This operating instructions manual provides all the information you
need for the mounting, set-up and commissioning to ensure the safe
operation and disassembly of the safety switchgear. 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 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 machine or plant.
The safety switchgear 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".
4 Rear side Electrical connection
4.1 General information for electrical connection ................4
5 Operating principles and coding
5.1 Mode of operation of the safety outputs ....................5
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.
There are no residual risks, provided that the safety instructions as well
as the instructions regarding mounting, commissioning, operation and
maintenance are observed.
EN
1
Operating instructions
Safety switch
AZ201
1.6 Warning about misuse
In case of improper use or manipulation of the safety
switchgear, personal hazards or damages to machinery
or plant components cannot be excluded. The relevant
requirements of the standard ISO 14119 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:
2 p-type safety outputs
SD2Pserial diagnostic output and
2 p-type safety outputs
2.4 Purpose
The non-contact, electronic safety switch is designed for application in
safety circuits and is used for monitoring the position of movable safety
guards.
The safety switchgears are classified according to ISO 14119
as type 4 interlocking devices. Designs with individual coding
are classified as highly coded.
The safety function consists of safely switching off the safety outputs
when the safety guard is opened and maintaining the safe switched off
condition of the safety outputs for as long as the safety guard is open.
Series-wiring
Series-wiring can be set up. The response and risk times are not
altered by wiring in series. The number of components is only limited
by the external cable protection according to the technical data and the
line loss. Series-wiring of up to 31 AZ201…-SD components with serial
diagnostics is possible. In devices with the serial diagnostics function
(ordering suffix -SD), the serial diagnostics connections are wired in
series and connected to a SD Gateway for evaluation purposes. Wiring
examples for series-wiring, refer to appendix.
The user must evaluate and design the safety chain in
accordance with the relevant standards and the required
safety level. If multiple safety switchgears are involved in
the same safety function, the PFH values of the individual
components must be added.
The entire concept of the control system, in which the safety
component is integrated, must be validated to the relevant
standards.
ActuatorAZ/AZM201-B30-…
AZ/AZM201-B1-…
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 Comprehensive quality insurance to 2006/42/EC
Schmersal is a certified company to appendix X of the Machinery
Directive. As a result, Schmersal is entitled to autonomously conduct
the conformity assessment procedure for the products listed in
Appendix IV of the MD without involving a notified body. The prototype
test certificates are available upon request or can be downloaded from
the Internet at www.schmersal.com.
2
EN
Operating instructions
Safety switch
AZ201
2.5 Technical data
Standards:IEC 60947-5-1, IEC 60947-5-3,
ISO 13849-1, IEC 61508, IEC 62061
Material of the enclosure:glass-fibre reinforced thermoplastic,
self-extinguishing
Active principle: RFID
Frequency band: 125 kHz
Transmitter output: max. -6 dBm
Coding level according to ISO 14119:
- I1-version: high
- I2-version: high
- Standard coding version: low
Reaction time:
- Actuator: ≤ 100 ms
- Inputs: ≤ 0.5 ms
Duration of risk:< 200 ms
Time to readiness:< 4000 ms
Actuator:AZ/AZM201-B1, AZ/AZM201-B30
Series-wiring: Unlimited number of components,
please observe external cable protection,
max. 31 components in case of serial diagnostics
Length of sensor chain:max. 200 m
(cable length and cable section
alter the voltage drop depending
on the output current)
Mechanical data
Termination: Screw terminals or cage clamps,
Connector plug M12
Cable section:min. 0.25 mm², max. 1.5 mm²
(including conductor ferrules)
Cable entry:M20
Mechanical life: ≥ 1,000,000 operations
Actuating speed:max. 0.2 m / s
Tightening torque for the cover screws:0.7 ... 1 Nm (Torx T10)
Latching force:30 N
Switching distances to IEC 60947-5-3
Assured switching distance sao: 4.0 mm
Assured switch-off distance sar: 30 mm
Hysteresis:max. 1.5 mm
Repeat accuracy: < 0.5 mm
Switching frequency:1 Hz
Ambient conditions
Ambient temperature: −25 °C ... +70 °C
Storage and transport temperature: −25 °C ... +85 °C
Protection class:IP66, IP67 to IEC 60529
Protection class: III
Resistance to shock:30 g / 11 ms
Resistance to vibration:10 ... 55 Hz, amplitude 1 mm
Insulation values to IEC/EN 60664-1:
- Rated insulation voltage Ui: 32 VDC
- Rated impulse withstand voltage U
- Over-voltage category: III
- Degree of pollution: 3
Electrical data
Operating voltage UB: 24 VDC - 15% / +10%
Power consumption device:0.7 A
Required rated short-circuit current:100 A
No-load current Io:max. 0.5 A
External device fuse rating:
- Screw terminals or cage clamps: ≤ 4 A when used
- Connector plug M12: ≤ 2 A
Electrical data – Safety inputs
Safety inputs: X1 and X2
Switching thresholds: − 3 V … 5 V (Low), 15 V … 30 V (High)
Power consumption per input: typically 2 mA / 24 V
Accepted test pulse duration on input signal: ≤ 1.0 ms
- With test pulse interval of: ≥ 100 ms
Test pulse interval: 1000 ms
ZVEI classification:
Countersink:C1Source:C1C2C3
: 0.8 kV
imp
(stabilised PELV power supply)
in accordance with UL 508;
Electrical data – Safety outputs
Safety outputs:Y1 and Y2
Switching elements:p-type, short-circuit proof
Utilisation category: DC-13: Ue/Ie: 24 VDC / 0.25 A
Rated operating current Ie:0.25 A
Leakage current Ir: ≤ 0.5 mA
Voltage drop Ud: ≤ 4 V
Cross-wire monitoring by device: Yes
Test pulse duration: ≤ 0.5 ms
Test pulse interval:1000 ms
ZVEI classification:
Source:C2Countersink:C1C2
Electrical data – Diagnostic output
Diagnostic output: OUT
Switching element:p-type, short-circuit proof
Utilisation category:DC-13: Ue/Ie: 24 VDC / 0.05 A
Rated operating current Ie: 0.05 A
Voltage drop Ud:≤ 4 V
Serial diagnostic SD
Operating current: 0.15 A
Wiring capacitance: max. 50 nF
LED status display
green LED:Supply voltage
yellow LED: Device condition
red LED:Internal device error
Use isolated power supply only.
For use in NFPA 79 Applications only.
Adapters providing field wiring means are available from
the manufacturer. Refer to manufacturers information.
2.6 Safety classification
Standards: ISO 13849-1, IEC 61508, IEC 62061
PL: e
Control Category: 4
PFH value:1.9 x 10-9 / h
PFD:1.6 x 10
SIL:suitable for SIL 3 applications
Service life:20 years
-4
EN
3
Operating instructions
405
Safety switch
AZ201
3. Mounting
3.1 General mounting instructions
For fitting the AZ201 safety switch and the actuator, two mounting
holes for M6 screws with washers (washers included in delivery)
are provided. The safety switch must not be used as end stop. Any
mounting position. The mounting position however must be chosen
so that the ingress of dirt and soiling in the used opening is avoided.
The unused actuator opening must be sealed by means of the dustproof flap (included in delivery).
Minimum distance between two safety switchgear as well as to other
systems with same frequency (125 kHz): 100 mm.
The safety component and the actuator must be permanently
fitted to the safety guards and protected against displacement
by suitable measures (tamperproof screws, gluing, drilling,
pinning).
Please observe the relevant requirements of the
standards ISO 12100, ISO 14119 and ISO 14120.
Mounting of the actuators
Refer to the mounting instructions manual for the corresponding
actuator AZ/AZM201-B30… or AZ/AZM201-B1…
3.2 Dimensions
All measurements in mm.
4. Rear side 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.
The power supply of the safety switch must provide protection against
permanent overvoltage. To that effect, stabilised PELV supply units
must be used. The safety outputs can be directly integrated in the
safety circuit of the control system. For applications up to PL e / control
category 4 in accordance with ISO 13849-1, the safety outputs of the
safety switch (max. 31 components in series-wiring) must have an
assessment with the same control category (refer to wiring examples).
Inductive loads (e.g. contactors, relays, etc.) are to be provided with
suitable interference suppression circuitry.
Requirements for the connected safety-monitoring module:
• Dual-channel safety input, suitable for 2 p-type semi-conductor
outputs
Configuration of the safety controller
If the safety switchgear is connected to electronic safetymonitoring modules, we recommend that you set a
discrepancy time of 100 ms. The safety inputs of the safetymonitoring module must be able to blank a test impulse of
approx. 1 ms. The safety-monitoring module does not need to
have a cross-wire short monitoring function, if necessary, the
cross-wire short monitoring function must be disabled.
3,3
5
7,5
32,5
6,5
38
GN
RD
YE
155,5
220
M20x1,5
40
20 1
±
If the safety component is wired to relays or to non-safety relevant
control components, a new risk analysis must be carried out.
Cable
The cable entry is realised by a metric M20 gland. This gland must be
measured by the user so that it is suitable for the cable used. A cable
gland with strain relief and suitable IP protection class must be used.
The maximum cable length is 200 m (for ST2 M12 connectors approx.
20 m depending on the cable section used for an operating current
of 0.5 A). The maximum cable section is 1.5 mm², incl. conductuor
ferrules. Prior to the connection, the cable must be stripped by
40+5 mm and insulated by 5 mm. The fitted 24V, X1, X2 bridge is
included in the delivery of …-1P2P and …-SD2P.
Information for the selection of suitable safety-monitoring
modules can be found in the Schmersal catalogues or in the
online catalogue on the Internet: www.schmersal.net.
4
EN
Operating instructions
Safety switch
AZ201
5. Operating principles and coding
5.1 Mode of operation of the safety outputs
The opening of the safety guard causes the safety outputs to be
disabled within the risk time.
5.2 Actuator teaching / actuator detection
Safety switches with standard coding are ready to use upon delivery.
Individually coded safety switches and actuators will require the
following "teach-in" procedure:
1. Switch the safety switch's voltage supply off and back on.
2. Introduce the actuator in the detection range. The teach-in procedure
is signalled at the solenoid interlock, green LED off, red LED on,
yellow LED flashes (1 Hz).
3. After 10 seconds, brief cyclic yellow flashes (5 Hz) request the
switch-off of the operating voltage of the safety switch. (If the voltage
is not switched off within 5 minutes, the safety switch cancels the
"teach-in" procedure and signals a false actuator by 5 red flashes).
4. After the operating voltage is switched back on, the actuator must be
detected once more in order to activate the taught actuator code. In
this way, the activated code is definitively saved!
For ordering suffix -I1, the executed allocation of
safety switch and actuator is irreversible.
For ordering suffix -I2, the "teach-in" procedure for a new actuator can
be repeated an unlimited number of times. When a new actuator is
taught, the code, which was applicable until that moment, becomes
invalid. Subsequent to that, an enabling inhibit will be active for ten
minutes, thus providing for an increased protection against tampering.
The green LED will flash until the expiration of the time of the enabling
inhibit and the detection of the new actuator. In case of power failure
during the lapse of time, the 10-minutes tampering protection time will
restart.
6. Diagnostic functions
6.1 Diagnostic-LEDs
The safety switchgear signals the operational state as well as errors
through three coloured LED’s installed on the front side of the device.
green (Power) Supply voltage on
yellow (Status) Operating condition
red (Fault)Fault (s. Table 2: flash codes of the red diagnostic LED
6.2 Principle of operation of diagnosis output
The short-circuit proof diagnostic output can be used for central
visualisation or control functions, e.g. in a PLC. The closed condition of
the safety guard and the inserted condition of the actuator is indicated
by means of a 24V signal.
The diagnostic output is not a safety-related output!
Error
Errors, which no longer guarantee the function of the safety switch
(internal errors) cause the safety outputs to be disabled. An error that
does not immediately affect the safe functionality of the safety switch
(e.g. excess ambient temperature, safety output to external potential,
short circuit) will lead to a delayed shut-down (refer to table 2).
After fault rectification (fault at output Y1 or Y2, temperature fault), the
fault is acknowledged by opening and relocking the relevant guard door.
The safety outputs enable and allow a restart.
Automatic, electronic locking takes place if more than one
fault is detected at the safety outputs or a cross circuit is
detected between Y1 and Y2. This means that normal fault
acknowledgement is no longer possible. To reset this type
of interlocking, the safety switch must be isolated from the
power supply after elimination of the error causes.
Error warning
A fault has occurred, which causes the safety outputs to be disabled
after 30 minutes. The safety outputs initially remain enabled.
This enables the shutdown of the process in a controlled manner.
An error warning is deleted when the cause of error is eliminated.
EN
5
Operating instructions
Safety switch
Table 1: The diagnostic function of the safety switchgear
The safety switch signals the operational state as well as errors through three coloured LED’s installed on the device.
AZ201
System conditionLEDSafety outputs
Y1, Y2
Diagnostic
output
OUT
greenredyellow-1P2P
Safety guard openOnOffOff0 V0 V
Guard closed, actuator not insertedOnOffOff0 V0 V
Door closed, actuator insertedOnOffOn24 V24 V
Teach-in procedure actuator startedOffOnFlashes0 V0 V
Only I2: teach-in procedure actuator
FlashesOffOff0 V0 V
(release block)
1) after 30 min: disabling due to fault
2) refer to flash code
Table 2: Error messages / flash codes red diagnostic LED
Flash codes
(red)
DesignationAutonomous
switch-off after
Error cause
1 flash pulseError (warning) at output Y130 minFault in output test or voltage at output Y1,
although the output is disabled.
2 flash pulsesError (warning) at output Y230 minFault in output test or voltage at output Y2,
although the output is disabled.
3 flash pulsesError (warning) cross-wire short30 minCross-wire short between the output cables or fault at both outputs
4 flash pulsesError (warning) temperature too high30 minThe temperature measurement reveals an internal temperature
that is too high
5 flash pulsesActuator fault0 minincorrect or defective actuator
6 flash pulsesError actuator combination0 minAn invalid combination of actuators was detected
(blocking bolt detection or tamper attempt).
Continuous redInternal fault /
0 minDevice defective / supply voltage not within specifications
overvoltage or undervoltage fault
6.3 Safety switch with serial diagnostic function SD
Safety switches with serial diagnostic cable have a serial input and
output cable instead of the conventional diagnostic output. If safety
switches are wired in series, the diagnostic data is transmitted through
the series-wiring of the inputs and outputs.
Max. 31 safety switches can be wired in series. For the evaluation of
the serial diagnostics line either the PROFIBUS-Gateway SD-I-DP-V0-2
or the Universal-Gateway SD-I-U-... are used. This serial diagnostic
interface is integrated as a slave in an existing field bus system. In this
way, the diagnostic signals can be evaluated by means of a PLC.
The response data and the diagnostic data are automatically and
permanently written in an input byte of the PLC for each safety switch
in the series-wired chain. The request data for each safety switch are
transmitted to the component through an output byte of the PLC. In
the event of a communication error between the field bus gateway and
the solenoid interlock, the switching condition of the safety switch is
maintained.
Error
A fault has occurred, which causes the safety outputs to be disabled.
The fault is reset, when the cause is eliminated and bit 7 of the request
byte changes from 1 to 0 or the safety guard is opened. Faults at the
safety outputs are only deleted upon the next release, as the fault
rectification cannot be detected sooner.
Automatic, electronic locking takes place if more than one
fault is detected at the safety outputs or a cross circuit is
detected between Y1 and Y2. This means that normal fault
acknowledgement is no longer possible. To reset this type
of interlocking, the safety switch must be isolated from the
power supply after elimination of the error causes.
Error warning
A fault has occurred, which causes the safety outputs to be disabled
after 30 minutes. The safety outputs initially remain enabled.
This enables the shutdown of the process in a controlled manner.
An error warning is deleted when the cause of error is eliminated.
Diagnostic error (warning)
If an error (warning) is signalled in the response byte, detailed fault
information can be read out.
Accessories SD interface
For ease of wiring and series-wiring of SD devices, considerable accessories are available. Detailed information is
available on the Internet, www.schmersal.net.
When wiring SD devices, please observe the voltage drop on
the cables and the current carrying capacity of the individual
components.
6
EN
Operating instructions
Safety switch
Table 3: I/O data and diagnostic data
Bit n° Request byte Response byteDiagnostic error warningDiagnostic error
Bit 0:---Safety output activatedError output Y1Error output Y1
Bit 1:---Actuator detectedError output Y2Error output Y2
Bit 2:------Cross-wire shortCross-wire short
Bit 3:------Temperature too highTemperature too high
Bit 4:---Input condition X1 and X2--Bit 5:---Guard door detectedInternal device errorInternal device error
Bit 6:---Error warning
Bit 7:Error resetError (enabling path switched off) ------
1)
after 30 min -> fault
The described condition is reached, when Bit = 1
1)
Communication error between the field bus Gateway
and the safety switchgear
incorrect or defective actuator
---
AZ201
7. Set-up and maintenance
7.1 Functional testing
The safety function of the safety components must be tested.
The following conditions must be previously checked and met:
1. Check max. axial misalignment of actuator and safety switch
2. Fitting of the solenoid interlock and the actuator
3. Check the integrity of the cable entry and connections
4. Check the switch enclosure for damage
7.2 Maintenance
We recommend a regular visual inspection and
functional test, including the following steps:
1. Check max. axial misalignment of actuator and safety switch
2. Check for tight installation of the actuator and the switch
3. Remove particles of dust and soiling
4. Check cable entry and connections
Adequate measures must be taken to ensure protection
against tampering either to prevent tampering of the safety
guard, for instance by means of replacement actuators.
Damaged or defective components must be replaced.
8. Disassembly and disposal
8.1 Disassembly
The safety switchgear must be disassembled in a de-energised
condition only.
8.2 Disposal
The safety switchgear must be disposed of in an appropriate manner in
accordance with the national prescriptions and legislations.
EN
7
Operating instructions
GND
Safety switch
9. Appendix
9.1 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.
Wiring example 1: Series-wiring of the AZ201 with conventional diagnostic output
The series-wiring of multiple AZ201 solenoid interlocks is realised by wiring in the control cabinet or in on-site junction boxes.
In the example, 2 AZ 201 safety switches (max. 31 components) are wired in series. The diagnostic output ("OUT") is wired separately for each
device to a conventional PLC for evaluation. The maximum cable length of the safety circuits must not exceed 200 m.
In the series-wiring, the 24V-X1-X2 bridge must be removed from all components up to the last component.
The voltage is supplied at both safety inputs of the terminal safety component of the chain (considered from the safety-monitoring module).
The safety outputs of the first safety component are wired to the safety-monitoring module.
AZ201
X1
OUT
SPS/PLC
123568
X2
24V
GND
7
4
Y1
Y2
OUT
SPS/PLC
Y1
Y2
X1
X2
X1
X2
7
123568
4
Y1
Y2
24V
GND
Y1
Y2
Safety outputs → evaluation
24 VDC
n-participants max. 31 components in series
Wiring example 2: Series-wiring of the AZ201 with serial diagnostic function
The safety outputs of the first safety component are wired to the safety-monitoring module. The serial Diagnostic Gateway is connected to the serial
diagnostic input of the first safety component.
1235468
X1
X2
24V
GND
SD OUT
7
Y1
Y2
SD IN
1235468
X1
X2
24V
GND
SD OUT
7
Y1
Y2
SD IN
24 VDC
8
SD IN
Y1
Y2
n-participants max. 31 components in series
SD OUT
X1
X2
SD IN
Y1
Y2
EN
Field bus
Safety outputs → evaluation
Operating instructions
5
8
3
7
Safety switch
9.2 Wiring configuration and accessories
AZ201
Function safety switchgearPin configuration
of the connector
with conventional
diagnostic output
24 VU
X1 Safety input 122BNWH
GND GND35GNBU
Y1 Safety output 147YEBK
OUTDiagnostic outputSD output59GYGY
X2 Safety input 263PKPK
Y2 Safety output 278BUVT
IN without functionSD input84RDOR
without function–6
View of the terminal block for ordering suffix -SK or -CCView of the version with removable terminal blocks
Y1 Y2
IN
OUTGND
24V 24V X1 X2
AZM 200.-.-1P2P.
AZ201-.-.-T-1P2P
Connector plug ST2 M12, 8-pole
4
6
with serial
diagnostic function
e
24V 24V X1 X2
AZ201-.-.-T-SD2P
AZM 200.-.-SD2P.
Y1 Y2
11WHBN
IN
OUTGND
Configuration of
the removible
terminal blocks
2
1
AZM 200.-.-1P2P.-.
AZ201-.-.-T-1P2P
5
6
78
Colour code of the
Schmersal connector
to DIN 47100
4
3
9
Possible colour codes for more
commercially available connectors
based on IEC 60947-5-2: 2007
2
1
Accessories: Pre-wired cables
Connecting cables with coupling (female)
IP67, M12, 8-pole - 8 x 0.25 mm²
Cable lengthPart number
2.5 m
5.0 m
10.0 m
Further versions in other lengths and with angled cable exit are available upon request.
103011415
103007358
103007359
EN
9
Operating instructions
Safety switch
10. EU Declaration of conformity
EU Declaration of conformity
AZ201
OriginalK.A. Schmersal GmbH & Co. KG
We hereby certify that the hereafter described components both in their basic design and construction conform
to the applicable European Directives.
Name of the component:AZ201
Type:See ordering code
Description of the component:Safety Switch for safety functions