Operating instructions
Fail-safe standstill monitor
DE
Betriebsanleitung ........................... Seiten 1 bis 6
Original
FWS 1206
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.
EN
Operating instructions.................... pages 7 to 12
Translation of the original operating instructions
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FR
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
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.
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.
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
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. 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
relevant requirements of the standard EN 1088 must be
observed.
x.000 / v.A. / 01.2010 / BZ-Nr. 50137-16V900 / Teile-Nr. 1172040-EN / Ausgabe D
EN
1
Operating instructions
Fail-safe standstill monitor
FWS 1206
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 for-
bidden; 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:
FWS 1206
➀
No. Option Description
➀
Standstill frequencies of the inputs X1/X2:
A 1 Hz/2 Hz
C 1 Hz/1 Hz
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 fail-safe standstill monitor is designed for control cabinet mounting.
Standstill monitors serve for the fail-safe detection of the machine
standstill and control of solenoid interlocks. For the standstill detection,
the signals of one or two proximity switches and an additional standstill
signal are evaluated.
The additional standstill signal can be derived from an already available
standstill signal of the machine, e.g. evaluation of a tachogenerator by
a PLC or the standstill output of a frequency converter.
It is recommended to install the proximity switches on a disc cam
so that at least one proximity switch is always actuated. This can be
realised by a minimum 1:1 division of the disc cam. When the proximity
switches are correctly installed, the following exemplary signal sequence
should be obtained by the utilisation of the switching hysteresis of the
proximity switches during the rotation of the disc cam.
Proximity switch 1:
Proximity switch 2:
The adjustment of the proximity switches is facilitated, when the cam
has a 2:1 division (or higher).
Design
The fail-safe standstill monitor has a dual-channel redundant structure.
It is provided with two safety relays with monitored, positive-guided
contacts which are controlled by two independent microprocessors. The
NO contacts of the series-wired relays build the enabling paths.
The feed cables of both proximity switches (power supply) must be laid
so that in case of a wire breakage only one proximity switch is dead
(star-shaped routing).
To determine the Performance Level (PL) to EN ISO 13849-1
of the entire safety function (e.g. sensor, logic, actuator), an
assessment of all relevant components is required.
2.4 Technical data
Standards: EN 60204-1, EN ISO 13849-1,
IEC 61508, BG-GS-ET-20
Enclosure: glass-bre reinforced thermo-
plastic, ventilated
Feedback circuit (Y/N): yes
Standstill frequency: Version A: X1/X2: 1 Hz / 2 Hz
Version C: X1/X2: 1 Hz / 1 Hz
Rated operating voltage U
: 24 VDC ± 15%
e
Rated operating current Ie: 0.2 A
Internal electronic protection (Y/N): no
Power consumption: < 5 W
Input monitoring: 1- or 2-channel,
p-type impulse generator
Cross-wire detection: no
Wire breakage detection: yes
Earth leakage detection: yes
Hysteresis: 10% of the standstill frequency
Max. input frequency: 4000 Hz
Min. impulse duration: 125 μs
Input resistance: approx. 4 kΩ to GND
Input signal "1“: 10 ... 30 VDC
Input signal "0“: 0 ... 2 VDC
Max. cable length: 100 m with 0.75 mm2 cable
Outputs:
Stop category 0: 2
Stop category 1: 0
Number of safety contacts: 2
Number of auxiliary contacts: 0
Number of signalling outputs: 2
Signalling output: 2 semi-conductor outputs,
Y1 + Y2 = max. 100 mA,
short-circuit proof, p-type
Max. switching capacity of
6 A
the safety contacts:
Utilisation category to
EN 60947-5-1:
Rated insulation voltage U
Rated impulse withstand
voltage U
Thermal test current I
imp
:
the
: 250 V
i
: 6 A
AC-15: 230 V / 3 A;
DC-13: 24 V / 2 A
4 kV
Contact load capacity: max. 250 VAC, max. 6 A (cos φ=1)
Max. fuse rating: 6 A gG D-fuse
Mechanical life: 20 million operations
LED indication: Wiring diagram
Ambient conditions:
EMC rating: conforming to EMC Directive
Overvoltage category: III to DIN VDE 0110
Degree of pollution: 2 to DIN VDE 0110
Resistance to vibrations: 10 ... 55 Hz / amplitude 0.35 mm
Resistance to shock: 30 g / 11 ms
Ambient operating temperature: 0°C…+55°C
Storage and transport temperature: -25°C…+70°C
Protection class: Enclosure: IP 40,
Terminals: IP 20,
Clearance: IP 54
Fixing: Snaps onto standard DIN rails
to DIN EN 60715
Connection type: Screw terminals
Min. cable section: 0.2 mm
2
Max. cable section: 2.5 mm2, solid strand
or multi-strand lead
(incl. conductor ferrules)
Weight: 190 g
Dimensions (H/W/D): 100 x 22.5 x 121 mm
2
EN
Operating instructions
Fail-safe standstill monitor
FWS 1206
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
SIL: up to 2
Service life: 20 years
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
5 Operating principle and settings
Operating principle after the operating voltage is switched on
After the operating voltage is switched on, the initialisation is started.
After verication, the inputs of the fail-safe standstill monitor are
evaluated. The cyclic frequencies of the connected proximity switches
are compared to programmed limit frequencies.
To check the proximity switches, a second comparison between the
signal of the safety contact and the detected frequency is executed. If
the value drops below the programmed frequency and the contact of
the contactor indicates a standstill of the motor (contact closed), both
safety relays are actuated and the enabling paths are closed. If one of
the standstill conditions no longer is fullled (frequency or condition of
the contactor), the safety relays are disabled.
-7
/ h; applicable for
applications with up to max.
50,000 switching cycles / year and
max. 80 % contact load. Diverging
applications upon request.
Inputs X1-X4
X1: connection for proximity switch 1
X2: connection for proximity switch 2 or bridge to X1
X3: connection for reset button
The reset input has a double function
A rising ank (0/1) at X3 deletes all detected errors of the fail-safe
standstill monitor and causes the relays to be disabled. A static
High signal (closed contact) changes the function of output Y2.
Instead of a simple error message, the impulse sequence is
emitted for every detected error in accordance with the "Error
indication" table.
X4: connection for an additional standstill signal "high": standstill
Outputs
Enabling paths 13/14, 23/24
NO contacts for safety function
Additional outputs Y1/Y2
Y1: Authorized operation; the enabling path is closed
Y2: "error“ or impulse sequence to "Error indication" table
Note
The additional outputs Y1 and Y2 must not be integrated in the safety
circuit. If only one proximity switch is connected, the inputs X1 and X2
must be bridged.
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. Proper 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
When the motor is started through the contactor, the function of the
proximity switches is tested. Five seconds after the contactor start-up,
the programmed limit frequency must be exceeded at the cyclic inputs.
If not, the fail-safe standstill monitor signals an error. Error messages
cause the safety relays to be disabled.
When two proximity switches are connected
If the programmed upper or lower limit frequency is exceeded, the frequencies of both proximity switches are compared. A divergence of over
30% will be considered faulty and signalled. The yellow LED is ashing
(refer to ISD table).
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.
EN
3
Operating instructions
I
0
E
Fail-safe standstill monitor
FWS 1206
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.
Avoid laying proximity switch connection cables in areas where strong
interference signals are present (e.g. frequency converters or cable
leads from powerful electric motors); the utilisation of shielded cables
may be necessary.
Legend
A + B
Safety switch
S Feedback circuit
X Additional standstill signal
On/off switch
H
Start button
Unlocking button
M
3
+24 VDC
+24 VDC
max.
A2
0 V
K3
K4
0 V
L1
E
A1
A1
A2
100mA
X1
Y2
Y1
X2
K1
K2
X4
X3
23
13
14
24
FWS 1206
R
J Reset button
1413 21
+24 VDC
A1
max.
A2
100mA
AZM 161-12/12
K3
K4
41
22
42
52
51
72
71
63 64
A2
A1
N
L1
0
S13
S14 S21
A1
A2
Y1
Y2
S22
K1
K2
X2
X1
23
13
24
14
H2
M
3
+24 VDC
0 V
L1
E
A1
A1
X1
max.
100mA
A2
A2
Y2
Y1
X2
K1
K2
X4
X3
23
13
14
24
K3
0 V
AES 1235
4
K4
N
EN
0 V
+24 VDC
R
FWS 1206
H7
Operating instructions
Fail-safe standstill monitor
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)
LED ashes yellow
(2 Hz)
Table error indications
When two proximity switches are connected,
only one switch has exceeded the lower limit
frequency, the enabling paths are open.
The motor is running, the limit frequency
has been exceeded. The enabling paths
are open.
FWS 1206
Indication (orange)
LED
1 impulse
2 impulses
4 impulses
5 impulses
6 impulses
7 impulses
8 impulses
Deleting the error message
The fault message will be deleted once the fault has been rectied and
a rotational movement has been detected for the input signals check.
All fault messages will also be deleted when the reset button is pushed.
Error Cause
Frequency sensor 1
too low,
Error input X1
Frequency sensor 2
too low,
Error input X2
Interference at
inputs, no safe
evaluation
One or both relays
did not close within
the monitoring time
Relay not disabled
upon the actuation
of the switch
Malfunction of
internal data lines
Contactor error The condition of the
Defective lead or
defective proximity
switch
Defective lead or
defective proximity
switch
Only one proximity
switch: bridge X1/X2
is missing
Too high capacitive or
inductive interference at
the inputs or the supply
voltage lead
Too low operating
voltage U
Defective relay
May be due to contact
welding
Interruption of the
internal data transfer
due to a high capacitive
or inductive interference
on the internal data
lines
additional standstill
signal does not correspond with the
detected frequencies,
e.g. the additional
standstill signal signals
a standstill, whereas
the proximity switches
signal that the limit
frequency is exceeded.
e;
EN
5
Operating instructions
Fail-safe standstill monitor FWS 1206
Appendix
8.3 Declaration of conformity
EC Declaration of conformity
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 conforms to the applicable European Directives.
Name of the safety component / type: FWS 1206
Description of the safety component: Fail-safe standstill monitor
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
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
FWS 1206-B-EN
Note
The currently valid declaration of conformity can be
downloaded from the internet at www.schmersal.net.
K. A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Möddinghofe 30, D - 42279 Wuppertal
Postfach 24 02 63, D - 42232 Wuppertal
Telefon +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
Authorised signature
Heinz Schmersal
Managing Director
6
EN
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