vicinity of the device.
1.2 Target group: authorised qualied 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 specications 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.
Content
1 About this document
1.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.2 Target group: authorised qualied 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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 classication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
8.2 Integral System Diagnostics (ISD) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
8.3 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
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 proper 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 instruc-
tions manual, the country-specic 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 modications.
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.
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 rele-
vant requirements of the standard EN 1088 must be observed.
x.000 / v.A. / 02.2010 / BZ-Nr. 50109-11.01 / Teile-Nr. 1123387-EN / Ausgabe D
EN
1
Operating instructions
Safety-monitoring module
AES 2155/2156
AES 2165/2166
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 modications to the device are strictly forbidden; the
manufacturer shall accept no liability for damages resulting from such
invasive work, arbitrary repairs, conversions and/or modications to the
device.
2 Product description
2.1 Ordering code
This operating instructions manual applies to the following types:
AES 215➀
➁
No. Option Description
5 without start-up test
➀
6 with start-up test
.1 110 VAC
➁
.2 230 VAC
.3 24 VAC
AES 216➀
➁
No. Option Description
5 without start-up test
➀
6 with start-up test
.1 110 VAC
➁
.2 230 VAC
.3 24 VAC
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 specications 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 tting 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: IEC/EN 60204-1; EN 60947-5-1;
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: < 50 ms
Rated operating voltage U
: 110 VAC
e
230 VAC
24 VAC
Rated operating current I
Rated insulation voltage U
Rated impulse withstand
voltage U
imp
:
Thermal test current I
: 0.3 A
e
: 250 V
i
: 6 A
the
4 kV
Internal electronic fuse: no
Power consumption: 5 W
Input monitoring:
Cross-wire short detection: yes
Wire breakage detection: yes
Earth leakage detection: yes
Number of NC contacts: 2
Number of NO contacts: 2
Outputs:
Stop category 0: 1
Stop category 1: 0
Number of safety contacts: 1
Max. switching capacity
4 A
of the safety contacts:
Utilisation category to
EN 60947-5-1:
AC-15: 230 V / 2 A
DC-13: 24 V / 2 A
Max. fuse rating: 4 A gG D-fuse
Mechanical life: 20 million operations
LED indication: Wiring diagram
Ambient conditions:
Operating temperature: 0°C ... +55°C
Storage and transport
-25°C ... +70°C
temperature:
Protection class: Enclosure: IP 40
Terminals: IP 20
Wiring compartment: IP 54
Degree of pollution: 2
Fixing: Snaps onto standard DIN
rails to DIN EN 60715
Connection type: Screw terminals
Min. cable section: 0.25 mm
2
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 with 0.75 mm
2
cable
Weight: 410 g
Dimensions (H/W/D): 110 x 55 x 75 mm
2.5 Safety classication
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 ap-
plications 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
2
EN
Operating instructions
Safety-monitoring module
AES 2155/2156
AES 2165/2166
3 Mounting
3.1 General mounting instructions
Mounting: snaps onto standard DIN rails to EN 60715.
3.2 Dimensions
Device dimensions (H/W/D): 110 x 55 x 75 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
5 Operating principle and settings
AES 2155/2156
Monitoring of two safety switches, which are simultaneously actuated
by a safety guard (e.g. safety guard, diversitary actuation). The number
of connected safety switches is restricted by the contract transition resistance and the conduction resistance. This overall resistance must not
exceed 300 Ω. For magnetic safety sensors with LED, the brightness of
the LED’s reduce as the amount of guard doors opened increases.
AES 2165/2166
Monitoring of safety switches, which are actuated by different safety
guards (e.g. two guard doors, which are opened independently from
one another).
Enable delay time X5/X6
By bridging the connections X5/X5, the enable delay time (i.e. time
during which after the rst closing of the guard, bouncing of the switch
contacts or of the entire guard is possible without error message) can
be extended from 0.1 s to 1 s. The enable delay time simultaneously
is the minimum time, expiring between the guard being closed and the
relays being activated.
Outputs
Enabling path 13-14
NO contacts for safety functions
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 tting 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 safety-monitoring
module features maintenance-free functionality.
A regular visual inspection and functional test, including the following
steps, is recommended:
• Check the correct xing of the safety monitoring module
• Check the cable for damage.
Damaged or defective components must be replaced.
7 Disassembly and disposal
Operating principle after the operating voltage is switched on
Without start-up test AES 2155 / 2165
1. The functionality of the safety-monitoring module is tested.
2. If the safety guard is closed, the enabling path 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 2156 / 2166
1. The functionality of the safety-monitoring module is tested.
2. The safety guard must be actuated, in order to check the cables and
the connected safety switch (start-up test).
3. If the safety guard is closed, the enabling path of the safety-monitoring
module will close. The LED is green.
If the safety guard is opened, the enabling path of the safety-monitoring
module will open. The machine is stopped and the LED ashes yellow.
Inputs S1-S14/S22; S2-S14/S22
Safety switches with one NC and one NO contact must be connected to
the inputs S1/S2.
7.1 Disassembly
The safety monitoring module must be disassembled in the de-energised
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.
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 diagram is shown with guard doors closed and in a de-
energised condition. Inductive loads (e.g. contactors, relays, etc.) are
to be provided with suitable interference suppression circuitry. Do not
connect additional loads to terminal S..
EN
3
Operating instructions
Safety-monitoring module
AES 2155/2156
AES 2165/2166
AES 2155/56
U
e
A1 A2 S13 S14 S21 S22 13
S1
24VDC
K1
K2
S2
S13 S14 S21 S22 X5 X6 14
K3
L1
AES 2155/2156
K4
8.2 Integral System Diagnostics (ISD)
The LED indication of the safety-monitoring modules shows the different
switching conditions and errors. The switching conditions are explained
in the following tables.
Tables switching condition indication
Diagnostic LED System condition
The LED is green. Enabling paths closed
LED ashes yellow (0.5 Hz) Enabling paths open
LED ashes yellow (2 Hz)
The safety-monitoring modules have two more LED indications. The
yellow LED is intermittently on. The switching conditions are explained
in the following tables.
Indication (yellow) LED System condition
1 impulse
2 impulses
Table error indications
Safety guard closed, however no
release; possible causes: incorrect
operation (only one contact actuated
upon opening) or voltage drop
→ perform start-up test
Safety guard 1 open
Safety guard 2 open
AES 2165/66
BK
U
e
BU
WH
BN
A1 A2 S13 S14 S21 S22 13
S1
24VDC
S2
S13
S14 S21 S22 14
BK
BU
BN
X5 X6
WH
N
Legend
M
3
L1
K1
AES 2165/2166
Indication (orange) LED
1 impulse
2 impulses
3 impulses
4 impulses
K2
5 impulses
6 impulses
7 impulses
K3
K4
M
3
* Partial actuation: position of the switch, in which only one contact was actuated.
Deleting the error message
The error message is deleted, when the error cause is eliminated
and the AES can check all functions. In case of an error of switch 1
or switch 2, actuate the switch concerned (open the safety guard and
close it again). For all other errors, both switches must be actuated.
Error Cause
Inputs S1 Defective supply voltage
lead, defective switch,
erroneous tting of
the switch; switch only
partially actuated* for at
least 5 s
Inputs S2 refer to errors inputs S1
Inputs S1 and S2 refer to errors inputs S1
Interference signals
at the inputs (no
safe evaluation
assured)
One or both relays
did not close within
the monitoring time
Relay not disabled
upon the actuation
of the switch
Dynamic monitoring
of both channels
(cross-monitoring)
failure
Too high capacitive or
inductive interference
at the switch's cables
or the supply voltage
lead
Too low operating
voltage U
Defective relay
Relay contact welding
Fault in one channel;
internal data transmission interrupted
e;
A Positive break
A - D Safety switch
S Non-contact safety sensor
4
EN
Operating instructions
Safety-monitoring module
Appendix
8.3 Declaration of conformity
EC Declaration of conformity
AES 2155/2156
AES 2165/2166
Translation of the original declaration of conformity
valid as of December 29, 2009
We hereby certify that the hereafter described safety components both in its basic design and
construction conform to the applicable European Directives.
Name of the safety component / type: AES 2155/2156
Description of the safety component: Safety-monitoring module for non-contact
Harmonised EC-Directives: 2006/42/EC EC-Machinery Directive
Person authorized for the compilation
of the technical documentation:
Notied body, which approved the
full quality assurance system, referred
to in Appendix X, 2006/42/EC:
K.A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, D-42279 Wuppertal
Germany
Internet: www.schmersal.com
AES 2165/2166
safety switches and safety relay combi-
nation in connection with the BNS series
magnetic safety switches
2004/108/EC EMC-Directive
Ulrich Loss
Möddinghofe 30
42279 Wuppertal
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
AES 2155-B-EN
Managing Director
Note
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
EN
5
Elan Schaltelemente GmbH & Co. KG
Im Ostpark 2, D - 35435 Wettenberg
Postfach 1109, D - 35429 Wettenberg
Telefon: +49 (0)641 9848-0
Telefax: +49 (0)641 9848-420
E-Mail: info-elan@schmersal.com
Internet: www.elan.de
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